ABB Robotics’ WeldGuide III is a package of hardware and software specifically designed for ABB’s newer IRC5 controller, and requires less initial programming than traditional robotic welding control systems.

ABB Robotics is introducing an adaptive sensing system that performs weld seam joint tracking during the welding process, identifying variations in the weld joints to proactively correct the robotic torch path. WeldGuide^® III uses voltage and current sensors to take real-time measurements through the welding arc, to make any adjustments necessary to keep the robotic welding torch in the joint path no matter the programming.

“WeldGuide III is a direct result of consistent input from our key heavy welding integrators and customers,” states Joe Campbell, v.p. - sales and marketing for ABB Robotics, North America. “Welding and metal fabrication are primary growth areas for robotics and ABB will continue to develop best-in-class robots and control systems to serve these markets.”

Comprised of hardware and software specifically designed for ABB’s newer IRC5 controller, ABB Robotics emphasizes that WeldGuide III is priced at half the cost of its previous joint-tracking package, the Advance Weld Controller system. The company also indicates WeldGuide III is easier to install and operate than the prior package. Reportedly, WeldGuide III requires less initial programming than traditional robotic welding control systems and is particularly well suited for applications on heavy weldments.

More specifically, ABB indicates that WeldGuide III is effective for heavy-deposition welding where a 1- to 2-mm weave pattern must be used to fill the gap between the parts. Also, it points to the systems effectiveness in fabricating applications where the welding seam location moves slightly (or more) from one part to the next. Lastly, it says the WeldGuide III is effective for joining parts that require multiple passes to complete the weld. In heavy, high heat welds, ABB Robotics reports that WeldGuide III provides more precise path accuracy and better weld integrity than would be achieved with standard welding systems. With the tracking system automatically adapting to the part, WeldGuide III provides more consistent welds, even on parts where there is considerable part variation, providing far better throughput and less re-weld situations.

The primary applications that ABB Robotics identifies for the new package include off-highway and agricultural equipment, transportation, defense, and other manufacturers that fabricate large, heavy metal parts requiring longer, wider welds. However, Campbell adds that the technology “is so easy to use and cost-effective that it is even appropriate for the smallest job shops.”