Arc Welding Robot

The purpose of an arc welding robot is to fuse two metals by creating an electric arc between the work piece and electrode. It is a continuous process used to weld long joints. The electrode will emit sufficient electric current, which will be in a range of 5 500 amps or 10 30 volts.

Arc welding can be done by four different ways such as:

  • Flux Core Arc Welding (FCAW),
  • Gas Metal Arc Welding (GMAW),
  • Shielded Metal Arc Welding (SMAW), and
  • Gas Tungsten Arc Welding (GTAW).

During olden periods, the arc welding was done by a fitter (human worker). The working environment of this process was very hazardous. It was very harmful to a human vision, because the welding process produces the ultra-violet rays. To get rid out of it, the welders were wearing the helmet with a black-colored visible window, which gives protection to their eyes to some extent. Sometimes, sparks and smoke will also be more dangerous to the operators. As a result of all this difficulty, the arc welding robots came into the act.

An example of the Arc Welding Robot is KUKA KR 16 ARC HW.

Problems occurred in Arc Welding Robot:

During an arc welding process, a robot will experience several problems. Some of them are listed below:

  • The arc welding robots have problems in performing weld on some areas like pressure vessels, interior tanks, ship body, etc. This work can be done more effectively by humans than robots.
  • If there is a change of dimension in the work parts, then it will be a major setback for a robot to prepare a perfect weld.
  • The irregularity in the edges of work parts will cause gaps during welding.

Sensors in Arc Welding Robot:

The sensors used in the arc welding robot are commonly divided into two types:

  • Contact Sensors, and
  • Non Contact Sensors.

These kinds of sensor will be very helpful to check the change of dimensions, and irregularity of work parts.

Advantages of Arc Welding Robots:

  • Enhanced safety to the workers,
  • Increased productivity,
  • Better quality,
  • Reliability, and
  • Labor cost is decreased.

Disadvantages of Arc Welding Robot:

  • Highly expensive, and
  • A simple mistake will reduce the quality of a product.


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