Arc Welding

A programmed arm runs a torch over the seam while the wire feeder, gas supply, and power source keep the puddle stable. Most cells load two fixtures on a rotary or shuttle so the robot welds one side while an operator loads the other, which is how welding time stays close to arc-on time.

Payload is modest for the process itself, since a torch and cabling sit in the 3 to 20 kg window, and hollow-wrist routing matters more for cable life than the raw payload number. Reach in the 1400 to 2200 mm range covers most fabrication weldments, and dedicated arc arms like the Arc Mate 100iD or M-20iD/25 route wire, gas, and control lines through the wrist.

A positioner brings the joint into the flat or slightly downhill position, which cuts sag and helps penetration. Cell layout has to leave room for torch reach into fixtures, fume extraction ducting, and cable dress that survives full articulation.

Porosity almost always traces to shielding gas coverage, a contaminated joint, or wire feed problems. Robot motion is a distant cause; if the arc still wanders after those are ruled out, verify the tool frame at the wire tip and confirm seam tracking is active for that program.

Arc welding rewards consistent fit-up, since sensors can only correct so much variation before weld quality drops. For thin sheet or cosmetic joints where distortion has to stay minimal, laser welding puts heat in a much smaller zone.

A common layout pairs a Fanuc Arc Mate 100iD with a two-station rotary positioner, and the operator loads one fixture while the robot welds the other. Programs get built from arc weld schedules that pair travel speed, wire feed, and voltage per joint.

Spend real time on arc welding parameter setup and torch calibration at commissioning, before chasing defects in the motion program. A tuned schedule and a clean tool frame save more hours than any amount of program tweaking afterward.