From reamers or nozzle cleaning stations to wire cutters and anti-spatter sprayers, welding peripherals and accessories can contribute significantly to the success of a robotic welding operation. In addition to improving weld quality, they can also help companies maintain high levels of productivity.
|A reamer requires the most attention, as this peripheral operates regularly, performing essential welding nozzle cleaning that helps keep the robotic welding cell up and running and quality on par.|
Reamers, in particular, are most prevalent in automotive manufacturing, where uptime and quality are critical. This peripheral cleans the welding consumables — for example, welding nozzles and gas diffusers — free of spatter, and most automotive welding operations rely on the process after virtually every weld cycle. Other industries, such as heavy equipment manufacturing, also employ reamers and other peripherals in their robotic welding operations, as do some general manufacturers.
It’s not by chance that peripherals work the way they do. Like any equipment, caring for them with routine preventive maintenance (PM) is important to gaining optimal performance and longevity.
PM tips for reamers and accessories
A reamer requires regular attention since it operates frequently during the weld cycles. Its job is important though, as it performs essential welding nozzle cleaning that helps keep the robotic welding cell up and running and quality on par. With the PM for this equipment also comes PM for its associated accessories: the lubricator, cutter blades and anti-spatter sprayer. All require varying levels of PM activities — some daily, weekly, monthly or yearly.
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Preventive Maintenance Checklist
In addition to inspecting the consumables for wear and replacing as needed, follow this PM routine on a daily basis:
|Check daily that the lubricator is working properly with the right level of oil and clean the filter weekly, replacing it as needed.|
On a weekly basis, continue to examine the integrity of the consumables and follow these guidelines:
Monthly PM for reamers and accessories requires less steps but is more intensive. It may require scheduling a time off cycle to complete.
Lastly, on an annual basis:
While it may seem time-consuming to implement these PM measures, they can typically be completed during routine pauses in production. More intensive activities can be scheduled so as to prevent interruption to production. Ultimately, the PM is time well spent and can help protect the investment in the reamer and its accessories.
PM tips for wire cutters
Wire cutters are increasingly being used in automotive and other manufacturing operations. This equipment is integrated into a reamer configuration and used in conjunction with a wire brake on the robotic MIG gun. The wire brake prevents the welding wire from moving, while the wire cutter cuts it at a set distance. This allows for a consistent wire stickout so the robot can touch sense and track the joint before welding. The results are more accurate weld placement and smooth arc starting.
|Wire cutters are increasingly being used in automotive and other manufacturing operations and can help with smooth arc starting.|
PM for wire cutters is relatively simple.
The value of peripherals
Peripherals like reamers with anti-spatter sprayers and wire cutters can help companies realize a greater return on their investment in a robotic welding system. They aid in high weld quality, minimize rework and help meet productivity goals. Train welding operators to follow recommended PM activities as a part of a routine care of the weld cell. The time and cost to care for them properly will be small in comparison to the improvements they can provide to the bottom line.
As a premium quality brand of robotic MIG guns, consumables and peripherals, Tregaskiss has earned a reputation as an experienced, dependable partner to its customers in the automotive, fabrication, heavy equipment, agriculture, shipbuilding and repair, truck and trailer, and construction industries. Tregaskiss offers air-cooled robotic MIG guns, water-cooled robotic MIG guns, reamers, nozzle cleaning stations, anti-spatter liquid, wire cutters, anti-spatter sprayers, clutches, welding consumables, nozzles, MIG welding tips, welding torches, welding cables, and automatic welding torches.