Setting Up Arc Welding Parameters on a Robot

Confirm power source communication

Verify the robot controller and welding power source are communicating over their digital interface and that basic status signals report correctly.

Enter the base weld schedule

Set voltage, wire feed speed or current, and travel speed according to the welding procedure specification for the joint and material.

Configure arc start and end conditions

Set initial current and voltage for arc start, along with crater fill parameters for the end of the weld to prevent crater cracking.

Set weave parameters if required

Configure weave pattern, width, and dwell time for joints that need it, based on the WPS.

Configure gas pre-flow and post-flow

Set shielding gas timing before arc start and after arc end to ensure proper coverage.

Teach the weld path

Put the robot in Teach Mode (T1) at reduced speed with the enabling device held before jogging the torch. Program the travel path with correct torch angle and work angle for each pass, referencing the WPS. Do not teach or edit points while the cell is in automatic or high-speed mode.

Caution: Never program robot motion under power outside Teach Mode T1 with reduced speed and the enabling device active. Keep all other personnel clear of the robot envelope while teaching.

Weld test coupons

Run the program on test material and inspect the weld against the acceptance criteria in the WPS.

Fine-tune and lock the schedule

Adjust parameters based on coupon results, then document and lock the finalized schedule for production use.