ANSI AWS D16.2M D16.2-2007 Guide for Components of Robotic and Automatic Arc Welding Installations.pdf

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1、AWS D16.2M/D16.2:2007An American National StandardGuide forComponentsof Roboticand AutomaticArc WeldingInstallations550 N.W. LeJeune Road, Miami, FL 33126AWS D16.2M/D16.2:2007An American National StandardApproved by theAmerican National Standards InstituteAugust 25, 2006Guide for Componentsof Roboti

2、c and AutomaticArc Welding Installations3rd EditionSupersedes AWS/NEMA D16.2/D16.2M:2001Prepared by theAmerican Welding Society (AWS) D16 Committee on Robotic and Automatic WeldingUnder the Direction of theAWS Technical Activities CommitteeApproved by theAWS Board of DirectorsAbstractAWS D16.2M/D16.

3、2:2007, Guide for Components of Robotic and Automatic Arc Welding Installations, provides perfor-mance recommendations for evaluating components of a typical robotic or automatic welding installation.Emphasis is placed on the role of the welding interface. A pin arrangement and specific pin function

4、 for each location in astandardized 37-pin connector are proposed.iiAWS D16.2M/D16.2:2007International Standard Book Number: 0-87171-054-4American Welding Society550 N.W. LeJeune Road, Miami, FL 33126 2006 by American Welding SocietyAll rights reservedPrinted in the United States of AmericaPhotocopy

5、 Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in anyform, including mechanical, photocopying, recording, or otherwise, without the prior written permission of the copyrightowner.Authorization to photocopy items for internal, personal, or educati

6、onal classroom use only or the internal, personal, oreducational classroom use only of specific clients is granted by the American Welding Society provided that the appropriatefee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:.iiiAWS

7、D16.2M/D16.2:2007Statement on the Use of American Welding Society StandardsAll standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules o

8、f theAmerican National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, ormade part of, documents that are included in federal or state laws and regulations, or the regulations of other govern-mental bodies, their provisions carry the full legal authority

9、of the statute. In such cases, any changes in those AWSstandards must be approved by the governmental body having statutory jurisdiction before they can become a part ofthose laws and regulations. In all cases, these standards carry the full legal authority of the contract or other documentthat invo

10、kes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirementsof an AWS standard must be by agreement between the contracting parties.AWS American National Standards are developed through a consensus standards development process that bringstogether vol

11、unteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or the soundness of any judgments

12、contained in its standards.AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whetherspecial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or relianceon this standard. AWS also makes

13、no guaranty or warranty as to the accuracy or completeness of any informationpublished herein.In issuing and making this standard available, AWS is not undertaking to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertaking to perform any duty owed by any

14、 person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek theadvice of a competent professional in determining the exercise of reasonable care in any given circumstances.This standard may be superseded by the issuance o

15、f new editions. Users should ensure that they have the latest edition.Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard acceptany and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the inf

16、ringement ofany patent or product trade name resulting from the use of this standard.Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, w

17、hen discovered, are postedon the AWS web page (www.aws.org).Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,in writing, to the Managing Director, Technical Services Division, American Welding Society, 550 N.W. LeJeune Road,Miam

18、i, FL 33126 (see Annex A). With regard to technical inquiries made concerning AWS standards, oral opinionson AWS standards may be rendered. However, such opinions represent only the personal opinions of the particularindividuals giving them. These individuals do not speak on behalf of AWS, nor do th

19、ese oral opinions constitute officialor unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should not be used as asubstitute for an official interpretation.This standard is subject to revision at any time by the AWS D16 Committee on Robotic and Automatic Weldi

20、ng. It mustbe reviewed every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations,additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should beaddressed to AWS Headquarters. Such comments will

21、receive careful consideration by the AWS D16 Committee onRobotic and Automatic Welding and the author of the comments will be informed of the Committees response to thecomments. Guests are invited to attend all meetings of the AWS D16 Committee on Robotic and Automatic Welding toexpress their commen

22、ts verbally. Procedures for appeal of an adverse decision concerning all such comments are providedin the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the AmericanWelding Society, 550 N.W. LeJeune Road, Miami, FL 33126.This page is intentionall

23、y blank.ivAWS D16.2M/D16.2:2007vAWS D16.2M/D16.2:2007Personnel*AdvisorAWS D16 Committee on Robotic and Automatic WeldingV. L. Mangold, Jr., Chair NAMANJ. S. Noruk, 1st Vice Chair Servo Robot CorporationT. B. Hansen, 2nd Vice Chair ABB, IncorporatedP. Howe, Secretary American Welding SocietyC. T. And

24、erson Motoman, Incorporated*J. Berge Berge Engineering and AutomationJ. M. Blahnik Caterpillar, IncorporatedD. J. Erbe Panasonic Factory Solutions Company*J. Fryman Robotic Industries AssociationK. W. Gerhart Alcan Products CorporationL. K. Gross Milwaukee Area Technical College*J. F. Hinrichs Frict

25、ion Stir Link, Incorporated*H. L. Jones, Jr. Dominion/Virginia Power CompanyG. M. Lipnevicius The Lincoln Electric CompanyS. Mazzulla OTC-Daihen, IncorporatedS. D. Nelson Trek Bicycle CorporationR. F. Noch Johnson Controls, IncorporatedM. W. Perry Preston-Eastin, IncorporatedJ. L. Petersen Crenlo, L

26、LCW. R. Polanin Illinois Central CollegeWRP AssociatesD. L. Pratt Industrial Tooling and FabricationD. P. Rhoda Wolf RoboticsK. Summers Miller Electric Manufacturing CompanyK. W. Trumbull Genesis Systems GroupH. Volkhart Cloos Robotic Welding, IncorporatedJ. W. Williamson ABB, Incorporated*G. G. Win

27、chester NEMA*C. L. Woodman Automation Consultant*D. A. Wright, Sr. Zephyr Products, IncorporatedThis page is intentionally blank.viAWS D16.2M/D16.2:2007viiAWS D16.2M/D16.2:2007ForewordThis foreword is not a part of AWS D16.2M/D16.2:2007, Guide for Components of Roboticand Automatic Arc Welding Insta

28、llations, but is included for informational purposes only.The AWS Committee on Robotic and Automatic Welding was organized in 1985 to provide a centralized source for theexchange of technical information between manufacturers, installers, and operators of robotic and automated equipment.In 1988, the

29、 Committee was expanded to include representation of the Arc Welding Section of the National ElectricalManufacturers Association (NEMA). The relationship was formalized in September 1989 when the NEMA Codes andStandards Committee approved formation of a joint AWS/NEMA Committee to prepare a series o

30、f documents on variousphases of the installation, maintenance, and operations of robots for welding.The original edition of this standard, ANSI/AWS/NEMA D16.2-94, set guidelines for evaluating the performance ofindividual components that make up a typical robotic installation. Emphasis was placed on

31、 the standardization of thewelding interfaces.Since the publication of the second edition, AWS/NEMA D16.2/D16.M:2001, NEMA has officially withdrawn as apartner in this joint committee but continues in an advisory capacity through its representation on the D16 committee.This third edition of D16.2 ha

32、s been updated to include the latest terms and technology, and to meet the new AWS specifi-cations for standards. Two informative annexes, one on sample maintenance schedule and one on sample spare parts list,were added to this guide. Revised areas are denoted by underlines or bars in the margin.Com

33、ments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,AWS D16 Committee on Robotic and Automatic Welding, American Welding Society, 550 N.W. LeJeune Road, Miami,FL 33126.Official interpretations of any of the technical requirements of this stand

34、ard may only be obtained by sending a request,in writing, to the Managing Director, Technical Services Division, American Welding Society (see Annex A). A formalreply will be issued after it has been reviewed by the appropriate personnel following established procedures.This page is intentionally bl

35、ank.viiiAWS D16.2M/D16.2:2007ixAWS D16.2M/D16.2:2007Table of ContentsPage No.PersonnelvForeword viiList of Tables .xiList of Formsxi1. Scope.12. Normative References .13. Definitions 14. Arc Welding Power Sources .34.1 Overview34.2 Continuous Duty. 34.3 Remote Control 35. Arc Welding Torches and Acc

36、essories .35.1 Overview35.2 Torch Design Details .35.3 Torch Holder Details 45.4 Collision Protection Device 45.5 Torch Accessories 46. Dereeling System 46.1 Overview46.2 Equipment46.3 Characteristics 57. Welding Interfaces. 57.1 Overview57.2 General Requirements .57.3 Input/Output Signal Requiremen

37、ts 58. Shielding Gas Delivery Systems 68.1 Overview68.2 Regulators and Flowmeters .78.3 Fitted Hose Assemblies .79. Welding-Electrode Feeding Equipment . 79.1 Overview79.2 Service Conditions 79.3 Rating and Performance 79.4 Construction . 79.5 Installation and Operation 810. Welding Circuit 810.1 Co

38、mponents 810.2 Design. 810.3 Integrity 810.4 Conductor Size . 8xPage No.AWS D16.2M/D16.2:200710.5 Support Equipment Isolation 810.6 Methods of Weld Circuit Completions (Workpiece Leads)811. Communication Control Wiring.911.1 Design. 911.2 Location 912. System Grounding . 912.1 Grounding Mechanics. 9

39、12.2 Ground Identification . 913. Cable and Hose Management . 913.1 Routing 913.2 Voltage . 1013.3 Cable Fatigue.1013.4 Extended Length .1014. Maintenance 1014.1 Personnel1014.2 Preventive Maintenance . 1014.3 Spare Parts .10Annex A (Informative)Guidelines for the Preparation of Technical Inquiries

40、11Annex B (Informative)Informative References13Annex C (Informative)Sample Maintenance Schedule for a Robot Arc Welding System. 15Annex D (Informative)Sample Spare Parts List for a Robot Arc Welding System.17List of AWS Documents on Robotic and Automatic Welding . 19xiAWS D16.2M/D16.2:2007List of Ta

41、blesTable Page No.1 Typical Connector Pin Assignments .62 Minimum Hose Assembly Breaking Strength.7C.1 Sample Maintenance Schedule16D.1 Sample Spare Parts List.18List of FiguresFigure Page No.1 Typical Robotic Arc Welding Arrangement22 Pin Layout for a Standard 37-Pin Connector (Ref. MS3102A-28-215)

42、53 Typical Robot Welding Circuit .94 Protective Earth (Ground)10This page is intentionally blank.xiiAWS D16.2M/D16.2:20071AWS D16.2M/D16.2:20071. ScopeThis document applies to the recommended design, inte-gration, installation, and use of industrial welding roboticand automatic systems. This documen

43、t is intended forthe gas metal arc welding (GMAW) and flux cored arcwelding (FCAW) processes. Pertinent parts may addressadditional welding processes.Robotic and automatic arc welding systems consist of amanipulator, power source, arc welding torch and acces-sories, electrode feed system, dereeling

44、system, shieldinggas delivery system, welding circuit, shielding andcommunication control, and grounding system. Theremay be other accessories that are outside the scope ofthis document, such as safety devices and monitoring,joint-tracking, and vision systems. A typical system isillustrated in Figur

45、e 1.This standard makes use of both the International Systemof Units (SI) and U.S. Customary Units. The measure-ments may not be exact equivalents; therefore, each sys-tem must be used independently of the other withoutcombining in any way. The standard with the designationD16.2M:2006 uses SI Units.

46、 The standard designationD16.2:2006 uses U.S. Customary Units. The latter areshown within brackets or in appropriate columns intables and figures.Safety and health issues and concerns are beyond thescope of this standard and therefore are not fullyaddressed herein. Safety and health information is a

47、vail-able from other sources, including, but not limited to,ANSI Z49.1, Safety in Welding, Cutting, and AlliedProcesses, and applicable federal and state regulations.Other safety documents are listed in Annex B.2. Normative ReferencesThe following standard contains provisions which,through reference

48、 in this text, constitute provisions ofthis AWS standard. For undated references, the latestedition of the referenced standard shall apply. For datedreferences, subsequent amendments to, or revisions of,any of these publications do not apply.AWS Documents:1AWS A3.0, Standard Welding Terms and Defini

49、tions3. DefinitionsTerms used in this document are in accordance withAWS A3.0, Standard Welding Terms and Definitions. Inaddition, for the purposes of this document, the follow-ing definitions apply:analog input. A dc voltage signal from the processequipment to the robot controller that may vary from 0 to100% of the output range.analog output. A dc voltage signal from the robotcontroller to the process equipment that may vary from 0to 100% of the output range.arc established. A discrete input signal indicating that awelding arc is present.arc on/arc off. A discrete output signal tha