Ed's how to establish Robot MIG Welding Process Control
Program for all Steel / Stainless Gage Applications.

Weld transfer modes. Short Circuit - Spray and Pulsed Transfer.

Ed set the robot welds for Volvo Cabs, Corvette bodies, Harley bikes and Ford 150 truck frames.

E-mail From Marcus di Sabella

Ed, I just received your robot process control materials and within five minutes of skimming, I found many flaws in our weld techniques and process data. Your robot weld process control training materials will be very helpful to our organization! Thanks for your expertise and prompt service!

Process Engineer.Car Sound Exhaust System, Inc / Magnaflow Performance Exhaust.
Rancho Santa Margarita, CA.

No other resource will provide you with the specific MIG process control
data and the root cause solutions necessary to minimize robot MIG weld defects?

PULSED MIG ON ROBOT APPLICATIONS? CONSIDER TIP TIG
IF WELD QUALITY IS YOUR FIRST CRITERIA.

Ed's Robot Weld Process Control CD Training Resource
is applicable to all types of robots and weld equipment.

While Panasonic, Motoman, Fanuc and ABB may try to sell your organization complex, costly solutions to your robot
weld issues, Ed's approach to robot weld process control simplification typically enables robot weld process quality - productivity
optimization through nothing more than "robot weld process expertise". The weld decision maker who presents this
training presentation needs no robot weld process control expertise.

Robots Management Choices. Maybe you are that manager who wants to eliminate time wasting weld trials with your robot supplier who in many instances when it comes down to those welds will talk the talk but they unable to walk the walk. Perhaps you would like it if your robot weld personnel stopped playing around with the robot weld data. Perhaps after investing hundreds of thousands of dollars in those robot cells you would like to dramatically reduce that robot down time and senseless weld rework - scrap. Or perhaps you are simply confused with the ever increasing array of useless costly bells and whistles that are ending up in the robot cells. If this is the case Ed's program for you.

Robots Process Parameter - Consumable Choices. There are many unnecessary weld transfer modes and weld consumable options available to the plant engineers and technicians when making robot welds on thin parts < 4 mm. When welding gage applications many plants will use the wrong size weld wire, a poor weld gas choice or simply use weld transfer mode or weld data which is not optimum.

Any company that purchases a welding robot without "weld process control expertise" is a company looking to fail. For the robot weld decision maker looking to get to the root cause of the robot down time / weld issues, the process questions may be many yet the weld reality is the process solutions will often simple. Please remember weld process expertise does not come from the knowlege of a skilled welder. Robot's want optimum automated weld data and few welders or technicians have this expertise.

[] When should you use short circuit, globular, spray or pulsed?
[] When should you utilize that 0.035 - 0.045 and 0.052 (1- 1.2- 1.4mm) MIG wire?
[] How will you know you are at attaining optimum robot weld quality / productivity?
[] What robot techniques will assist with my weld issues?

A SOLUTION TO PLAYING AROUND WITH WELD CONTROLS: You have to be aware that you rarely will optimize the robot weld results as long as the robot personnel are playing around with the robot weld data. Ed'd weld programs provide the "Weld Clock Method" (WCM). Ed developed this unique simple approach to weld process control over 35 years. With theWCM your weld personnel will not have to take notes while training and they will instantly know the required settings and solutions for optimum weld quality and productivity. Being aware of the numerous factors that influence your robot weld production potential and down time, and providing instant solutions to the problems, can have a dramatic impact on your weld quality and production costs. Once you present E one day program to your employees, typically you can anticipate the highest weld quality possible with a 20 to 50% increase in your daily robot weld productivity.

Note. Your supervisor, technician, engineer or trainer needs no weld process expertise to present this program as all the data you will ever need is presented in a simple manner. Visit E'ds training resources for more info.

Don't play around with weld controls and settings
and end up with questionable weld quality.

For weld defect prevention,
provide instant robot weld process solutions.

Ed's Robot Process Control Programs reduce your weld liability concerns.

View the weld and provide the instant robot weld process solution.

There is no other global program that provides you with instant,
logical process solution to your common robot weld defects.

With a few hours exposure to E CD program, your employees
will have the ability to provide instant process solutions to;

[] Robots and Lack of Weld Fusion.
[] Robots and Weld Start Issues.
[] Robots and Weld Burn Through Issues.
[] Robots and Wire Burn Backs.
[] Robots and Contact Tip Issues.
[] Robots and Weld Crater Issues.
[] Robots and Weld Arc Instability.
[] Robots and Inconsistent Welds.
[] Robots and Poor Weld Profiles.
[] Robots and Weld Spatter.
[] Robots and Solutions to Variable Weld Gaps.
[] Robots and Process solutions to Part Dimension Inconsistency.
[] Robots and Weld Porosity.
[] Robots and Weld Cracks.
[] Robots and Weld Undercut.
[] Robots and The requirements for High Speed Welds.

E-mail. From Jose Ignacio Moreno. Spain. Ed. I work as manufacturing engineer in Johnson Controls Alagon (Spain). We mainly build car seat structures and we have some robot welding cells. Last week I received your robot process control material, which I've been reviewing. I find it really interesting and practical. Your approach to weld process control is unique and it certainly works. It seems you have been in our company as most of the robot MIG weld issues you address are part of our every day work.

Thank you JM.

Note: Ed set optimum robot welds for Toyota, Subaru, BMW,
Peugeot, Volkswagen, Citroen, Ford and GM car seats.

E-mail From: Tom Plummer: USA. Ed. I just wanted you to know that Tenneco has plants all over the world. We have been very enlightened by your " Robot MIG Weld Process Control" training materials " We are slowly implementing your process control and best practice concepts to the shop floors.

Tenneco .USA.
Aug 2007:

E-mail: From a Dana Corporation Employee:Jan 2007: 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 truck frames per-hour and the majority required extensive weld rework. Thanks to your robot weld process control / best weld practices program the results from our employees are today staggering. Yesterday this plant hit very close to a record of 76 frames jobs 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 F-150 line.

Many thanks R G!

A Grateful Employee
Dana Corporation.

March 2007: Update from RG. Hey Ed:Just thought I would drop you a line and let you know that in the beginning of April we will be working on switching over the 5th Dana plant to your process recommendations of an 0.040 wire and the traditional spray mode instead of the 0.052 wire and Rapid Arc (Lincoln's pulse program). Thanks again RG.

This unique, robot weld process training CD which
Ed updates twice a year can be two things.

[1] A tremendous resource when you need solutions for your robot weld issues.

[2] The world's most effective Robot MIG Process Control training program for all steel and stainless gage applications < 4mm.

This CD provides all the information and tools necessary for managers, engineers, technicians, maintenance and QA personnel to;

[A] Take complete ownership of the robot welds.

[B] React in a uniform manner to instantly resolve robot weld performance, productivity / quality issues.

[C] Enable the establishment of uniform Best Weld Practices.

[D] Provide all the data necessary for the implementation of highly effective Weld Process Controls.

E-mail from l. KD - P&F.
12/07

Ed, you would be interested to know that by the end of the year I will have at least 100 of our robots welding with US 0.035 (1 mm) wire using conventional spray transfer with no pulsing. It took 10 years Ed, but finally using the recommendations you made to us in the nineteen nineties. I now have the top guy in North America convinced traditional spray is the way to go with the robot MIG applications. In regards to your MIG process control training programs and resources we now have two other plants that will be contacting you.

Note from Ed: This tier one supplier to Honda and Toyota is the largest robot welded parts supplier in the USA. The plant has hundreds of Panasonic robots and Panasonic pulsed MIG equipment. The Panasonic weld equipment and pulsed process was a requirement of the Japanese parent company. For more than a decade, this pulsed MIG equipment daily generated numerous pulsed weld and production issues that dramatically impacted the daily robot weld quality and production. With all the problems, the blinkered corporate engineers and apathetic managers in Japan were reluctant to hear that the traditional, more durable, lower cost, North American CV equipment using convention spray transfer would provide highly effective solutions to the majority of their daily robot weld issues.

Continue with info on Ed's Robot Weld Process Control Training Resources.

Welding Books

Welding CD's

Ed's how to establish Robot MIG Welding Process Control
Program for all Steel / Stainless Gage Applications.

Welding Books

Welding CD's

Ed's how to establish Robot MIG Welding Process Control Program for all Steel / Stainless Gage Applications.

Ed's how to establish Robot MIG Welding Process Control
Program for all Steel / Stainless Gage Applications.