If
you want to control those robots or
establish uniform weld practices and
process
controls in your weld shop,
this is the resource you need.
"MIG
& Pulsed MIG. Training CD:
Best
Weld Practices and Weld Process Controls
for Robots and Manual Welds"
Price $275. Order here.
MAGNA is an auto parts supplier that has
over two hundred plants and generates over 15 billion dollars annually.
Dana does close to 7 billion dollars annually in auto / truck part sales.
Both these companies in 2004 and 2005 had specific facilities or personnel
that decided to establish a Robot Weld Best Practices and
a Robot Weld Process Control training program for their key technicians,
engineers and management robot personnel.
After reviewing the available
North American training resources both Magna and Dana companies purchased Ed's
unique training program.
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Consider
this an ever evolving book or training resource for your company.
A
few of the >300 Power Point slides are provided
on the world's
most effective robot MIG weld best practices
and MIG weld
process controls.
So
mary variables influenece robot welding issues.
Inconsistent
arc starts. Poor start stop / data,
birds nest, balls on end of the wire, crater
issues,
weld inconsistency. Why not get to the root cause of
the robot
weld problems that cause robot down time.
There
are many reasons for that robot weld spatter.
Using globular parameters, wire
stick out vaiations,
incorrect voltage and lack of parameter knowlege.
Inconsistent
welds from poor placement of leads?
You can play around with the leads or know
the best
location for the volt sensing leads.
A
complete evaluation of MIG equipment is provided. The reasons
are given why
on the majority of steel applications
you can attain the same weld quality
from a $2000 power
source as you can from a $12000 power source.
Just
one of the real world differences
between pulsed and spray.
A
salesman can say one thing about welding equipment and
consumables, Ed's training
programs will show the weld reality.
HOW
ED'S ROBOT PROCESS CONTROL TRAINING INFLUENCED
THE BEST SELLING TRUCKS SOLD
IN NORTH AMERICA:
E-Mail
July 2006
Ed
I wanted to send update about that E-Town plant that you visited a few years ago:
As you know on your first visit to this plant, our robot lines were producing
less than 40 Ford truck frames per-hour and the majority required extensive weld
rework. Thanks to your weld process and consumable recommendations, your training
books and your MIG manual / robot Weld Process Control Training Program, today
the results from our employees are staggering. Yesterday this plant hit very close
to a record of 76 truck frames per hour. We daily attain our average goal of one
frame per-minute. We had two recent weld audits. One weld audit had a total of
two failures, and the 2nd weld audit was the first 100% pass weld audit in the
history of the Ford F-150 truck frame line.
Many
thanks!
A
Grateful Employee of
Dana Corporation.
Robot
cell equipment decisons? Make the right choices
as they will effect, the robot
quality, productivity and down time.
Restarts.
TCP controls. Robot collision options.
Weld joint tracking options?
When
you make the right choices befor you purchase the robots,
you have a sound
investment in your robot equipment.
Optimum
weld procedures, the best weld equipment and the most
expensive robot equipment,
will mean nothing without calibration knowlege.
An
in-depth evaluation of short circuit transfer and the
correct robot weld parameters
for all steel and
stainless gage applications.
After this training
session no weld decision maker in your
organization will ever have to
play
around with those MIG parameters.
A simple weld
process control method shows your employees
how to instantly set optimum Spray
Transfer parameters
and why on many steel applications, spray is preferred
to pulsed.
AND
YOUR ROBOT GOALS ARE?
With
this robot MIG weld process control training, the following four production, robot
weld goals are simple.
[1]
Attain no more than two percent daily weld rework
from each robot.
[2]
Attain maximum weld speeds and weld deposition rates
per-application.
[3]
Achieve less than 20 minutes each shift for robot
down time.
[4] Have a weld team that completely
understands the tools and equipment they are asked
to operate and manage.
The weld reality is that fewer than 10% of the companies
that have purchased robots will in 2007 attain these goals.
MANY
COMPANIES WILL THIS YEAR PURCHASE MORE ROBOTS WHEN THE ROBOTS THEY OWN HAVE NEVER
REACHED THEIR WELD PRODUCTION POTENTIAL.
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Everything
you need to know about pulsed, its benefits, its
disadvantages and how to
set those many pulsed parameters.
Every
weld decision maker should know how to
best utilize pulsed, short circuit
and spray.
There
are many things designers can do to
improve robot weld quality and productivity.
E-Mail:
April 2005. Dear Mr. Craig ,
Mr. Craig. Your web
site was recommended by a friend, I really enjoyed going through it ! you must
be congratulated for making a rather dry subject like welding both colorful
and interesting'.
Wishing
you all success and happiness,
With warm regards T.A.Ramesh
Grafs
Welding Institute and Consultancy Services ,
Mumbai, India.
As
most weld equipment provides no weld data, Ed provides
a unique simple approach
to setting the weld equipment.
Once
you learn the the clock method, setting any weld consumable on
MIG equipment
for any application becomes simple.
With
any MIG or flux core wire there are only four
settings for every possible
application. Do you
or your employees know those 4 setings?
While
Ed shows you the four simple settings for every
sheet metal weld application
in the world, some weld
equipment manufactures will try to sell you their
electronic MIG equipment offers 4 million wave forms.
Setting correct arc lengths. Using wire stick outs
to resolve robot weld issues
Poor arc starts. Wire
burn backs. Crater fill. End Data. Every weld
decision
maker needs to know the little things that
can impact weld production or quality.
Why
weaves benefit certain applications and we
need to limit them on others.
If
you want robot rework of less than 3% and maximum, daily weld productivity
I
would recommend you implement these 7 logical steps to Robot MIG Process Controls.
E-Mail
to Ed.
Having
read your site from cover to cover I loved every bit of it as it provides the
only "non-biased" view of the MIG welding process and related equipment
and consumables. Keep up the great work,
Regards Bill.
Devon, England.
E-Mail: Hi Ed.
Its Matt Finn, I spoke with you on the phone a couple of weeks ago. Well contrary
to the beliefs of my coworkers I must say your concepts on GMAW are worth trying.
Your story of reading weld literature and finding it was not as it seems inspired
me to do the same. Over the last three years all I have done and continue to do
is read from a variety of welding resources. So this past week I have focused
my study on the "hands-on" practical aspect. Its amazing what you learn
from having your nose in the arc rather than observing from out side a fence.
From this approach I now fully understand how and why globular transfer is not
a reliable mode of transfer, especially when utilizing it for high travel speeds
(50- 70imp). Tonight thanks to your books I was able to figure out how you achieved
robot speeds of 70 to 100ipm in spray mode. I went snooping around the plant and
found an old style of diffuser that was shorter than our common ones. I then took
your advice from your WELD MANAGEMENT AND ENGINEERS book and cut about a quart
inch off the end of a tip. With having the tip recessed in to nozzle allowed for
a longer stick out dropping the amperage but still within the spray range. The
longer wire stick out permitted me to run higher WFS (deposition rate) without
the extra amperage that would cause unwanted weld defects. The spatter was minimal
and easy to remove. Also the recessed tip and diffuser were spotless. After thinking
about it I now makes sense. Thanks
for your contribution to my weld education.
Matt Finn. USA.
