Small automatic welding robots in China

Core Concept: What is "Teach-Free" Welding?

Traditional welding robots require engineers to program them step-by-step using a teach pendant, planning paths, postures, and welding parameters—a time-consuming and labor-intensive process. The core of "teach-free" welding lies in:

Visual Perception: Automatically identifying the workpiece's position, shape, and weld seam using a 3D vision camera (such as laser scanning or structured light).

Intelligent Planning: Software automatically generates optimized robot motion trajectories and welding torch postures.

Process Integration: Welding parameters (current, voltage, speed) are intelligently matched with the trajectory, eliminating the need for manual segmented settings.

One-Click Operation: Workers only need to perform two actions: "load material -> click start" to complete the welding of complex workpieces.

Part 1: Fao Collaborative Robots
Fao is a leading domestic manufacturer of collaborative robots, whose products provide an ideal platform for teach-free welding.

1. Core Advantages:

Extreme Flexibility: Lightweight design allows for easy deployment on benches, tracks, or mobile platforms, quickly switching between different workstations.

Safe Collaboration: Equipped with force sensing and collision detection, eliminating the need for safety fences (where risk assessment permits), enabling human-machine collaborative work and facilitating workpiece clamping and inspection.

Ease of Use: A graphical drag-and-drop programming interface allows welders without robot programming experience to quickly get started. This is crucial for integrating "teach-free" software.

High Precision and Stability: Repeatability up to ±0.02mm ensures precise execution of the welding trajectory.

2. Commonly Used Welding Models:

FR5 / FR10: 5kg and 10kg load models are the most common. The 10kg load is sufficient to support the welding torch, wire feeder, and most vision sensors, making it the mainstay model for welding applications.

FR16: Suitable for larger welding torches with heavier loads or multi-functional end effectors.

Part Two: Megmeet Welding Machines
Megmeet is a leading domestic manufacturer of industrial power supplies and automation components, renowned for its welding machines' stable performance and high degree of digitalization.

1. Core Advantages:

Excellent Arc Welding Performance: Performs exceptionally well in pulsed MIG/MAG welding and DC welding processes, exhibiting stable arc and excellent spatter control.

Powerful Communication Interface: Supports standard industrial Ethernet protocols such as Ethernet/IP, PROFINET, and Modbus TCP, as well as buses like DeviceNet and CANopen. This is crucial for achieving deep integration with robots and "teach-free" operation.

Digitalization and Programmability: The welding machine can store multiple welding programs internally, which can be quickly recalled via network commands, enabling synchronized changes in parameters and trajectories.

High Cost-Effectiveness: Offers near-top-tier international brand performance while maintaining a significant cost advantage.

Commonly Used Series for Robotic Welding:

MC/MD Series Digital Welding Machines: High-performance pulsed gas shielded welding machines, the primary choice for robotic welding.

MagCycler Series: Suitable for welding special materials requiring precise waveform control.

Part Three: System Integration and Core Components for "Teach-Free" Welding The Fao robot + Megmeet welding machine is an excellent hardware combination. However, to achieve the "teach-free" function, the following core integrations are required:

1. 3D Vision System (The System's "Eyes")

Brand: Typically, well-known third-party brands are chosen, such as Cognex, SICK, Hikrobot, Lingyun Optoelectronics, etc., or customized solutions from Fao's ecosystem partners.

Function: Quickly scans the workpiece before welding, generating 3D point cloud data including weld location, type (lap, corner, bevel), and even gap size.

2. Teach-Free Software Platform (The System's "Brain")

Function:

Weld Recognition and Extraction: Automatically identifies and extracts weld lines from the point cloud.

Trajectory Planning: Automatically generates the optimal welding torch movement trajectory (including walking angle, working angle, and oscillation mode) based on the weld type and process requirements.

Process Parameter Matching: A built-in or self-learning welding expert database automatically associates different weld positions, thicknesses, and bevel types with corresponding welding parameters (current, voltage, speed, swing frequency).

Communication Hub: The generated trajectory program is sent to the Fao robot, and the corresponding welding program number and parameter instructions are sent to the Megmeet welding machine via the network.

3. Integration Methods:

Deep Integration Solution: Fao or a core integrator provides an integrated hardware and software suite. The software is directly embedded in Fao's robot control system; vision and welding machine drives are pre-configured, and users can use it after simple training.

Project Integration Solution: The system integrator performs secondary development and integration of the Fao robot, Megmeet welding machine, vision hardware, and third-party no-teach software according to the specific project.

Part Four: Typical Workflow

Preparation: The worker places the workpiece (which can be a single piece or multiple randomly placed small parts) on the welding station.

Scanning: The job is started, and the 3D vision camera automatically scans the workpiece.

Calculation: The teach-free software completes recognition, planning, and program generation within seconds.

Welding: The robot automatically executes the generated program and simultaneously notifies the Megmeet welding machine via Ethernet to invoke the corresponding welding program, completing a high-quality weld.

Material Unloading: The worker removes the welded workpiece, places a new workpiece, and begins the next cycle.

Part Five: Application Scenarios and Value
Applicable Scenarios:

Small-batch, multi-variety welding: Such as non-standard customized fields like engineering machinery, rail transportation, steel structures, furniture, and door and window railings.

Poor workpiece consistency: The vision system can automatically compensate for dimensional deviations in incoming materials or positional deviations in clamping.

Complex trajectory welding: Scenarios such as spatial curve welds and intersecting circular pipes, where manual programming is extremely difficult.

Shortage of skilled welders: Reduces reliance on senior welders and robot programmers.

Core value brought to customers:

Significantly reduced programming time: Reduced from hours of teaching to minutes of automatic completion.

Improved equipment utilization: Minimizes robot standby and programming time.

Reduced skill requirements: Simplified operation, suitable for general workers.

Improved welding quality consistency: Eliminates human error fluctuations, ensuring stable and controllable quality.

Fast return on investment: Particularly suitable for production models with frequent product changeovers, offering a short return on investment cycle.

Summary: The Fao no-teach welding robot paired with a Megmeet welding machine solution is a flexible, intelligent, and digital welding productivity combination.

The Fao robot provides a flexible, safe, and easy-to-use motion execution platform.

The Megmeet welding machine provides a stable, efficient, and interconnected welding energy source.

3D vision and intelligent software endow the entire system with the ability to perceive, think, and adapt.

This solution perfectly addresses the two major pain points of "insufficient flexibility" and "complex programming" faced by the manufacturing industry in its transition to automation, making it a powerful tool for driving SMEs to achieve intelligent manufacturing upgrades. When choosing this solution, it is recommended to directly consult Fao or its authorized professional integrators, who can provide a complete demonstration and evaluation tailored to your specific workpiece and process.