Weld Builder - Using the Weld Wizard

What is the Weld Wizard

The Weld Wizard is one of the two options available when creating a new job. This method of job creation guides users through the process of weld parameter creation and programming a basic weld path. The Wizard integrates the features of the Weld Advisor to assist users in selecting welding travel speed & weld process parameters.

One important limitation to note about the Weld Wizard is as follows. While multiple welds can be programmed into the robot path, only a single set of weld parameters will be applied to all welds created by the Wizard. After the Wizard is completed and job created, the application will then allow the user to make any desired edits within the Weld Editor.

Refer to the Understanding the Weld Editor article for more information.

Basic Features

Navigation & Warnings

At the bottom of the page are the navigation controls for Back & Next. Allowing the user to progress with each step of the Wizard.

Additionally, in the center is a warning box that may display a message about missing or incorrect data. These warnings will prevent navigating to the next page until resolved.

Progress Bar

Along the top of the page, a progress bar indicates the step in which the user is located. Users can navigate back to any step by pressing any blue circle.

Initial Setup

The first step of the Wizard provides some initial feedback of the power source and its connection status. The user must then select how the welding parameters will be controlled.

• [ ROBOT ]
  Allows the robot to control the weld parameters from inline INFORM instructions or Arc Conditions Files.
• [ POWER SOURCE ]
  Has the welding power source command the welding parameters by having the robot call a dedicated "Job Number".
  
  This option may disabled if no Job Mode process is defined within UWI Settings.

Enabling the Weld Advisor

One key feature of the Weld Wizard is the Weld Advisor. As this feature gives new users some guided feedback on selecting their welding parameters prior to programming their weld path.

By default, this feature is enabled. However, it can be turned on or off through the use of the toggle switch labeled "Enable Weld Advisor".

Refer to the Using the Weld Advisor article for more information.

Defining Welding Parameters

Welding Travel Speed

This defines the speed of the robot's torch tip during the any welds programmed in the following steps. The displayed speed units are the same as the system wide TCP Speed defined in the Settings Controller Settings menu.

The user may receive an advised travel speed while using the Weld Advisor feature. This speed can be used as a starting point and may be adjusted up or down manually.

Weld Parameters

Here the weld process and the main control parameter Wire Feed Speed or Amperage is defined. The list of available processes is derived from the configurations within UWI Settings. If the required process is not available, check the selected filter data (Gas, Wire Material, Wire Size) on the setup step and ensure the Process Table is properly configured.

Refer to the Configuring UWI Weld Processes article for more information.

When specifying a Wire Feed Speed (WFS), the value may be manually entered or automatically advised by using the [ USE RECOMMENDED ] button provided when using the Weld Advisor. The Wire Feed Speed should be proportional to the welding travel speed. Meaning, if the WFS is increased the travel speed must also be increased to maintain the same deposition rate.

Refer to the Using the Weld Advisor article for more information on recommendations.

While the primary control parameter within Weld Builder is Wire Feed Speed, some weld processes may also require the use of Amperage. Here, the user will be requested to manually enter an Amperage value instead of Wire Feed Speed. In this case, the Weld Advisor will not be capable of recommending an Amperage value.

Optional Weld Path Features

Weld Builder offers a couple optional features that can either be enabled or disabled to change the behavior of the programmed weld path. These features include:

• Weaving
• Stitching

These options are defined within the Wizard just prior to programming the motion of the weld path. After path programming is completed the option to modify these settings is still permitted in most cases.

Pressing the button labeled with each optional feature on the left of the screen will select that option. Enabling must be done by sliding the "Enable" toggle switch to the right. Once this is done the options for each feature will be provided below. Depending on the feature, they may have more than one page of options. These can be navigated between using the arrows or Next and Back buttons.

Weaving Weld

Enabling this option will add a sine wave pattern to the programmed motion path during all programmed welds. 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.

Refer to the Creating a Weaving Weld article for more information.

Stitch Weld

Enabling this option will generate several intermittent welds along the programmed weld seam. This process can be useful to help better distribute heat input along the joint and reduce the amount of deposition when it may not be required.

Refer to the Creating a Stitch Weld article for more information.

Programming Robot Motion

The final required step is to complete the programming of the welding motion for one or more weld seams. This section will guide the user through the process of generating a basic weld path using helpful text and graphics.

By default, the user will be asked to teach seven moves to create a single weld. However, this number is not fixed as the user is only required to teach a minimum of four moves to successfully create the weld job. Adding more motion is also possible with no real limit on the number of motions taught or number of welds.

Note : The Wizard restricts the definition of the motion path to a more specific sequence to better guide the user through the procedure.

Before beginning motion programming, ensure that the Servos are enabled. The following section describes the available controls for teaching the motion path:

	Label	Description
	Motion Table	Displays the content of the programmed motion path. Select a line to program the next point beneath.
	Clear	Clears the entire programmed motion path. Deleting any single instruction is not yet available within the Weld Wizard.
	Teach	Saves the robot's current position to the job.
	Reteach	Overwrites the selected position with the robot's current position. Updating the motion type as well.
	Joint Motion	The taught motion will move the robot in such a way that all motors reach their final destination at the same time. Resulting in a somewhat flexible or curved path.
	Linear Motion	The robot will reach the taught position by ensuring the TCP moves in a straight line from the previous point in the job.
	Circular Motion	The robot will reach the taught position by ensuring the TCP moves in a circular path. Where in which the path is determined by a sequence of three or more circular moves.
	Jogging	Will reveal the jogging panel of which can be hidden again by pressing the collapse button located to the right-hand middle of the screen. See image below:

Reviewing the Weld

In this final optional step, the user will be asked to confirm their weld settings and programmed motion. The option is available to go back and modify any previously entered data prior to finalizing the job. Once all the data has been reviewed and the job is ready, pressing the [ CREATE ] button will generate the final job and navigate the user to the Weld Editor.

At which point, the job can either be freely modified or can run in PLAY mode whenever appropriate. However, edits can continue to be made prior to completing the Wizard.

Making Adjustments

If any of the data needs to be adjusted, the user can easily navigate back to any previous page. This can be done either by using the [ BACK ] button located in the lower left or by clicking on the blue circles of the progress bar at the top to quickly hop to another step.

If the travel speed of the robot is incorrect, this can be adjusted on the review page for air cut (non-welding) motion. The same speed, depending on motion type, will be applied to all moves. Once the job is created the speeds can be individually modified within the Weld Editor immediately following job creation.

Due to the correlation between welding travel speed and welding parameters, like Wire Feed Speed, the welding speed must be modified by navigating back to the "Define Weld" section. Alternatively, this speed can also be adjusted once in the Weld Editor.

Testing the Path

Pressing the [ TEST START ] button will collapse the view to reveal the Test Start panel. Here, holding down the large [ TEST START ] button will run through the programmed motion from the selected line. Releasing the button will halt motion. Return to the full Weld Builder view by clicking the "Collapse" button in the middle right-hand side of the screen.

Note : The selected line number of the displayed programmed motion may not represent the current executing step after performing the Test Start operation.

Note : The "Welding during test-start" toggle switch does not affect this test run.