Heath Suraba

Heath Suraba is an automation application technologist in the Automation Division of The Lincoln Electric Company, 22801 Saint Clair Avenue, Cleveland, OH 44117-1199, 216-481-8100, Fax: 216-486-1751, heath_suraba@lincolnelectric.com, www.lincolnelectric.com.

Articles by Heath Suraba(showing 1 to 8)

Welding with Laser Touch Sense

Laser touch sensing works on heavy mill scale and on aluminum applications. These two areas are traditionally problematic applications for contact wire touch sense. The laser has no problem with either. The heavy mill scale on steel and the aluminum oxide that naturally forms aluminum are often insulators that prevent conventional wire touch sense from working 100 percent of the time.
Because of its low cost and ease of use, laser touch sense is quickly growing in popularity to locate weld joints and parts that are moving in location relative from one part to the next.

How to Increase the Speed of Your Robotic Welding System

Select a wire-feed speed range that’s the sweet spot for welding. Typically for .035 and .045 wires, that’s between 330 ipm and 450 ipm. Select a wire diameter at the optimum wire feed speed and adjust the travel speed to give you the appropriate fill.
The speed you really need to weld is all about how fast in seconds per year you can weld the parts. That is the first step in properly selecting which high speed welding process you want to use. Here are some other considerations. 

FILL THE GAP: ROBOTS FOCUS ON QUALITY

A welding robot takes on the burden of tedious, repetitive jobs easily and frees up the skilled welders to work on complex weldments that are not suitable or cost effective for robotics.
Though many might argue that the progression of robotic welding technology has always focused on profit, Heath Suraba of Lincoln Electric explains why you must have quality before you can realize profit.

Synchronized Tandem MIG® Process Revealed

Figure 1. The maximum deposition rate in a traditional single wire GMAW (MIG) process is limited by the saturation current(I) for any specific wire diameter. To overcome this limitation, Tandem MIG combines two separate MIG welds into a single application.  The outcome is a process capable of nearly double the deposition rate of single wire MIG.
This examination of Tandem MIG shows how it extends the welding productivity range beyond that possible with conventional single-wire processes.

I Choose That Welding Torch, Please

If the cumulative temperature at the contact tip exceeds the melting temperature of the filler wire, then a droplet of metal will form and eventually disrupt the wire feeding. The torch is unaffected, but the welding wire melted at the end of the contact tip. This is often misdiagnosed as being a wire feed problem when its actually a heating problem or, said another way, a lack of cooling.Click on photo to enlarge it)
Though this simple tool does some serious grunt work, most robot users do not put enough thought or care into selecting what welding torch they will use for the rest of their robot’s life. Heath Suraba of Lincoln Electric explains what should be considered when choosing.

Welding Robots Justified

Robots are a manufacturing enabler that spur real growth and fast-track production. Shops find they can take on more work when productivity goes up, so they hire additional labor to cover the new business.
The traditional ROI focused on robots as a direct replacement for people. But many fabricators now investing in automation with welding robots eventually hire more people too. What is going on?

The Higher Power Behind Power Sources

Customize welding variables and set limits that comply with your specific Welding Procedure Specifications or Procedure Qualification Records. Train the system by making several “good” welds within your boundary limits. Once the system is trained on a sample of acceptable welds, if a weld happens to fall outside the “trained” definition of acceptable weld criteria, a fault signal can be communicated (output) to the robot, PLC or operator and then be dealt with accordingly.
Many welders are still not aware that it is now possible to combine and capture all the information associated with their welding operation into one simple interface – their power source. This is the most advanced way to approach data acquisition and production monitoring in the welding industry.

Welding with Robot Vision

Robotic vision is all about contrasts and the consistency of that contrast. Most vision systems “see” in shades of gray. When one pixel has sufficient light to dark difference as compared to the one next to it, it triggers an edge line. The unique image created by these edge lines is the basic principle used by robot vision. (Click on photo to enlarge it)
Weld fixtures not repeatable? Inconsistent weld joints? Robots can now automatically adapt to solve these issues and more. Heath Suraba of Lincoln Electric shares some tips on how to see the best return from your vision investment.