PRODUCT IMPROVEMENT –
Nozzle Detection Option for TOUGH GUN TT3 and TT3E Reamer Robotic Nozzle Cleaning Stations
April 28, 2017
An improvement has been made to the nozzle detect option for our TOUGH GUN® TT3 reamer. This same option is also now available on our TOUGH GUN TT3E reamer.
This new nozzle detect uses a proximity sensor mounted on the side of the reamer that can be used independently of the ream cycle and is compatible with any nozzle size. The robot positions the front end of the MIG gun close to the sensor to detect the presence of the nozzle. If the nozzle is present, a signal is then sent back to the robot controller or PLC.
Affected Part Numbers
- TT-2333 + TT-2334 – OLD nozzle detect for TOUGH GUN TT3 reamer (analog model); available only for 1.062″ nozzle O.D.
- TT3E-2344 – NEW nozzle detect for TOUGH GUN TT3 and TT3E reamer; available for all nozzle O.D. sizes
- RS-500-5 – 4m cable with 3 poles (M12 connector); required for analog model only and only when selecting Nozzle Detection option
- TT3E-2343 – Splitter; required for Ethernet model only and only when selecting both the nozzle detect and the wire cutter options together
To learn more about our TOUGH GUN TT3 reamer offering, or configure your reamer online.
April 28, 2017 Upgrades have been made to the TOUGH GUN® TT3 reamer to allow for a more common design between this model and the TOUGH GUN TT3E reamer. These upgrades include a common frame, replacement of the terminal strip with a new wiring harness, easy access setup switches, and a new check valve. The wiring harness: Click here for additional information about the TOUGH GUN TT3 reamer.
April 15, 2017 The check valve on the TOUGH GUN® TT3 and TT3E reamer robotic nozzle cleaning stations have been upgraded to a more robust and durable design. The new check valve is now common between both the analog and the Ethernet model. Important Notes: Learn more about our TOUGH GUN TT3 reamer offering.
In welding, poor wire feeding is a common challenge — one that can be extremely costly for an operation and take a toll on productivity. From the downtime for troubleshooting to faster wear and replacement of consumables, wire feeding issues such as bird-nesting, burnback and liner clogging can have a significant impact on the bottom line. There are many potential causes of poor or erratic wire feeding. It can stem from the style or size of liner being used, the contact tip size, the gun and whether it’s coiled, or other factors. While finding the cause of the problem can be complicated, wire feeding issues often have simple solutions. To best troubleshoot the problem, start by checking for possible issues in the wire feeder and then work toward the front of the gun to the contact tip. There are numerous issues related to the equipment that can cause erratic wire feeding. If the drive rolls don’t move when the gun trigger is pulled, this could be a feeder relay malfunction or a broken relay. Consult the feeder manufacturer in this case. No response when pulling the gun trigger could also stem from a broken control lead. Control leads can be easily tested with a multimeter to see if a new cable is needed. In applications where an adapter is used to connect the gun to the feeder, a poor adapter connection could also be the source of wire feeding problems. Check the adapter with a multimeter and replace it if it’s malfunctioning. Multimeters can also be used to check trigger switches, which can cause feeding issues if they are worn, dirty or damaged from the gun being dropped. In addition, an improper guide tube installation or an improper wire guide diameter can also cause wire feeding issues. The guide tube is used between the power pin and the drive rolls — typically when there is an adapter being used on the feeder — as a way to keep the wire feeding properly from the drive rolls into the gun. Be sure to use the proper size of guide tube, adjust the guides as close to the drive rolls as possible and eliminate any gaps in the wire path to avoid feeding issues. Wire guides are used between the two sets of drive rolls inside the feeder, guiding the wire from one drive roll to the next. These must be properly sized for the wire to avoid problems with wire feeding. The use of incorrect drive rolls can be another common source of erratic or poor wire feeding. When it comes to selecting the right drive rolls, there are several best practices to keep in mind for successful wire feeding. Drive roll size: Drive roll size should match wire size — a .035-inch wire needs to be paired with .035-inch drive rolls. Drive roll style: Choosing the right drive roll style depends on the type of wire being used. The types of drive rolls – V-knurled, U-knurled, V-groove and U-groove – offer pros and cons depending on the wire type. A solid wire is typically used with smooth drive rolls, for example, while a U-shaped drive roll in smooth or knurled tends to work better for flux-cored and metal-cored wires. For context, the groove term refers to the geometry of the shape in the drive roll while the knurled term references the finish inside the groove. Drive roll tension: Setting the proper drive roll tension is important to ensure pressure on the wire is sufficient to push it through without changing its shape or fracturing it, leading to poor wire feeding. Worn drive rolls: Inspect drive rolls every time a new spool of wire is put on, and replace them as needed. An additional note on drive roll styles: take care when setting the tension on knurled drive rolls with cored wires. While the teeth of the drive rolls can help push the wire through, setting the tension too high can result in the teeth fracturing the thin column of the wire, causing bird-nesting in the feeder. When using knurled drive rolls with solid wires, which is sometimes acceptable, proper tension adjustment is critical. There should be enough tension to push the wire through the cable, but too much tension will cause the knurled teeth to dig into the wire and create shavings that can clog the liner. In applications where the welding operator is having trouble feeding cored wire, it can be helpful to use a U-shaped smooth drive roll on top with a U-shaped or V-shaped knurled drive roll on the bottom. The teeth on the bottom drive roll can help push the wire through, while the smooth drive roll on top helps protect the wire shape. Liner issues are among the most frequent causes of wire feeding problems. Here are some things to check: Liner length: A liner that is cut to an incorrect length can cause wire feeding issues, wire chatter, an erratic arc and/or burnbacks. Using a liner gauge can help when trimming the liner. There are also consumables that lock the liner in place (after loading it through the gun’s neck) at the front and back of the gun while concentrically aligning it to the contact tip and power pin. The liner is then trimmed flush with the power pin at the back of the gun. There is no need to measure. This type of system provides a flawless wire-feeding path. Liner size: Using the wrong size liner for the wire can also cause feeding issues. It’s recommended to use a liner that is slightly larger than the diameter of the wire to provide more room for the wire to feed through the liner. Because welding wire is coiled, it tends to corkscrew its way through the liner as it unspools. If the liner isn’t large enough, it takes more force to push the wire through. This can result in the wire breaking inside the gun or bird-nesting at the feeder. Liner style: Liners are available in plated or non-plated styles, and the right choice depends on the geometry of the wire. A plated liner has a smooth finish, while a non-plated liner has a rough finish. It takes less force to feed wire through a smooth, plated liner. Therefore, it’s recommended to use a plated liner with cored wires since they are softer, and using too much force to push them through the liner could cause them to break. Liner buildup: A buildup of debris inside the liner can also lead to poor wire feeding. Debris can be the result of using the wrong type of drive roll, which can cause wire shavings inside the liner, or it can be due to microarcing as the wire corkscrews through the liner. Over time, this microarcing can result in weld deposits inside the liner, which can require more force to push the wire through. Also, dragging the liner across the floor can cause it to pick up dirt and debris. Replace the liner when buildup results in erratic wire feeding. Welding operators can also blow compressed air through the cable to remove dirt and debris each time the liner is changed. Watch for contact tip wear Worn or dirty contact tips can cause wire feeding issues. The hole at the end of the contact tip is large enough for the wire to feed through. With use over time, the contact tip can wear and the hole becomes more oblong in shape. This is called keyholing. In addition, small balls of spatter can sometimes become welded inside the contact tip, causing burnback and poor feeding of the wire. To minimize the opportunity for keyholing, look for a consumable system that concentrically aligns the liner and contact tip, since this connection creates less mechanical wear on the tip’s interior diameter and reduces the risk of keyholing. Less keyholing also means less chance of an erratic arc, excessive spatter or burnback, which helps lengthen the life of the contact tip. These systems also bury the contact tip further in the gas diffuser to protect it from heat damage. Shielding gas cools the contact tip tail as it flows through the gun, further reducing heat and minimizing contact tip wear. Lastly — the gun: Using a gun with a 25-foot cable when one with a 10-foot cable would suffice often results in bunching of the cable. The minute the operator starts coiling the weld cable during welding, wire feeding troubles can result. Choose the proper gun length for the application and keep the cable as straight as possible during welding to help prevent feeding issues. Wire feeding issues can cost time and money in downtime, wear and replacement of consumables and lost productivity. While there are many potential causes to poor wire feeding, many of them have simple solutions. It’s often a matter of methodically working through the checklist, starting at one end and working toward the other, to find the issue and implement a solution.
March 16, 2017 Bernard is pleased to announce that we have added a 300 amp model to our Clean Air™ fume extraction MIG gun offering. Reduce smoke at the source with an industrial-duty fume extraction gun that is comparable in size and weight to a regular welding gun. Click here to learn more about the Clean Air fume extraction MIG gun.
Through-arm robotic welding systems are becoming increasingly common in the industry, as more equipment manufacturers turn to the development of this style compared to conventional robots. However, there are some applications where it is better to use a conventional robotic gun for these systems, instead of the through-arm gun typically chosen. The good news is that most through-arm robotic welding systems allow for mounting either type of gun — providing more options and flexibility depending upon the needs of the application. And while the choice of gun is sometimes an afterthought, it can significantly impact efficiency, throughput and quality of the finished weld. Choosing the best option for the job up front is key. As the name suggests, the power cable assembly of a through-arm MIG gun runs through the arm of the robot as opposed to over the top of it like in a conventional gun. Because of this design, the through-arm gun style is often more durable, since the power cable is protected. However, because conventional guns can be used on either type of system — a through-arm robotic system or a conventional robot — they can sometimes offer greater flexibility, and can be used with more robot makes and models. There are numerous factors to consider when making the choice between a through-arm gun and a conventional robotic gun for a through-arm robotic welding system: Conventional style guns, which typically offer a longer neck, can provide more flexibility in accessing or reaching certain weldments, whereas through-arm guns may have difficulty reaching around fixturing or tooling in some cases. In applications where a through-arm gun is installed and it doesn’t reach the weldment as needed, a conventional gun can be swapped in for access purposes. In addition, conventional guns are often a good choice in smaller, more modular weld cells that feature short-armed robots. Through-arm guns may not work as well in these situations because there is not as much cable, and therefore the robot doesn’t have as much slack for articulation. Also, because of the way the cable lies in a conventional gun, the bend radiuses of the cable are much larger than in through-arm guns. When welding aluminum, for example, wire feeding is a major contributing factor to poor weld quality, and therefore tight bend radiuses are not recommended. This makes conventional guns a good option when robotic welding aluminum. Uptime and throughput are also critical in robotic welding applications, and maintenance is a key factor that impacts productivity, downtime and costs. Conventional guns often provide easier maintenance because everything is outside of the arm, allowing for parts to be changed or repaired quickly to minimize downtime. Another benefit of conventional guns is they tend to be more cost-effective to purchase and can be installed much faster — saving time and money in setup. Through-arm guns provide their own advantages when matched with a through-arm robotic welding system. In applications that require plunging deeply into a fixture or part, a through-arm gun is often a better choice. Think of a through-arm gun as an extension of the robot arm. This extension allows it to access different areas within the part being welded, depending on the application. In addition, because the cables are more protected on a through-arm gun they tend to last longer overall, which helps reduce replacement costs. The through-arm design naturally protects the power cable and makes it less prone to snagging on fixturing, rubbing against the robot or wearing out from routine torsion. With either a conventional gun or a through-arm gun, there are some common best practices that can contribute to success in robotic MIG welding. First, it is critical that the cable is never under tension when using a through-arm gun, to help prevent premature cable failure. Cable tension is visible on a conventional style gun but not on a through-arm gun since the cable runs through the gun. This makes proper setup especially important with through-arm guns. In addition, it’s best to use a cable management system when using a conventional gun to ensure there isn’t too much slack in the cable. With too much slack, the cable will rub on anything around it and possibly catch on fixturing. When a robot moves at production speed, it can break the cable or fixture. Keep these factors in mind, along with joint access requirements and weld cell layout, when making the gun choice to help improve throughput and productivity.
February 13, 2017 Tregaskiss is pleased to announce an improvement to our low-stress robotic (LSR) unicable design whereby the cable conduit will be fixed only on the torch end, and floating on the power pin end. This design change will result in a more flexible, less restricted, longer lasting LSR unicable for all TOUGH GUN® TA3 robotic MIG gun product. Click here for more information about low-stress robotic (LSR) unicables.
As companies seek to gain a competitive edge, it’s not surprising that some turn to welding automation. It offers numerous advantages, including greater productivity, improved quality and cost savings compared to a semi-automatic welding operation. However, to gain the most out of the investment it’s important to follow some best practices in the weld cell. These considerations include the careful selection, installation and maintenance of gas metal arc welding (GMAW) guns. As with any type of welding equipment, the goal is to implement the GMAW gun in a manner that optimizes performance, reduces downtime and prevents the accrual of unnecessary costs. It is important to note that the considerations for achieving these benefits may vary depending on whether the robotic welding system uses a through-arm gun or a conventional-style gun. Following are some tips to help. All automated welding systems need some form of collision detection to minimize damage to the robot and the GMAW gun in the event of an impact. Today’s robots typically have built-in collision detection software, making it appropriate to use only a solid gun mount to connect and position the GMAW gun. In some cases, companies like the secondary insurance of using a clutch on robots featuring this software. Doing so, however, can add unnecessarily to the expense of the operation, increase weight on the front end of the robot arm and cause the tool center point (TCP) to be less repeatable. When possible, it is preferable to use a solid mount coupled with collision detection built into the robot, instead of a clutch. Solid mounts offer numerous advantages, especially for systems using a through-arm style gun. A solid mount can aid in achieving a more accurate TCP, providing greater repeatability for more consistent welds. They are also more cost effective and lighter weight, which allows for quicker movement and potentially better productivity. The use of a solid mount, in conjunction with a through-arm robotic GMAW gun, typically opens up the work envelope, so the robot arm can better access the weld joint. For systems with a conventional gun, a solid mount provides little benefit over a clutch in terms of opening up the work envelope or increasing productivity due to the position of the gun in comparison to the faceplate of the robot. Air blast is an optional technology on GMAW guns that can help enhance gun performance. This feature can be factory-installed or retrofitted into a gun. Utilizing air blast when possible helps eliminate debris in the front part of the robotic GMAW gun, reducing opportunities for weld contamination that can lead to poor weld quality, costly rework and downtime. As the name implies, the air blast feature blows compressed air through the front of the gun to remove debris. It can be used with air-cooled robotic guns or water-cooled models. In addition to removing debris that can cause poor weld quality or contamination, air blast can help increase the time between cycles by removing spatter from the front of the gun. The air blast function can also be used to cool down the gun between weld passes, to help operations avoid going over the duty cycle limit when using air-cooled guns. Using simulation software to model the proposed weld cycle before selecting and implementing a robotic GMAW gun can help in achieving the best results with an automated welding system. While the goal with an automated welding system is often to move as quickly and freely as possible, it’s important to remember that it’s typically best to limit excessive robot movements, as it results in longer gun life thanks to reduced equipment stress. Simulation programs can be used to determine proper system setup, including TCP requirements and which nozzle and GMAW gun neck are best suited to get the desired joint access or angle. The reach and access of the gun neck, in particular, is an important factor in system movement and stress. Changing the neck angle from 22 degrees to 45 degrees, for example, can have a significant impact on robot articulation. This is where a simulation program is beneficial, since it can be used to determine the type of neck and the neck angle that are best for the application before making the investment. To gain optimum speed and performance from the gun, it may be as simple as slightly adjusting the height of the risers or tooling to gain better access to the weld and reduce stress on the gun. Among several peripherals that can be added to maximize system performance, a neck inspection fixture is one that can help improve throughput, minimize unnecessary downtime — and help gain the best performance from the robotic GMAW gun. A neck inspection fixture verifies that the gun neck is set to the intended TCP and allows the neck to be readjusted after a collision or if it becomes bent during routine welding. When neck adjustment is needed, the welding operator can simply adjust the neck to meet specifications. This helps prevent costly rework due to missed weld joints and can prevent the downtime it takes to reprogram the robot to meet the necessary welding specifications with a bent neck on the gun. In some cases, the welding operator can simply remove the bent neck and exchange it with a spare neck to get the system back online quickly. The damaged neck can be set aside for inspection later, resulting in less interruption to the weld cycle. Using a neck inspection fixture from day one of an automated welding system helps ensure a consistent TCP. Choosing the right gun and cable for the application — and installing them properly — are key steps toward maximizing performance of the robotic GMAW gun. Consider the weld length, the required amperage and the type and thickness of material being welded when selecting a robotic GMAW gun. Air-cooled guns work well on lower amperage applications and high-volume welds. In heavy equipment manufacturing and similar industries, a water-cooled GMAW gun may be necessary to weld on thicker materials for longer periods of time. Water-cooled guns offer high amperages — usually up to 600 amps — at 100 percent duty cycle. Selecting the appropriate neck, power cable and other gun components can also have an impact on productivity and performance. Choosing the proper neck style and length for the application provides the gun with easy and complete access to the weld joint, which helps reduce weld defects and downtime for rework. Available neck angles typically range from 180 to 45 degrees, with varying lengths to accommodate most robotic welding applications. Necks can also be special ordered for custom TCP requirements when necessary. In addition, power cable style and length can also impact efficiency in robotic welding operations. For through-arm applications, the power cable is often sold in set lengths to match a specific model of robot, so the selection process is easier. For conventional style robots, it’s important to verify the exact length needed. Too long of a cable can easily kink or move during the welding process, while too short of a cable can stretch and shorten cable life. In both cases, it can result in downtime, premature cable failure and increased costs. Also, look for a sturdy power cable that can withstand UV damage from the arc and resist wear. Cables with quick-change features can extend cable life, simplify cable changeover and maximize arc-on time when installed properly. Regularly check all connections on the GMAW gun to ensure they are tight and secure. Doing so helps prevent issues that can lead to weld defect and downtime. Tighten front-end consumables and check that all seals are in good condition. Also be certain the power pin is secure. While checking that welding cable leads are secure, look for signs of wear and replace them as necessary. Remove spatter from the GMAW gun nozzle regularly, ideally applying anti-spatter to protect against buildup. Implement a reamer when possible to minimize damage to the gun and front-end consumables. A reamer (or nozzle cleaning station) removes spatter from the nozzle bore and clears away debris that accumulates around the diffuser during welding, resulting in longer life of the consumables and higher weld quality. The reamer can be programmed to run between welding cycles — either during part loading or transfer — so it does not add to the overall cycle time per part. In addition, track the life span of the GMAW gun liner and replace it prior to failure. Replacement liners should be trimmed to the appropriate length using a liner gauge. Automated welding operations that are larger in size may need to do more frequent preventive maintenance. It’s especially important for companies that complete large weldments on thick materials because they stand to have greater costs and downtime for rework in the event of gun failure. Automated welding systems add speed, accuracy and repeatability to the welding operation. They can help companies increase productivity and reduce costs in a relatively short period. Implementing some best practices can help companies extend the life of the GMAW gun and consumables, and optimize performance and efficiency of an automated welding system — offering them the most out of the investment.
February 3, 2017 Tregaskiss now recommends trimming all rear-loading conventional and front-loading QUICK LOAD® liners that are 6-feet in length and shorter with a 1/2-inch stick out. This new trim length provides performance improvements for the liner and cable, and for wire feeding overall. It also helps to reduce some strain on both the liner and the cable while still maintaining a proper liner seat in both the retaining head and the power pin. Effective late February, all bagged 6-foot Tregaskiss conventional and QUICK LOAD liners will include a new 1/2-inch blue liner gauge along with a technical insert outlining these updated trimming instructions. The outside of each bag will also be marked with a sticker indicating a change to liner trim length.
December 16, 2016 Bernard has changed the finish on all Clean Air™ fume extraction gun vacuum tubes and chambers from chrome to black. Effective immediately, all new guns, replacement vacuum tubes and replacement chambers will have the new darker finish. This change is purely aesthetic, and has no impact on performance, part numbering or price. Click here for more information about the Clean Air™ fume extraction gun.
Ensuring a robotic welding cell stays productive and consistently generates a positive return on investment is determined, in large part, by the amount of downtime it incurs. Since robotic welding systems are built for speed, accuracy and repeatability, the cost of arc-off time spent addressing issues is exponentially higher than in a typical welding cell. Having welding operators and robotic weld cell supervisors who can quickly troubleshoot and solve problems makes all the difference when it comes to keeping costs down, generating high-quality results and maintaining optimal efficiency. Here are five common causes of downtime that can occur in a robotic welding operation, along with ways to prevent and address them. If a power cable rubs against the robot, on parts or against tooling, it can prematurely fail and cause unnecessary downtime. In some cases, the cable may even catch on components and wear them out, too. Cables that are too long or too short create excessive strain by either being pulled too tight or flopping around too much and creating strain at the front housing — both of which lead to premature cable failure. These issues are common with conventional style robots, where the power cable connecting to the robotic MIG gun is external to the robot arm. The goal is to set cable length to allow it to exit the front housing with a smooth arc, resulting in minimal strain. Alternately, in the case of a through-arm robotic welding system, downtime often occurs due to improper installation of the gun and/or improper cable length. By adding cable tensioners, which are essentially spring-loaded cable devices that hold the power cable, operators can ensure the cables stay properly supported on a conventional robot. Programming the robot so that it doesn’t accelerate or decelerate too quickly or abruptly can also protect against premature cable failure. In some cases, if the work envelope is quite small, cable rubbing may be unavoidable. Using a protective wrap to shield the cable from rubbing can help. These are available in the marketplace as either a leather or woven nylon cover, or a plastic spiral wrap. When installing a through-arm robotic MIG gun, be sure to position the robot with the wrist and top axis at 180 degrees, parallel to each other. Then install the insulating disc and spacer the same as with a conventional over-the-arm robotic MIG gun. Always be sure the power cable position is correct and has the proper “lie” with the robot’s top axis at 180 degrees, and ensure the power cable has about 1.5 inches of slack when installing it, so it is not too taut. Although consumables may seem like a small part of the robotic welding process, they can have a big impact on how productive and effective an operation is. Nozzles, contact tips, retaining heads (or diffusers) and liners can all fail prematurely or perform poorly for a variety of issues, including spatter or debris buildup, loose connections and improper installation. Issues with the contact tip — especially burnbacks and cross-threading — are also relatively common, and are often caused by a liner being trimmed too short. Choosing durable, easy-to-install consumables is key to minimizing both planned and unplanned downtime in a robotic welding operation. Longer lasting consumables require less frequent changeover. Plus, designs that help less experienced welding operators install consumables correctly result in less troubleshooting. Contact tips with coarse threads and a long tail ensure the tip aligns concentrically in the gas diffuser before the threads engage. These features help minimize the risk of cross-threading. Also, contact tips with greater mass at the front end and that are buried further down in the gas diffuser better withstand heat from the arc to help them last longer. For pulsed welding operations, contact tips with a hardened insert help the tip last 10 times longer than those made of copper or chrome zirconium. That is important since the pulsed waveforms are especially harsh on contact tips and cause them to wear prematurely. Operators should always inspect consumables for signs of spatter or debris buildup during routine breaks in production and, if signs of either are present, replace or clean them. They should also ensure their nozzle cleaning station or reamer is working properly, if one is present, and that it is programmed to ream at a rate that is appropriate for that specific application. It may be necessary to increase the frequency of the anti-spatter spray application or reaming throughout the programmed welding cycle. Check that all consumable connections are clean and secure, as loose connections can generate additional heat through increased electrical resistance, shortening consumable life and/or causing them to perform poorly. Consumable designs that are tapered can also help minimize heat buildup and extend consumable life by offering better electrical conductivity. Welding operators should always follow the manufacturer’s instructions for liner trimming and installation, as a liner can cause inconsistent feeding if cut too short. It is a good idea to use a liner gauge to confirm the correct liner length. There are also spring-loaded modules that work in conjunction with a front-loading liner to help minimize issues if the liner is cut to an incorrect length. These are housed in the power pin and apply forward pressure on the liner after it is installed. They typically allow up to 1 inch of forgiveness if the liner is too short. It is also important to replace liners frequently enough, as a clogged liner full of debris and dirt will not feed properly, and may cause premature contact tip failure. Excessive spatter buildup in consumables can be caused by a nozzle cleaning station that isn’t operating properly and can easily cause unnecessary downtime. Issues related to nozzle cleaning stations can be caused by an incorrect position between this peripheral and the robotic MIG gun nozzle; poor anti-spatter compound coverage; or a dull or improperly sized cutter blade. If a nozzle cleaning station doesn’t appear to be working properly, first check that the robotic MIG gun is concentric to the cutting blade on the reamer. Misalignment of the nozzle can lead to partial cleaning and excessive spatter buildup. Also check that the anti-spatter sprayer, if present, is full, correctly positioned and properly coating the nozzle during spraying. The nozzle should be slightly damp on the inside and outside, and covered up to three-quarters of an inch from the bottom of the nozzle. Note that over-spraying anti-spatter compound can cause nozzles to deteriorate prematurely, so it should never be sprayed for more than half a second. Be sure that the cutter blade matches the diameter of the nozzle bore, so that it can effectively clean during the ream cycle without hitting the nozzle or the gas diffuser. It is also important to have a sharp cutter blade and to make sure that the nozzle is at the correct depth within the jaws of the nozzle cleaning station. Finally, adding an air blast feature to a robotic GMAW gun can help support the nozzle cleaning station’s overall effectiveness. An air blast feature blows high-pressure air through the gun’s front end, which helps remove spatter, debris and other contaminants. This feature can help reduce how often a nozzle cleaning station needs to be used and, ultimately, boost productivity. Collisions can occur as the result of tooling that hasn’t been secured properly, an item inadvertently being left in the weld cell or poor part fit-up. Unfortunately, not only can collisions create unwanted downtime, but they can also damage the robot arm, the robotic MIG gun and/or front-end consumables. Many newer robots are equipped with collision detection software that serves the same function as a shock sensor, but some companies still use a shock sensor as a backup safety measure. For robots that don’t have built-in collision software, a shock sensor can act as a safety device to protect the robot arm and gun from damage if the robot crashes. In the event of a collision, the shock sensor sends a signal back to the robot to alert it to shut down. In order to determine that the shock sensor switch is working properly, operators should conduct a continuity check in the open and closed position of the switch using a multimeter or manually trip it by bumping the neck with their hand. If the sensor is working properly, it will send a signal back to the robot indicating there is a problem. Always reset the shock sensor to its home position and recheck the tool center point (TCP) after a collision, and confirm that both the TCP and clutch are correct. If welding operators are using a newer robot with collision detection software, they should make sure it’s set up correctly and that both the TCP and center of mass or balancing point have been programmed according to the gun manufacturer’s specifications. Doing so helps ensure the robot will react properly in the event of a collision. Poor wire feeding in a robotic welding system is usually caused by one of three things: 1) issues with the liner, such as a clogged liner, 2) a wire feeder that isn’t functioning properly or 3) power cable kinking. Regardless of the cause, the result is poor arc stability and weld quality. As previously mentioned, regularly changing the liner and using a robotic MIG gun with an “air blast” feature help eliminate debris in a liner. If an air blast feature is not available, welding operators can also manually blow compressed air through the liner periodically. If it is suspected that the wire feeder’s drive rolls are the culprits of the poor wire feeding, there are two ways to further investigate and assess the situation. One is to visually inspect the drive rolls for signs of wear, and the other is to conduct a “two-finger” test. The latter involves disengaging the drive rolls, grasping the welding wire and pulling it through the gun. The wire should be able to be pulled easily with two fingers. Lastly, look for kinks in the power cable, which can also lead to poor wire feeding, and then straighten or unwind the cable, if necessary. Remember, knowing how to troubleshoot common problems in a robotic welding operation can make the difference between costly downtime and consistently productive, arc-on time. And making the effort to address potential issues up front can actually save time and money in the long run.
BEECHER, Ill., November 22, 2016 – Bernard has announced the expansion of handle options from six to seven choices for its BTB semi-automatic MIG gun line. Handle options now include the new C series straight handle, which provides all the benefits of the existing T series straight handle, plus additional ergonomic benefits such as a handle overmold and rear swivel — at no extra cost. Designed for maximum configuration flexibility and industrial-grade performance, Bernard BTB semi-automatic MIG guns provide users with options ranging from 200 to 600 amps with numerous cable length choices between 8 to 25 feet. The new C series straight handle is available for guns rated from 200 to 500 amps. By visiting the BTB MIG gun configurator, users can customize their gun with the C series straight handle or other handle options, choosing from three high performance consumables series — Centerfire™, TOUGH LOCK® or Quik Tip™ consumables — and multiple trigger options. Insight Limited™ triggers are an available option when selecting the new C series handle, and are designed specifically for use with power sources from Miller Electric Mfg. Co. that feature Insight Centerpoint™ welding information management systems. Users can also choose from 20 fixed and rotatable necks in various angles and lengths on any front handle style, and power cables are available in industrial-grade or steel monocoil to meet a variety of user needs. The BTB semi-automatic MIG guns feature a one-year warranty plus lifetime warranties on both the rear strain relief and the front handle. Additionally, BTB guns equipped with the new C series straight handle or a T series straight handle feature the double-life MIG gun system. When the front end of the gun becomes worn from routine use, this system allows users to simply flip the front end of the gun with back end for additional use.
December 18, 2019 Tregaskiss manufactures TOUGH GUN® TA3 through-arm welding torches for many Yaskawa® Motoman® robot models including but not limited to: On the current robot models listed above, the spacers and through-arm cables on a Tregaskiss® gun may originate from either Tregaskiss or from Yaskawa Motoman. It is important to note that the spacers and cables from Tregaskiss have significantly different dimensions than these same items from Yaskawa Motoman. This means that they are NOT interchangeable. Ordering the wrong replacement spacer and/or cable for an existing installation will significantly impact Tool Center Point (TCP) and cable life – please see Configuration Comparison Chart below for both solid mount and clutch mount setups with a short 45-degree neck for reference. For each model above, when a TOUGH GUN TA3 MIG gun is configured through Tregaskiss, the complete torch solution is Tregaskiss branded and includes: consumables, neck, torch, cable and power pin. For AR/MA1440, MH12, AR/MA2010, AR/MA3120, AR1730, MH24 models, the system also includes a Tregaskiss-specific aluminum spacer which allows us to bury the cable termination into the torch and away from the articulation on axis 5. When Yaskawa Motoman integrates a welding solution with Tregaskiss product, a Motoman through-arm cable replaces the Tregaskiss through-arm cable for all models listed above (consumables, neck, torch and power pin remain Tregaskiss branded). For AR/MA1440, MH12, AR/MA2010, AR/MA3120, AR1730, MH24 models, the system also includes a Motoman-specific plastic torch spacer which allows us to bury the cable termination into the torch and away from the articulation on axis 5. This Motoman spacer is shorter than the Tregaskiss spacer and as a result, the Motoman cable for this setup is also shorter than the Tregaskiss-specific setup. NOTE: Reference chart above is applicable for Yaskawa Motoman robot models AR/MA1440, MH12, AR/MA2010, AR/MA3120, AR1730, MH24. 58SM016 Solid Mount Solid Mount Motoman Solid Mount 58SM002 58SM038 58SM038AW MA3120, AR3120 Solid Mount AS-114-13 58SM032 58SM032A 58SM032W 58SM032AW 58SM039 58SM039W Clutch 58CM016A 58CM016AW Motoman EA1900 XRC Clutch N/A 58CM001A Motoman 58CM035 Motoman 58CM002AW AS-114-13 Clutch 58CM031W 58CM031AW Clutch 58CM032 58CM032A 58CM032W 58CM039W NOTE: If Tregaskiss® TOUGH GUN I.C.E.® technology is required for your application, the cable must be purchased from Yaskawa Motoman for all of their robot models. If you require Yaskawa Motoman components, please contact Yaskawa Motoman directly. Otherwise, if you require Tregaskiss components, please contact us for assistance.
The new C series straight handle expands our handle offering from six to seven options within our Bernard BTB MIG gun configurator. This new handle provides all the same benefits as our current T series straight handle, plus additional enhancements such as comfortable handle overmolding and an ergonomic rear swivel. Click here to learn more about the new C series straight handle.
Being as comfortable as possible contributes to welding operator safety and productivity — and it’s a factor that can impact the quality of the finished weld. There are numerous issues that play a role in welding operator comfort, including the heat generated by the welding process, the repetitive motions and, at times, cumbersome equipment. These challenges can take a toll, resulting in aches, fatigue and physical and mental stress for welding operators. There are some steps, however, to help reduce the impact of these factors. These include choosing the right equipment for the job, utilizing tools and accessories designed to improve operator comfort, and following some best practices that promote proper operator form. Promoting operator comfort can lessen the chance of injuries associated with repetitive movement, as well as reduce overall fatigue. Choosing a GMAW gun that meets the needs of the application — and in some cases customizing the gun — is a critical way to impact welding operator comfort so he or she can achieve the best results. A gun’s trigger, handle, neck and power cable design all help determine how long a welding operator can comfortably weld without experiencing fatigue or stress. The application’s weld joint geometry also plays a role in welding operator comfort, and it impacts what components to choose for optimal joint access. Here are some issues to consider in GMAW gun selection that can impact comfort, as well as quality and productivity: Gun amperage can have a significant impact on welding operator comfort because, typically, the higher the amperage, the larger — and heavier — the gun. Therefore, a larger amperage gun may not be the best choice if that amperage rating is not necessary to meet the needs of the application. Choosing a smaller amperage gun when possible can help minimize fatigue and stress on the welding operator’s wrists and hands. In selecting the right amperage, consider the application’s duty cycle requirements. Duty cycle refers to the number of minutes in a 10-minute period that a gun can be operated at its full capacity without overheating. For example, a 60 percent duty cycle means six minutes of arc-on time in a 10-minute span. Most applications do not require the welding operator to use the gun constantly at full duty cycle. In many cases, a higher amperage gun is only needed when the power source is being run continuously. Handle options for GMAW guns include straight and curved styles. The right choice typically comes down to the specific process, application requirements and — most often — operator preference. Keep in mind that a smaller handle tends to be easier to hold and maneuver. In addition, the option of a vented handle promotes improved operator comfort, since this style can cool down faster when the gun isn’t in use. While operator comfort and preference are important considerations, handles must also meet the gun and application’s amperage and duty cycle requirements. A straight handle provides flexibility by allowing to mount the trigger on the top or bottom of the handle. Putting it on top is a good choice to improve operator comfort in high-heat applications or for those that require long welds. There are numerous trigger choices that can improve comfort and safety. Look for a trigger that doesn’t require more pull force than necessary to maintain the arc, to minimize stress on the operator. Also, locking triggers are a good option to alleviate stress on the welding operator’s finger caused by grasping, sometimes called “trigger finger.” A locking trigger, as its name implies, can be locked into place. This feature allows the welding operator to create long, continuous welds without having to hold the trigger the entire time. Locking triggers also help distance the welding operator from the heat generated during welding, making them well-suited for high amperage applications. Another part of the gun that plays a role in operator comfort is the neck. Rotatable and flexible necks are available in various lengths and angles, and can be adjusted to meet specific application needs, offering many choices to help reduce operator strain. Joint access, gun amperage and duty cycle required for an application are important considerations when choosing a gun neck. For example, a longer gun neck can improve operator comfort when the application requires a long reach. A flexible neck can do the same when accessing joints in a tight corner. The best choice for pipe welding might be an 80-degree neck, while a 45- or 60-degree neck might be better suited for welding in the flat position. Rotatable necks allow welding operators to rotate the neck as needed, such as in out-of-position or overhead welding. In cases where you need a longer neck, another option is to utilize a neck coupler, which is a tool that combines two gun necks. The flexibility provided by these numerous neck options can result in reduced opportunity for operator fatigue, strain and injury. The power cable adds weight to the gun and can also add clutter to the workspace. Therefore, smaller and shorter cables are recommended, as long as they meet the needs of the application. Not only are shorter and smaller cables typically lighter and more flexible — to ease the fatigue and strain on a welding operator’s hands and wrists — but they also help reduce clutter and tripping hazards in the work area. Different welding guns can offer different “balance,” which refers to the feel and ease of movement experienced when the welding operator holds the gun. For example, a heavier gun that is balanced properly can lessen operator fatigue compared to a heavier gun that is not balanced properly. A gun that is properly balanced will feel natural in the operator’s hands and be easy to maneuver. When a gun is not balanced correctly, it might feel more unwieldy or uncomfortable to use. This can make a difference in operator comfort and productivity. Because welding applications differ for every welding operator, customizable GMAW guns can be a good option to gain greater comfort. Poor welding operator comfort can directly impact productivity and efficiency. Some gun manufacturers offer online resources to help welding operators configure a GMAW gun for the exact specifications of the job. This helps ensure the gun is suited to operator preferences and the needs of the application — for greater comfort and productivity. ttFor example, most welding operators do not make huge, sweeping movements when using a GMAW gun. Instead, they tend to use more minute, delicate maneuvering of the gun. Some configurations allow users to choose an option available for fume extraction guns — for example, a ball and socket swivel design that helps the vacuum hose to move separately from the handle. This improves flexibility and reduces the wrist fatigue for the welding operator. Utilizing proper weld position and form are additional ways that welding operators can maximize comfort on the job. Repetitive strain or prolonged uncomfortable postures can result in operator injury — or even the need for costly and time-consuming rework due to poor quality welds. Whenever possible, place the workpiece flat and move it into the most comfortable position. It’s also important to maintain a clean working environment. In some cases, a fume extraction gun paired with the proper portable fume extraction system can be a viable option to replace wearing a powered air purifying respirator and lessen the amount of equipment the welding operator must wear. To maintain compliance and safety, it’s always a good idea to consult an industrial hygienist to be certain that’s an appropriate step. In addition, operator comfort can be maximized by using stable posture and avoiding awkward body positioning, and by not working in one position for long periods. When welding in a seated position, operators should also have the workpiece slightly below elbow level. When the application requires standing for long periods, use a foot-rest. Having the right equipment, choosing equipment or accessories that are easy to operate and promote operator comfort, and utilizing proper welding technique and form are all important steps toward achieving a comfortable, safe work environment for welding operators. Lightweight welding guns with appropriate handle and neck designs for the job and for the operator can help achieve safe and productive results. The reduction of heat stress, wrist and neck fatigue and repetitive motions can also help decrease overall physical and mental stress for welding operators. To achieve optimal results, consider the numerous options available in tailoring a GMAW gun that is right for the application and operator preference.
Self-shielded flux-cored arc welding (FCAW-S) offers numerous benefits, including good weldability, high deposition rates, and excellent chemical and mechanical properties. These make the process a common choice for many applications, such as structural steel erection, bridge construction and heavy equipment repair. But like any welding process, it is not without its challenges. There are a few simple tips and best practices that can help address these challenges. Using this knowledge — with a bit of practice — can save time, money and frustration, and help achieve high weld quality. Slag inclusions — the result of molten flux from inside the welding wire becoming trapped inside the weld — can commonly occur in out-of-position and multi-pass FCAW-S applications. Preventing this issue depends on following key best practices and utilizing proper welding techniques. These include: Porosity is a common weld defect that occurs when gas is trapped in the weld. Cleaning the base material thoroughly prior to welding is the main way to prevent this problem. Remove all dirt, rust, grease, oil, paint, moisture and other contaminants from the full length of the weld joint. While welding, be sure to maintain wire stick-out of no more than 1 1/4 inch beyond the contact tip. In addition, using filler metals containing added deoxidizers can help prevent porosity and allow for welding through light contaminants. However, these wires are not a replacement for proper cleaning. Another defect, wormtracking, refers to marks on the surface of the weld bead caused by gas that the flux inside the wire creates. Take care to avoid excessive voltage for the wire feed setting to help prevent this problem. In situations where wormtracking occurs, reduce the voltage in increments of 1/2 volt until the problem stops. Undercutting and lack of fusion Lack of fusion occurs when the weld metal does not properly fuse with the base material or with the preceding weld bead during multi-pass welding. Using an improper gun angle is the main cause of this problem. Maintain heat input and correct work angle of the gun to help prevent lack of fusion. Use a gun angle drag of 15 to 45 degrees, and keep the arc on the trailing edge of the welding puddle. When using a weaving technique, hold the arc on the groove’s sidewall. A dirty work surface is another common cause of lack of fusion. Proper and thorough cleaning of the surface before welding and in between passes is recommended. Undercutting causes a weaker area at the toe of the weld by allowing a groove to melt in the base metal that is not filled in by the weld metal. This defect can often lead to cracking. To prevent undercutting, follow welding parameters for the appropriate welding current and voltage. Gun angle also plays a key role in this issue. In addition, be sure to maintain a travel speed that allows the weld metal to fill the melted-out areas of the base material completely. When it comes to weld joint penetration, too much and too little are both problematic. Good joint penetration is critical to completing high-quality welds, so it’s important to pay attention to how much weld metal is going into the joint. When weld metal melts through the base metal and hangs underneath the weld, this is excessive penetration. It is most often caused by too much heat. Avoid this problem by maintaining proper heat input for the application. Lower the voltage range, reduce wire feed speed and increase travel speed. When the problem is a lack of penetration — or a shallow fusion between the weld and base metals — taking the opposite steps will help: increase the voltage range and wire feed speed, while reducing travel speed. Joint preparation also plays a role in proper penetration. To maintain the right wire extension and obtain necessary arc characteristics for good weld quality, it is imperative to access the bottom of the groove. As with any welding process, FCAW-S can present some challenges. By utilizing proper welding technique and taking steps to address the issues, it will be easier to identify and solve problems quickly — or even prevent them from occurring — in order to reap the productivity and quality benefits the process offers.
WINDSOR, Ontario. Sept. 13, 2016 — A new online configurator from Tregaskiss makes it quick and easy to customize the company’s TOUGH GUN® TT3 reamer robotic nozzle cleaning stations to match the needs of their welding application. Users simply follow a series of steps to configure a reamer model, first selecting the V-block and cutter blade to match the outside diameter (OD) and bore of their robotic MIG gun nozzle. Users can then select from various add-ons, including a wire cutter, lubricator, air blast and/or filter/regulator. Tregaskiss also offers the option to choose accessories sold separately, such as a reamer stand, anti-spatter liquid and an anti-spatter multi-feed system. After choosing all desired components, the configurator provides a summary of the selections, along with a part number for the reamer. Users are given the option to request a quote for the reamer, download spec sheets or owner’s manuals, print the selection summary and part number, or contact Tregaskiss for more information. To help users save time, the online configurator incorporates a new reverse part number lookup function that provides a complete replacement parts list for their reamer based on an existing part number. The reamer is available for customization in both analog and Ethernet models. The analog TOUGH GUN TT3 reamer features improvements to the sprayer system, new plug and play replacement parts, and simplified internal wiring for reliable performance and ease of maintenance. The TOUGH GUN TT3E reamer offers the same high levels of durability, serviceability and repeatability and is enhanced with digital Ethernet communications for better integration into facilities’ digital controls infrastructure.
When it comes to welding, too much of a good thing can often add up to unnecessary costs, potential downtime and lost productivity — especially if you have too large of a MIG gun for your application. Unfortunately, many people believe a common misconception: that you need a MIG gun rated to the highest amperage you expect to weld (e.g., a 400-amp gun for a 400-amp application). That is simply not true. In fact, a MIG gun that provides a higher amperage capacity than you need typically weighs more and may be less flexible, making it less comfortable to maneuver around weld joints. Higher amperage MIG guns also cost more. The truth is, because you spend time moving parts, tacking them and performing other pre- and post-weld activities, you rarely weld continuously enough to reach the maximum duty cycle for that MIG gun. Instead, it’s often better to choose the lightest, most flexible gun that meets your needs. For example, a MIG gun rated at 300 amps can typically weld at 400 amps and higher — for a limited amount of time — and do just as good of a job. In the United States, the National Electrical Manufacturers Association, or NEMA, establishes the MIG gun rating criteria. In Europe, similar standards are the responsibility of Conformité Européenne or European Conformity, also called CE. Under both agencies, MIG guns receive a rating that reflects the temperatures above which the handle or cable becomes uncomfortably warm. These ratings, however, do not identify the point at which the MIG gun risks damage or failure. Much of the difference lies in the duty cycle of the gun. Manufacturers have the option of rating their guns at 100-, 60- or 35-percent duty cycles. For that reason, there can be significant differences when comparing different MIG gun manufacturer’s products. Duty cycle is the amount of arc-on time within a 10-minute period. One MIG gun manufacturer may produce a 400-amp MIG gun that is capable of welding at 100 percent duty cycle, while another manufactures the same amperage MIG gun that can weld at only 60 percent duty cycle. In this example, the first MIG gun would be able to weld consistently at full amperage for a 10-minute time frame, whereas the latter would only be able to weld for 6 minutes. Before deciding which MIG gun to purchase, it is important to review the duty cycle ratios for the product. You can typically find this information in the product literature or on the manufacturer’s website. Based on the gun rating explanation above, it is also essential for you to consider the length of time you spend welding before you make your MIG gun selection. Look at how much time you actually spend welding over the course of 10 minutes. You may be surprised to discover that the average arc-on time is usually less than 5 minutes. Keep in mind that welding with a MIG gun rated to 300 amps would exceed its rated capacity if you were to use it at 400 amps and 100-percent duty cycle. However, if you used that same gun to weld at 400 amps and 50-percent duty cycle, it should work just fine. Similarly, if you had an application that required welding very thick metal at high current loads (even 500 amps or more) for a very short period of time, you might be able to use a gun rated at only 300 amps. As a general rule, a MIG gun becomes uncomfortably hot when it exceeds its full duty cycle temperature rating. If you find yourself welding for longer on a regular basis, you should consider either welding at a lower duty cycle or switching to a higher rated gun. Exceeding a MIG gun’s rated temperature capacity can lead to weakened connections and power cables, and shorten its working life. There are two types of heat that affect the handle and cable temperature on a MIG gun and also the amount of time you can weld with it: radiant heat from the arc and resistive heat from the cable. Both of these types of heat also factor into what rating of MIG gun you should select. Radiant heat is heat that reflects back to the handle from the welding arc and the base metal. It is responsible for most of the heat encountered by the MIG gun handle. Several factors affect it, including the material being welded. If you weld aluminum or stainless steel, for example, you will find that it reflects more heat than mild steel. The shielding gas mixture you use, as well as the welding transfer process, can also affect radiant heat. For example, argon creates a hotter arc than pure CO2, causing a MIG gun using an argon shielding gas mixture to reach its rated temperature at a lower amperage than when welding with pure CO2. If you use a spray transfer process, you may also find that your welding application generates more heat. This process requires an 85 percent or richer argon shielding gas mixture, along with a longer wire stick out and arc length, both of which increase the voltage in the application and the overall temperature. The result is, again, more radiant heat. Using a longer MIG gun neck can help minimize the impact of radiant heat on the handle by placing it further from the arc and keeping it cooler. The consumables you use can in turn affect the amount of heat that the neck absorbs. Take care to find consumables that connect tightly and have good mass, as these absorb heat better and can help prevent the neck from carrying as much heat to the handle. In addition to radiant heat, you may encounter resistive heat in your welding application. Resistive heat occurs by way of electrical resistance within the welding cable and is responsible for most of the heat in the cable. It occurs when the electricity generated by the power source cannot flow through the cable and cable connections. The energy of the “backed up” electricity is lost as heat. Having an adequately sized cable can minimize resistive heat; however, it cannot eliminate it entirely. A cable large enough to completely eliminate resistance would be too heavy and unwieldy to maneuver. Using a lighter MIG gun can often improve productivity since it is easier to maneuver for longer periods of time. Smaller MIG guns can also reduce your susceptibility to repetitive motion injuries, such as carpal tunnel syndrome. When choosing your MIG gun, remember that not all products are created equal. Two MIG guns rated to 300 amps could vary widely in terms of their overall size and weight. Take the time to research your options. Also, look for features like a ventilated handle that permits air to flow through it and keeps it running cooler. Such features can often allow a gun to be rated to a higher capacity without adding any size or weight. Finally, assess the time you spend welding, the process and shielding gas you use, and the materials you are welding. Doing so can help you select a gun that strikes the ideal balance between comfort and capacity.
Investing in a robotic welding system goes beyond the initial purchase — it is equally important to find ways to maximize the abilities of this equipment. When implemented properly, speed, accuracy and cost savings are fundamental benefits of welding automation. These factors rely on everything from the robot itself to personnel overseeing the weld cell to the smallest factors, like the front-end consumables on the robotic MIG gun. Although consumables may seem insignificant, the nozzles, contact tips and gas diffusers can have a huge impact on performance. The right combination reduces downtime and waste, and improves productivity and quality. In fact, a contact tip often serves as a barometer of the overall effectiveness of the welding process, by indicating how optimized it is — or isn’t. Always consider consumables as a part of the planning process when working with an integrator to design a robotic welding system. Doing so prevents issues with joint access — if the consumables are an afterthought, it’s possible that the front-end of the robotic MIG gun won’t be able to maneuver properly around the part or the fixturing to reach the joint. Reconfiguring the system can be time-consuming and costly. Bottleneck, straight or tapered nozzles can help accommodate for joint restrictions since they are narrower than standard nozzles and provide better access. Take caution when using tapered nozzles, however, as they are thinner and may not be able to withstand the higher amperage or higher-duty-cycles of robotic welding, leading to more frequent changeover. They may also collect more spatter buildup due to their narrower bore. For jobs requiring 300 amps or greater and/or those with a high level of arc-on time, a heavy-duty style nozzle with thicker walls and insulators will be more heat-resistant. It’s usually best to select the heaviest duty consumable for the application that still allows access to the tooling. Consult a robotic integrator or welding distributor whenever in doubt. Consumables come in a variety of materials and sizes. For example, heavy-duty contact tips are available in copper or chrome zirconium and feature an outside diameter (OD) of around 0.3125 inch. In addition to pulsed welding (discussed more later), higher-amperage applications can benefit from chrome zirconium contact tips, as they generally offer a longer performance life than copper contact tips. Nozzles are typically available in brass or copper. The brass variety tends to be more spatter-resistant. However, these nozzles have a lower melting point and can fracture or deteriorate more quickly than copper, if they come into direct contact with the molten weld pool. This factor makes them ill-suited for tight access applications. Extra-heavy-duty consumables are also available in the marketplace and are good for high-amperage applications requiring larger-diameter welding wires — 0.052 inch and greater. Contact tips in this category generally have an outer diameter of about 0.375 in. Regardless of the material, look for consumables that are well-machined with a smooth, consistent surface. These are less prone to spatter buildup and may therefore last longer. In some cases, these consumables may be more expensive, but it’s important to weigh the upfront costs with the longer-term savings of minimizing changeovers and downtime. Likewise, poorly functioning consumables, or ones that are simply not appropriate for the application, can generate weld quality issues that compound productivity delays and could lead to expensive rework. Robotic welding systems typically operate for longer periods of time at higher amperages than semi-automatic applications. As mentioned, heavy-duty consumables, which are more heat-resistant than standard-duty consumables, are often used. But they aren’t always necessary. In some cases, standard-duty consumables can replace them. For example, in applications with low duty cycles, there is less heat because less time is spent welding, and standard-duty consumable will suffice. It is important, however, to test for durability on a given application before introducing them into the welding operation. Also, when frequent consumable changeover is part of a company’s protocol, standard-duty consumables could work on high-amperage applications because the welding operator changes them over before a failure occurs from high heat levels. Mechanical wear on the contact tip is inevitable in any welding application, as the constant friction of the welding wire feeding through the tip naturally wears on it. But electrical wear also can be an issue in high-amperage welding that uses a pulsed welding mode. Pulsed welding programs have a unique waveform that causes the power source to move between low background currents and high peaks, which is particularly harsh on consumables. Often these waveforms reduce weld spatter but are harder, electrically speaking, on the contact tip. It is important to select contact tips that are durable enough for the application, and often chrome zirconium contact tips are the best choice for this welding mode. It is also a good idea to monitor contact tip usage regularly in pulsed welding applications. Changing over contact tips before they are too damaged can help to prevent issues such as loss of electrical conductivity, burnbacks and excessive spatter, resulting in poor weld quality, rework and downtime. Welding operators can use the time during routine breaks in production to changeover contact tips and maximize efficiencies. Robotic welding often uses large drums of wires — 500 to 1,000 pounds — to minimize changeover. The wire in these drums tends to have less cast or helix than wire that feeds off of a smaller spool and, as a result, feeds through the contact tip in a relatively straight fashion, making little or no contact with the tip. This action minimizes the electrical conductivity necessary to create a good arc and a sound weld. It also can cause the welding wire to contact the part being welded and arc back into the contact tip, creating a burnback. This condition automatically creates downtime because the contact tip needs to be changed. Undersizing contact tips, particularly when using solid wire in a high-amperage application, is a good fix. For example, a 0.040-in.-diameter contact tip could work for a 0.045-in. wire. The welding operator should check with a trusted welding distributor for applications requiring metal-cored wires because undersizing is not always an option. It’s worth considering the impact that the wire type has on the longevity of the contact tips as well. Non-copper-coated solid wires, for example, tend to wear contact tips more quickly than copper-coated ones because the coating acts like a lubricant to improve feedability. Improved feedability can, in turn, lead to longer contact tip life. A nozzle cleaning station or reamer cleans spatter from the robotic gun nozzle and clears away debris in the gas diffuser that accumulates during the welding process. Reamers can be outfitted with a sprayer that applies a water-based anti-spatter compound to protect the nozzle, retaining head and workpiece from spatter. Reamers and anti-spatter combined are a good defense against premature consumable failure and poor shielding gas coverage (caused by spatter-blocked gas ports), and can help extend the life of front-end consumables. For the best results, place the nozzle cleaning station close to the robot so it’s easily accessible, and program the robot to use it in between cycles — during part loading or tool transfer, for example. It should only take six seconds for the nozzle cleaning station to complete its job and the results are measurable: less spatter and longer consumable life.
BEECHER, Ill./WINDSOR, Ontario. August 9, 2016 – Bernard and Tregaskiss have introduced a new reverse part number lookup function for their semi-automatic and robotic MIG gun online configurators — online tools that allow users to customize a MIG gun for their exact needs, by selecting amperage, neck style and angle, consumables and more. The new time-saving reverse part number lookup function provides users with the complete replacement parts list — from power pin to contact tip — for previously configured MIG guns, based on the existing part number. Reverse lookup information is available for the Bernard® BTB semi-automatic MIG guns and Clean Air fume extraction guns, along with Tregaskiss® TOUGH GUN® CA3 and TA3 robotic MIG guns. It is also available for the TOUGH GUN G2 series robotic MIG guns (both conventional and througharm styles) and features additional functionality for these products to simplify conversion to a TOUGH GUN CA3 or TA3 robotic MIG gun. Users of Tregaskiss robotic water-cooled MIG guns (600 amp) and TOUGH GUN TT3 reamers can also benefit from this reverse part number lookup function. To utilize the part number lookup function, users can visit Tregaskiss.com/ConfigureMyGun and follow the prompts on the home screens to enter an existing part number.
When it comes to robotic welding operations, uptime is key. Minimizing air movements and ensuring consistent workflow are just as important as selecting the right robot, power source and robotic gas metal arc welding (GMAW) gun. Everything should work in conjunction to bring about the greatest efficiencies. The result can be higher productivity, better weld quality and an improved bottom line — not to mention, the potential for a competitive edge. A nozzle cleaning station (also called a reamer), along with a sprayer for delivering anti-spatter compound, can be simple and effective additions to the robotic weld cell — and ones that offer a good return on investment. Anti-spatter compound can also be delivered from a single large drum via a multi-feed system to numerous robotic weld cells. Anti-spatter compound protects the front-end consumables on a robotic GMAW gun from excessive spatter accumulation, which can restrict shielding gas flow, increasing the risk for porosity. This compound also helps prolong the life of the nozzle, contact tips and gas diffuser, and can reduce downtime for consumable changeover. In addition, it can lower the cost for consumable inventory (and its management), and reduce operating costs by improving weld quality and lessening rework by way of consumables that operate at peak performance. All of these factors contribute to a more productive and profitable welding operation. The what, when and where of anti-spatter compounds Constant-voltage (CV) applications and those utilizing solid wire and/or the welding of galvanized steel tend to produce high levels of spatter, and therefore, often benefit the most from the use of anti-spatter compound. However, the application of anti-spatter compound is ideal for any high-volume, high-production environment seeking to minimize potential weld quality issues, extend consumable life and also reduce downtime. Its application can easily be programmed so that it is sprayed onto the consumables after each ream cycle, during routine pauses in production for part changeover. When selecting an anti-spatter compound, be certain that it is capable of providing uniform coverage to protect the entire nozzle, that it cleans up easily and leaves no residue, and that it is compatible with the nozzle cleaning station being used. Water-soluble anti-spatter compound is the most popular option, and is typically non-toxic and eco-friendly. Oil-based anti-spatter compound is also available in the marketplace, but is generally less desirable to use because it is more difficult to clean up if it settles on fixtures or elsewhere in the weld cell. It is also important to note that oil-based anti-spatter compound is not always compatible with all nozzle cleaning stations and it can clog up this equipment. Despite the fact that the more popular water-based anti-spatter compound is non-toxic, welding operators and/or maintenance personnel should still take care when handling and using it. They should avoid breathing in spray mists and always wash their hands after coming in contact with the compound (for example, when filling the sprayer). The use of a NIOSH certified (or equivalent) respirator during spraying is recommended. Also, personnel should wear Nitrile or Butyle gloves and wear chemical safety goggles for the best protection. Local exhaust ventilation near the sprayer is also important. Store anti-spatter compound containers according at the temperatures recommended by the manufacturer. Best practices for anti-spatter compound use Spraying for about a half-second is the standard recommendation. If a company finds that it is necessary to spray the anti-spatter compound any longer, that usually means the sprayer is too far away. In fact, anti-spatter compound should never be sprayed for three or more seconds. In addition to causing harm to the consumables, excess spraying can leave a residue of the compound in the weld cell that could lead to safety issues, such as slick floors and slipping hazards. Over-application of anti-spatter compound may also damage equipment, such as power sources, by adversely affecting electrical circuits it comes in contact with. Some manufacturers offer a spray containment unit, which can help capture excess anti-spatter compound. This 3 to 4-inch unit fits over the spray head on the anti-spatter compound sprayer. After the spatter has been cleared from the nozzle during the reaming cycle, the nozzle docks on the spray containment unit. An opening at the top of the cylinder allows the anti-spatter to spray onto the nozzle while an O-ring seals the nozzle in place so only the outside edge and inside of the nozzle are sprayed. The spray containment unit also collects any anti-spatter compound runoff at the bottom of the unit so it can be easily drained into a container and disposed of properly. Anti-spatter compound cannot be reused and should be disposed of in accordance with federal, state and local environmental control regulations. When employing a spray containment unit, it is important to inspect it regularly, removing any spatter or debris from the bottom that could prevent it from working properly. As part of a preventive maintenance activities, clear the screen or filter inside the unit of contaminants using clean, compressed air. Doing so helps ensure that the screen can continue to fulfill its intended purpose of improving air quality. As with any part of the robotic welding operation, when employed properly, this unit and the use of anti-spatter compound can yield positive results. Always follow the manufacturer’s recommendation for use and consult with a trusted welding distributor with any questions. In conjunction with anti-spatter compound, a nozzle cleaning station improves quality and productivity in robotic weld cells by helping extend consumable life and reducing downtime for changeover. Here are some tips to get the most out from this equipment. Correct placement: Place the nozzle cleaning station in close proximity to the robot so it is easily accessible. Match parts and sizes: Make sure the V-block inside the top of the nozzle cleaning station is the correct size for the nozzle, that the cutter blade is the correct size for the nozzle bore, and that the insertion depth of the nozzle to the reamer is adequate. Monitor the home signal: Monitor the home signal on the nozzle cleaning station to reduce issues during the cleaning cycle and minimize guesswork regarding whether the equipment is ready for use or done with its cycle. Clean and scrape parts: Clean the top seal on the spindle under the cutter and make sure all clamp faces are kept clean by scraping the faces and jaws on the V-block to remove debris. Buildup on these parts can push the nozzle out of position, leading to the fit-up no longer being concentric — and, potentially, to broken cutter blades.
BEECHER, Ill./WINDSOR, Ontario. August 2, 2016 – Bernard and Tregaskiss will attend FABTECH 2016 in Las Vegas, November 16 to 18, where they will share booth N3733 with Miller Electric Mfg. Co. There, the companies will showcase the latest products for improving welding in the fabrication and manufacturing industries. Bernard will feature its semi-automatic MIG guns and consumables, while Tregaskiss will showcase its robotic MIG guns, peripherals and consumables — all designed to improve quality, productivity and cost-savings. Select products will be featured on Miller power sources and robotic welding equipment for static and live demonstrations. New products to be featured at the show, include: TOUGH GUN TT3E reamer — The new reamer from Tregaskiss has been enhanced with digital Ethernet communications to simplify integration into companies’ digital controls infrastructure, all at a lower cost. Remote monitoring capabilities allow companies to oversee and troubleshoot the I/O of reamer functioning in real time — without removing the reamer from the weld cell. TOUGH GUN reamer stand – Designed exclusively for Tregaskiss TOUGH GUN TT3 and TOUGH GUN TT3E reamer robotic nozzle cleaning stations, this durable new stand is customizable in heights ranging from 18 to 45 inches. A simplified design allows for lower pricing, while features such as precision- manufactured, reamer mounting hole pattern specific to the two reamer models eliminates potential issues associated with third-party stands. Quick, accurate installation is easy due to compatibility with both reamers’ quick-change base plate.
A nozzle cleaning station, or reamer, is a peripheral that can be integrated into an automated welding system to maximize its performance. Reamers remove spatter from inside the gas metal arc welding (GMAW) gun’s front-end consumables — nozzles, contact tips and retaining heads — that accumulates during routine welding. In doing so, this equipment improves quality and productivity in robotic weld cells by extending consumable life and reducing downtime for maintenance. In addition, utilizing a reamer helps prevent loss of shielding gas coverage, a problem that can lead to expensive rework to correct porosity or other weld defects. From proper installation and setup to effective operation, there are best practices to gain the highest performance, quality and long-term use from reamers.
The heat and repetitive motions that accompany gas metal arc welding (GMAW) can take their toll. Customizing your GMAW gun to match your application, however, can make a big difference in improving your comfort, and gaining the best welding performance. A GMAW gun’s trigger, handle, neck and power cable design all impact how long you can comfortably weld without experiencing fatigue or stress. By ensuring your comfort, you lessen the chance of injuries associated with repetitive movement and reduce overall fatigue. To help, some manufacturers offer online systems to help you configure a gun to your exact specifications.
PRODUCT UPDATE – TOUGH GUN TT3 Reamer Upgrades
PRODUCT UPDATE –
TOUGH GUN TT3 Reamer UpgradesTerminal Strip vs. Wiring Harness
New Easy Access Setup Switches
New Check Valve
PRODUCT IMPROVEMENT – New TOUGH GUN TT3 Reamer Check Valve
PRODUCT IMPROVEMENT –
New TOUGH GUN TT3 Reamer Check Valve
(previously used on the TOUGH GUN TT3 Reamer)
(previously used on the TOUGH GUN TT3E Reamer
(replaces SR-500-20 and OLD TT3E-500-20)Reduce Costly Downtime By Preventing Poor Wire Feeding
Reduce Costly Downtime By Preventing Poor Wire Feeding
Feeder, adapter and other equipment issues
Drive roll considerations
Check the liner
For all consumable systems, inspect the contact tips regularly and replace as necessary.
keep the cable as straight as possible during welding to prevent issues with wire feeding.
If the other components and consumables have been inspected and adjusted as needed and wire feeding remains a problem, it may be that the wrong length of gun is being used. Troubleshooting feeding issues
Related Articles
PRODUCT UPDATE – 300 amp Clean Air Fume Extraction MIG Gun Now Available
PRODUCT UPDATE –
300 amp Clean Air Fume Extraction MIG Gun Now Available
Features and Benefits
Conventional Guns on Through-Arm Robotic Welding Systems: When to Make the Choice
Conventional Guns on Through-Arm Robotic Welding Systems: When to Make the Choice
Considerations in choosing robotic guns
Benefits of conventional guns
When to stay with a through-arm gun
Best practices for performance
PRODUCT IMPROVEMENT – LSR Unicables
PRODUCT IMPROVEMENT –
Low-Stress Robotic (LSR) Unicables
OLD LSR Unicable Design
NEW LSR Unicable Design
Six Tips for Implementing Your Robotic GMAW Gun… and Getting the Most From It
Six Tips for Implementing Your Robotic GMAW Gun … and Getting the Most From It
Tip No. 1: Choose a solid mount instead of a clutch
Tip No. 2: Use an air blast feature
Tip No. 3: Utilize a simulation program
Tip No. 4: Utilize a neck inspection fixture
Tip No. 5: Ensure proper gun and cable installation
Tip No. 6: Conduct proper gun maintenance
gun to ensure they are tight and secure. Doing so
helps prevent issues that can lead to weld defect
and downtime.
Choosing and properly installing the right gun and cable is just the beginning. Proper ongoing maintenance is also an important factor to optimize performance. Optimize the system
PRODUCT UPDATE – New Liner Trim Length for Liners 6-Feet Long and Shorter
PRODUCT UPDATE –
New Liner Trim Length for Liners 6-Feet Long and Shorter
NOTE: Liners longer than 6-foot in length should still continue to be trimmed with a 3/4-inch stick out. No change to liner gauges or trim instructions for conventional or QUICK LOAD liners longer than 6-feet is recommended.PRODUCT UPDATE – Clean Air Gun Vacuum Tube and Chamber Finish Change
PRODUCT UPDATE –
Clean Air Gun Vacuum Tube and Chamber Finish Changes
Solving Five Causes of Downtime in a Robotic Welding Operation
Solving Five Causes of Downtime in a Robotic Welding Operation
Cause No. 1: Poor cable management and/or incorrect cable selection
Solutions:
Cause No. 2: Premature consumable failure
Solution:
Cause No. 3 Excessive spatter buildup in consumables
Solution:
Cause No. 4: Collisions
Solution:
Cause No. 5: Poor wire feeding
Solution:
Bernard Adds to Handle Options for BTB Semi-Automatic MIG Guns
Bernard Adds to Handle Options for BTB Semi-Automatic MIG Guns
PRODUCT UPDATE – TOUGH GUN TA3 Torch Solutions for Yaskawa Motoman Robots
PRODUCT UPDATE —
Tregaskiss TOUGH GUN TA3 Torch Solutions for Yaskawa Motoman RobotsOverview
Details
Configuration Comparison
Configuration Tregaskiss Cable Motoman Cable Tregaskiss Spacer: AS-114-13 Solid mount, with or without wire brake Yes No Clutch mount, with our without wire brake Yes No Motoman Spacer: 168535-1 Solid mount, with or without wire brake No Yes Clutch mount, with or without wire brake No Yes Proper Setup – No impact on TCP or cable life
A complete Tregaskiss setup consists of all Tregaskiss branded components. The torch spacer will be aluminum and approximately 4-3/8″ in length. The cable will have a corrugated hose from front to back.
A hybrid Tregaskiss/Motoman setup consists of a Tregaskiss torch and consumables with a Motoman spacer and cable. The spacer will be approximately 2-3/8″ in length. The cable will have a loose spring from front to back.Improper Setup – Negative impact on TCP and/or cable life
Installing a Tregaskiss cable on a system with a plastic spacer will result in a cable that is too long. Although this cable can be physically installed, this setup will result in premature cable failure.
Installing a Motoman cable on a system with an aluminum spacer will result in a cable that is too short. This cable will not be long enough to plug the power pin into the wire feederTregaskiss Spacer and LSR Unicable Part Number Reference Chart
Robot Make Robot Model Mount Style Tregaskiss Spacer LSR Unicable Part Number No Options Air Blast Wire Brake Air Blast + Wire Brake Motoman® EA1400 XRC Solid Mount N/A 58SM016A 58SM016W 58SM016AW Motoman EA1900 XRC N/A 58SM017 58SM017A 58SM017W 58SM017AW Motoman EA1400N, SSA2000, MA1400, VA1400 Solid Mount N/A 58SM001 58SM001A 58SM001W 58SM001AW Motoman MA1440, AR1440, MH12 AS-114-13 58SM035 58SM035A 58SM035W 58SM035AW EA1900N N/A 58SM002A 58SM002W 58SM002AW Motoman MA2010, AR2010 Solid Mount AS-114-13 58SM038A 58SM038W Motoman MA3100 Solid Mount N/A 58SM031 58SM031A 58SM031W 58SM031AW Motoman Motoman AR1730, MH24 Solid Mount AS-114-13 58SM039A 58SM039AW Motoman EA1400 XRC N/A 58CM016 58CM016W 58CM017 58CM017A 58CM017W 58CM017AW Motoman EA1400N, SSA2000, MA1400, VA1400 Clutch N/A 58CM001 58CM001W 58CM001AW MA1440, AR1440, MH12 Clutch AS-114-13 58CM035A 58CM035W 58CM035AW EA1900N Clutch N/A 58CM002 58CM002A 58CM002W Motoman MA2010, AR2010 Clutch 58CM038 58CM038A 58CM038W 58CM038AW Motoman MA3100 N/A 58CM031 58CM031A Motoman MA3120, AR3120 AS-114-13 58CM032AW Motoman AR1730, MH24 Clutch AS-114-13 58CM039 58CM039A 58CM039AW
IMPORTANT!
NEW PRODUCT – C Series Handle Option for BTB MIG Guns
NEW PRODUCT –
C Series Handle Option for BTB MIG GunsNew C Series Straight Handle
Tips for Maximizing Welding Operator Comfort and Productivity
Tips for Maximizing Welding Operator Comfort and Productivity
Selecting the right gas metal arc welding (GMAW) gun
Amperage:
Handle:
Trigger:
Neck:
Power cable:
Consider gun balance
Customize for the job
Use correct positioning and form
Maximizing comfort
Best Practices for Success in Self-Shielded Flux-Cored Welding
Best Practices for Success in Self-Shielded Flux-Cored Welding
Slag inclusions
Porosity
Wormtracking
Two additional defects affecting weld quality are lack of fusion and undercutting. Preventing these issues can help welding operations save time and money in rework and downtime. Problems with penetration
Finding success
Tregaskiss Offers Online Configurator for Robotic Nozzle Cleaning Stations
Tregaskiss Offers Online Configurator for Robotic Nozzle Cleaning Stations
Understanding Gun Ratings: What You Need to Know to Select Your MIG Gun
Understanding Gun Ratings: What You Need to Know to Select Your MIG Gun
Gun ratings explained
How do you operate?
Understanding the impact of heat
Radiant Heat
Resistive Heat
As an air-cooled MIG gun increases in amperage, the size of the cable, connections and handles also increases. Therefore, a MIG gun with a higher rated capacity almost always has greater mass. If you are an occasional welder, that weight and size increase may not bother you; however, if you weld all day, every day, it is better to find a lighter and smaller MIG gun suited to your application. In some cases, that may mean switching to a water-cooled MIG gun, which is smaller and lighter, but can also provide the same welding capacity. Deciding between air- and water-cooled
Final thoughts to keep you comfortable
Considerations for Consumables in Robotic Welding Applications
Considerations for Consumables in Robotic Welding Applications
Space and duty cycle factors
Consumable materials and sizes
good defense against premature consumable
failure and poor shielding gas coverage,
and can help extend the life of front-end
consumables.Heavy- versus standard-duty
Welding mode and wear
Consider the impact of welding wire
Maintaining Consumables
New Reverse Part Number Lookup Function for Online MIG Gun Configurators Saves Time
New Reverse Part Number Lookup Function for Online MIG Gun Configurators Saves Time
Gain Efficiencies and Extend Consumable Life with Anti-Spatter Compound
Gain Efficiencies and Extend Consumable Life with Anti-Spatter Compound
Although it resembles water in its consistency, anti-spatter compound (when applied correctly and in the appropriate volume), will not drip like water. It simply creates a sacrificial barrier between the nozzle and any spatter generated during the welding process; the spatter easily falls off when the nozzle cleaning station performs the reaming cycle, thereby leaving the nozzle and other front-end consumables clean. The compound must be reapplied frequently to help maintain that barrier. tt
Positioning the robotic GMAW gun and front-end consumables in the correct location for the ream cycle and anti-spatter application helps the compound to be applied uniformly. To gain optimal spray coverage, always follow the manufacturer’s instructions for proper setup based on the nozzle bore size. If the sprayer is too far away from the nozzle, it will not provide adequate coverage to prevent spatter buildup. If the nozzle and sprayer are too close, too much spray may saturate the nozzle insulator, which can lead to premature failure.Adding a spray containment unit
This 3- to 4-inch unit fits over the spray head on the anti-spatter compound sprayer. Additional tips for effective nozzle cleaning station operation
Bernard and Tregaskiss to Attend FABTECH 2016
Bernard and Tregaskiss to Attend FABTECH 2016
Tips for Optimizing Reamer Usage
Tips for Optimizing Reamer Usage
This article has been published as an exclusive with The Fabricator. To read the entire article, provided by Ryan Lizotte, Tregaskiss field technical support specialist, please click here.
Customizing Your GMAW Gun for the Job
Customizing Your GMAW Gun for the Job
This article has been published as a web-exclusive on thefabricator.com. To read the entire story, please click here.
