Weld Builder - Creating a Weaving Weld

Weaving is the process of introducing patterned motion into a weld path. Within Weld Builder this pattern takes the shape of a sine wave. This process is useful when looking to improve weld seam quality by ensuring better fusion of the metal. Additionally, adding a weaving pattern may help fill larger weld seams quicker and more reliably.

The Weaving Waveform

Weld Builder defines the weaving pattern as a sine wave which may also be referred to generally as the "waveform". This waveform is defined by specifying two parameters:

• Amplitude: The extent of the oscillating robot movement's deflection from the centerline of the waveform. The input value can range from 0.1mm to 99.9mm (0.01" - 3.93").

  This "centerline" is the original programmed path. Therefore the robot will deviate from this path by the amount specified by the amplitude.

• Frequency: How quickly the torch oscillates or how many oscillating motions the torch completes per second. The input value can range from 0.1 to 5 Hertz.

It may also be important to note that there is a limit of the combination of these two parameters. Both parameters may not exceed 30.0mm (1.18") and 4.0 Hz simultaneously.

Weaving Plane Adjustment

Weld Builder aids in simplifying the process of defining weaving motion by automating creation of "Reference Points". These Reference Points help inform the robot about the correct direction of travel for the weave and the angle of the Weaving Plane.

This is achieved by assuming the weaving plane to be 90° perpendicular to the Weld Wire. Adjusting the angle of the torch at the programmed motion points will therefore also adjust this weaving plane. This is shown in the graphic above where the steeper torch angle, relative to the part, will result in a more shallow angle of the weaving plane.

When programming the motion segments of the weld the wire should be located approximately in the center of the joint. Alignment of these taught positions will be reflected as the center of the waveform.

Important Note: For this function to generate correct motion it is imperative that the programmed tool data and therefore Tool Control Point (TCP) is accurate.

Programming a Weaving Weld

This section defines how to adjust the weaving parameters for a preexisting weld. Whether using the Weld Editor or Weld Wizard to generate a new weld job, either option will allow for creation of a weaving weld.

The topic of programming the exact welding path will not be covered.

1. Locate the weaving configuration page. Then move the toggle switch to the right to enable weaving. The graphics below indicate how to perform this action depending on which method of creation is being used:

   • Weld Wizard
     Located on the "Optional Weld Features" step of the wizard.
     
   • Weld Editor
     Located under the Path Features tab of the weld instruction. Press the [ CONFIGURE ] button after enabling.
     
2. Adjust Weaving Waveform
   
   
   • Set the Amplitude to the desired length. Remember, this value is only half the height of the waveform.
   • Adjust the Frequency to achieve the desired number of oscillations. By default this value is set to 2.5 Hz.
3. Angle Adjustment
   
   Here you will find information on what to consider when aligning the torch while programming the welding motion.

Remarks

While assigning a motion instruction's speed as part of a weaving weld, it is important to note that the defined speed represents the speed of the TCP should it follow the programmed path without weaving. Meaning, the lateral oscillations are not taken into account when running at the programmed speed. The robot may therefore move faster overall that the expected speed value.

It may be necessary to slow the travel speed of the weaving weld to compensate for this distinction. The amount will depend on the defined amplitude and frequency. As the greater the values, the more motion and and the larger the oscillations will become.