Troubleshooting Robotic Welding

In an ideal world, companies would never experience downtime or costs related to

troubleshooting problems in the weld cell. Unfortunately, that just isn’t the reality. And
like any welding process, robotic welding is no exception to problems caused by
equipment failures or human error. However, given that most companies invest in
welding automation to increase throughput and profitability, there is a lot at stake when
something goes wrong in the process.
Most often, when a problem occurs with a robotic welding system, it’s valuable to ask
first: What has recently changed in the process? Has the operator recently
reprogrammed the robot? Or was the system restarted after a long shutdown? What
about the consumables or robotic MIG gun — has anything changed with them?
Quite often, looking at the most recently changed variable in the process can help
narrow down the point of trouble. The issue may be something as simple as a loose
contact tip or more complex like an incorrect tool center point (TCP). Whichever the
case, it’s important to have good troubleshooting skills
to help narrow down the focus and get the robotic welding system back on line sooner.
Poor Consumable Performance and/or Premature Failure
The longevity of consumables — nozzles, contact tips, diffusers and liners — in a robotic
welding application depends in part on the material being welded and the welding
parameters. For example, high-amperage, high-deposition-rate applications tend to be
harsher on consumables than those with lower amperages. However, if it appears that
consumables for the given application aren’t lasting their usual length of time or they are
performing poorly, there could be multiple causes.
In many cases, a loose connection between consumables can be the culprit. Loose
connections increase electrical resistance, causing the consumables to generate
additional heat that can shorten their lifespan and/or cause them to perform poorly. Be
certain to tighten consumables properly upon installation, per the manufacturer’s
instructions, and check them periodically during routine pauses in welding. For
companies that weld thick materials or long welds, it is especially important to make sure
that consumables are tightened properly, as the rework for quality issues caused by
poorly performing ones can generate much more costly rework than an application that
produces multiple smaller parts.
Issues with the contact tip are also not uncommon, particularly burnbacks. These are
often the result of a liner being trimmed too short. Welding operators should follow the
manufacturer’s instructions for trimming and installation, and when possible use a liner
gauge to confirm the correct liner length.
If the robotic welding system utilizes a nozzle cleaning station (also called a reamer) and
consumable issues occur, such as spatter build-up, check to see that this equipment is
working properly. Also be certain that the reamer is cleaning the consumables at a
frequency that is appropriate for the application. It may be necessary to increase the
frequency of cleaning and/or anti-spatter spray application throughout the programmed
welding cycle.
If weld defects — like porosity or lack of fusion — are occurring frequently, it might also
be indicative of an issue with the consumables. Check to see that the contact tip and
nozzle are free of dirt and debris. Replace them as necessary.
Premature Cable Failure
Premature power cable failure can occur in both through-arm robotic welding systems,
where the cable feeds through the arm of the robot, or in standard robotic welding
systems (also referred to as over-the-arm). The power cable may become kinked or
worn, causing the failure — or in extreme cases, it may even snap.
If any of these situations occur, it is important consider the path the robot is programmed
to follow, as well as the length of the power cable being used. First, be certain that the
robot’s movements have not been programmed to be too fast or abrupt. Aggressive
movements can cause the power cable to snap. Or in some cases, it may cause it to flop
around, allowing the power cable to rub against the robot or tooling, or catch on
components — both instances that can lead to premature failure.
Also, check that the power cable being used is not too short for the application or too
long. If it is too short, the power cable will stretch beyond its capacity during routine
robotic movements, leading to greater wear. Conversely, if the power cable is too long it
may be prone to kinking or becoming pinched by the robot’s arm.
Poor Wire Feeding
Poor wire feeding in a robotic welding application can lead to equally poor weld quality.
Issues with the liner, including debris build-up, can often cause the problem. Be certain
to change out the liner during routine maintenance to prevent debris build-up from the
welding wires and the environment. Blowing compressed air through the liner also helps.
Ideally, consider using a robotic MIG gun with an “air blast” feature, which blows the air
through the liner during a scheduled time in the robotic program (for example, during a
reaming or cleaning cycle).
An improperly functioning wire feeder — specifically the drive rolls — can also cause
poor wire feeding. Over time, these components can become worn and may not guide
the welding wire properly. Or the drive rolls may not be tightened correctly. Inspect the
drive rolls for signs of wear and replace them as necessary.
Welding operators can also determine whether the drive rolls are the problem through a
process of elimination. Namely, by conducting a “two finger” test — disengage the drive
rolls, grasp the welding wire and pull it through the gun. It should be able to pull easily
through. If it does then it’s possible that the drive rolls are the cause of the poor wire
feeding. If the wire does not pull through easily, it indicates a problem outside of the wire
feeder and drive rolls, such as debris in the liner or another such restriction within the
robotic MIG gun. It may even be the result of having too small of a contact tip in place.
Welding operators should also look for kinks in the power cable, as these can also lead
to wire feeding problems.
Poorly Performing Peripherals
Peripherals — in particular, reamers — can help companies optimize their robotic
welding performance and extend the life of their consumables. If a welding operator
notices that there is an excessive build-up of spatter on the consumables, however, it
may indicate a problem with the reamer.
There are typically three reasons for a reamer to function poorly. The first relates to the
taught position of the robotic MIG gun nozzle in relation to the reamer. That is, where the
robot clamps to the reamer. The position should be exactly perpendicular to the cutting
blade on the reamer. Any misalignment of the nozzle during cleaning could lead to partial
cleaning of the nozzle and excessive spatter build-up. As a first step in troubleshooting,
check that the taught position is correct.
Secondly, if using anti-spatter solution, check that the spray location is correct. Is the
solution fully coating the inside of the nozzle? If not, adjust the location accordingly. The
nozzle should be coated until it is slightly damp on the inside and the outside should be
covered to within three-quarters of an inch from the bottom of the nozzle. And while it
seems like an obvious troubleshooting step: Always be sure to check that there is anti-
spatter solution in the sprayer!
Lastly, be certain the proper cutting blade is in place and that it is sharp.
Trouble with TCP?
In addition to speed, one of the greatest advantages of a robotic welding system is the
repeatability that it provides, and the subsequent quality of the welds. If a welding
operator begins to notice inconsistent welds or welds that are off-location, it may be a
problem with the TCP.
TCP is the focal point of a tool. In the case of a robotic welding system, it refers to the
location of the robotic MIG gun and how it corresponds with the position of the welding
wire in the joint (gun-to-work distance).
Most often, issues with TCP occur after a collision, during which the neck of the robotic
MIG gun becomes bent. To rectify the problem, welding operators should use a neck-
checking fixture or neck alignment tool to make sure the neck is bent to the proper angle.
It is also important to check that the neck is installed correctly. If the neck isn’t fully
seated, it may extend too far and lead to TCP problems. To protect against future issues,
it may also be helpful to program a TCP check to verify the proper position.
Welding operators, however, shouldn’t assume that welds that are off-location are
always caused by an incorrect TCP. In some cases, they can be the result of improper
fixturing, fixturing that allows the part to move or a loose robot base. Or there may be a
variation in the part itself.
To differentiate between a TCP problem and other problems that could cause off-location
welds, first take the neck off the robot, implement a TCP check via the robotic program
and verify that everything is on-location. If everything checks out properly, the problem is
likely a part or position variation.
Final Considerations
When something goes wrong in a robotic welding system, it is critical to identify the
problem as quickly and accurately as possible. Not only can swift troubleshooting ensure
that the operation returns to producing quality, repeatable parts, but it can also help
prevent unnecessary costs for replacing components that may not need replacing.
Always start with the simplest solutions first and consider keeping a checklist for setup
and maintenance procedures. Having a quick reference point can help facilitate the
troubleshooting process by identifying potential variables that have changed during the
course of routine operations.