Ed's how to establish Robot MIG Welding Process Controls for all Steel / Stainless Gage Applications < 4 mm.

Robot welds.Short Circuit, Spray and Pulsed Transfer.

Ed set the robot welds for Volvo Cabs, Corvette, Harley 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. These 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.

What other resources will provide you with specific MIG process control
data and the root causes and solutions to robot MIG weld defects?

PULSED MIG ON ROBOT APPLICATIONS COMPETE WITH 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.

Note: Ed has a reputation for weld process control simplification.
The weld decision maker who presents this training presentation needs
no robot weld process control expertise.

Robots, Process Parameter and Consumable Choices. There are many weld transfer modes and consumable options available to the plant engineers and technicians when welding those robot welds on thin parts < 4 mm.

With gage welds, Many plants will use the wrong size weld wires, or use weld transfer modes which are not optimum. This program takes the salesmanship out of weld equipmet / consumables and process control advice and provides the optimum weld transfer modes, consumables, weld parameters and techniques for all robot carbon steels, alloy steels and stainless gage applications.

If you want to eliminate time wasting weld trials and robot weld personnel playing around with weld data this is the program for you. The questions are many and the solutions will be simple.

[] 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?

THIS IS THE SOLUTION TO PLAYING AROUND WITH WELD CONTROLS: The program provides the "Weld Clock Method", a unique simple approach to process control. With this easy to learn process control method, your weld personnel will not have to take notes and they will nstantly know the required settings for optimum weld quality and productivity.

Root cause and instant weld resolutions. As few robots achieve their daily weld quality and production potential, the data that's presented in this program is extremely cost effective beneficial.

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 this one day program to your employees, typically you can anticipate a 20 to 50% increase in your daily robot weld productivity.

Note. You need no process expertise to present this program as all the data you will ever need is presented in a simple manner.

IF YOU WANT OPTIMUM ROBOT WELD QUALITY, THERE IS
ONLY ONE WELD PROCESS TO CONSISDER. TIP TIG

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.

[] Robots and Weld Rework: It's typical in many plants to find excess weld rework required for those robot welds. This program identifies the root causes of the rework and deals with all the major issues that impact weld quality and rework.

[] Robots and Weld Defect Prevention. All the common weld defects are covered and the process control data is provided to ensure your defects are minimized and weld rework in minimum.

[] Robots Weld Deposition Rates and High Speed Welds: This process optimization training program provides you with unique data on attaining the highest possible "stable" weld speeds for gage welds.

[] Robots and MIG Equipment: The training cuts through the sales bias of weld equipment and makes you aware of why Inverters and Pulsed MIG equipment can enhance weld quality on some applications and may have dramatic negative weld quality impact on other applications.

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 this 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.

To order Ed's Robot process control program, Click here.

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 we are 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 the traditional, more durable, lower cost, North American CV equipment would provide solutions to the majority of their daily robot weld issues.

If you want MIG process expertise in which your robot
welds are always optimum, I suggest this resource.
Back to Ed's Welding Training Materials

IF YOU WANT OPTIMUM ROBOT WELD QUALITY, THERE IS
ONLY ONE WELD PROCESS TO CONSISDER. TIP TIG

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Ed's how to establish Robot MIG Welding Process Controls for all Steel / Stainless Gage Applications < 4 mm.