Automated Reaming Stations: A Simple Addition to Maximize Productivity

Automated reamers, or nozzle cleaning stations, help maximize the productivity of robotic welding systems. In this video and blog post we will talk about the importance of reaming the torch head on your system and a solution we’ve integrated into one of our linear welding robots to help maximize efficiency.

Sections: 

• The Benefits of adding a Reaming Station to an Automated Welding System
• How does an automated Reaming Station work?
• Video: Automated Reaming Stations: A Simple Addition to Maximize Productivity [Watch Full video Below]

The Benefits of adding a Reaming Station to an Automated Welding System

Even in some automated systems, some of the tasks may still require operator involvement - such as,  reaming the nozzle, applying anti-spatter spray, and trimming the wire between passes.

Cleaning, or reaming, your nozzle specifically is a very important step to maximize the weld efficiency with robotic welding. Not only does reaming extend the life of your consumables and reduce downtime, but if you don't a dirty nozzle can contribute to weld defects, weld x-ray failures, and cause rework. If you fail to trim the wire when making these stops, you risk contamination from built up slag, or even reducing gas flow to the torch. So, essentially, cleaning the nozzle properly and trimming the wire are simple measures you can take to avoid rework.

However, this can be a time-consuming step –an operator has to stop the process and meticulously remove all splatter from the nozzles and contact tip. And, this isn’t just a once-a-month kind of thing. Doing this cleaning frequently helps improve weld quality. So as you can imagine, constant stops to ream the nozzle alone can work against efficiently.

How does an automated Reaming Station work?

To keep this linear welding robot hands-free we have included an automatic reaming station to the system and the torch head is programmed to visit the station after a set number of passes.

Three things will happen automatically each time the weld head visits:

1. Removes Slag Build up:
   When clamped into place, the reamer extends and spins to remove slag build up inside the welding nozzle. (Depending on the torch body style or nozzle size, there are various reamer options and styles you could choose from – it’s totally adaptable.)
   
2. Trimming the Wire:
   Once the reamer is finished the wire is trimmed to the appropriate stick out length – it’s an important step to avoid bad weld starts and also because this system has a laser seam tracker with very specific work distances set
   
3. Applies Anti-spatter spray:
   The weld head then moves to the third part of the station where the inside of the nozzle is coated with anti-spatter spray. This is a preventative measure to improve efficiency, reduce the frequency of reaming and reducing waste because it sprays the anti-spatter spray directly into the nozzle.

Take Aways: 

An automatic reamer station, like the one shown on the linear welding robot in the video, helps to create a hands-free welding system. Not only will cleaning the nozzle and other consumables help produce cleaner welds and prevent rework, but with programmed frequency and greater efficiently can help increase production and prolong the life of your robotic system.

Video: Automated Reaming Stations:
A Simple Addition to Maximize Productivity

[The Automated Reaming Station featured in this video is an
Intelliream EIP from Nasarc Technologies]

Interested in Learning more?

To get in touch with one of our welding automation specialists, schedule a meeting here. 

If you’re interested in learning more about this linear robot, some of it’s features, or some of IRCO’s other projects don’t forget to take a look at our YouTube channel or check out the following posts: 

• Quick Guide: Automated Beam Welding Systems
• NEWS: Linear Robot for Box Beam Welding
• What Different Types of Welding Automation are there?