I’m a long time advocate of narrow gap welding. The advantages are tremendous, but the challenges are too. A 5″ thick standard V Butt weld with a 75 degree included angle has five times the weld volume of a 1″ wide 5″ Square Butt. This means a narrow gap joint would have five times less weld wire, five times less arc time, much less distortion. And fewer defects because every inch of weld that you don’t make is an inch you don’t have to inspect and possibly repair.
Why isn’t narrow gap the standard technique for welding heavy sections? Because the technical challenges of welding vertical walls in confined spaces are huge. For good sidewall fusion, the arc must impinge on the walls. Otherwise, you risk lack of fusion defects at the bond line. Our new Narrow Gap Hot Wire Torch features a servo tungsten electrode oscillator to point directly at the sidewall. That is only half the battle. The wire must follow the tungsten. We did just that using a second independent servo this allows us full control of arc and the filler wire position. Finally, we use our HOT ONE AC constant voltage hotwire system to double the deposition rate, which cuts weld time in half.
In manufacturing, these are your only choices. Fortunately, there is still a place in the world for people. Some things humans do best. Any task which requires flexible adaptation to unpredictable dynamic environments is a good example. But sometimes the best man for the job is a robot, or possibly a machine.
When your only tool is a hammer the whole world looks like a nail. When your system integrator is a robot house you should expect a robotic solution. Over the last 30 years, robots have become faster, more reliable, cheaper, and easier to integrate and operate. So, we use ‘bots on an ever-increasing percentage of our systems. But not always.
Sometimes the best solution is a purpose-built machine. The reasoning may be a smaller footprint, or maybe you don’t need 6 axes of motion or standard robot software won’t fit your needs. What I have found over my 40 years of building machines is that a purpose-built machine is typically faster and more precise than a robotic solution. Today’s video showcases two welding solutions that my team decided to automate with an ARC Specialties purpose-built machines.
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FANUC Robotics in Houston, Texas is hosting an Open House on October 19th and 20th. As an integrator of FANUC Robotics, the team at ARC Specialties will represent the latest in robotic and automated manufacturing technology at this event.
The Technology Workshop will include sessions on ROBOGUIDE/Offline Programming, CNC Technology and General Motion Applications, and CNC Aftermarket Support and Maintenance Overview.