Abstract
Targeting the core pain point of Turkish customers’ existing Binzel welding machines—the lack of a compatible EtherCAT digital communication interface, which prevents integration into automated systems—NODHA Industrial Technology has innovatively proposed a customized transformation solution of "analog output + I/O signal interaction" based on its self-developed collaborative robot arm.This solution eliminates the need to replace the hardware of Binzel welding machines. It uses analog modules to achieve precise transmission of welding parameters, and is paired with I/O signals to complete equipment control and status feedback. Meanwhile, by combining the flexible operation characteristics of the collaborative robot arm, it unblocks the automated control link.After transformation, the equipment achieves "plug-and-play" functionality, with a significantly lowered operation threshold. This not only solves the EtherCAT communication compatibility problem, but also provides a cost-effective path for the automated upgrade of existing Binzel welding machines. It demonstrates NODHA Industrial Technology’s customized service capabilities in the field of industrial automation.
Keywords
Manual welding transformation; NODHA Industrial Technology; Analog control; I/O signal interaction; Existing equipment upgrade
Ⅰ. What is the Manual Welding Transformation Project? — An Automated Solution to Solve the EtherCAT Compatibility Issue of Binzel Welding Machines.All you need is a welding machine with ananalog external control interface, and it’s plug-and-play!
In the field of welding automation, most traditional robotic arm integration projects adopt digital protocols such as EtherCAT and Modbus to achieve inter-device linkage control, which requires matching with dedicated welding machines equipped with digital communication interfaces.However, many manufacturing enterprises still have a large number of manual welding equipment that only supports basic external control functions and has no digital communication interfaces. If the entire equipment is replaced to achieve automation, it will incur high procurement and replacement costs, and also cause waste of existing equipment resources.
Against this background, how to connect the control link between customers’ existing manual welding equipment and the automated system—while retaining the equipment—has become a key issue urgently to be solved in the industry.
The Manual Welding Transformation Project is a customized technical service launched by NODHA Industrial Technology for Turkish customers’ existing Binzel welding machines. These machines have basic external control functions but lack a compatible EtherCAT digital communication interface with Nuohan. The project’s goal is to "retain the core hardware of the equipment while enabling automated welding".Different from the traditional automation solution that "relies on EtherCAT digital communication to control welding machines", this project takes Nuohan’s collaborative robot arm as the control core. It is equipped with an analog conversion module and an I/O signal interaction system to replace the parameter transmission and equipment collaboration functions of EtherCAT communication. This enables Binzel welding machines—originally unable to connect to automated systems—to gain automated capabilities such as "precise parameter control, automatic execution of welding actions, and real-time status feedback".
Core Composition of the Manual Welding Analog Control Cabinet (As shown in Figure 1.1)：As a "signal transfer station" between the collaborative robot arm and the Binzel welding machine, the control cabinet integrates key functions such as power control, emergency stop protection, analog output, and digital I/O. The external components of the cabinet and their functions are listed in the table below, which allows for an intuitive understanding of its core role in the transformation.
Figure 1.1 Appearance and Components of the Control Cabinet
This is not a replacement solution that "replaces old welding machines to adapt to EtherCAT communication". Instead, it is an upgrade solution that "bypasses the EtherCAT adaptation bottleneck and builds a new control link for existing Binzel welding machines". It not only retains the Binzel welding machine assets that enterprises have already invested in, but also endows them with automated production capabilities through the combination of "collaborative robot arm + analog + I/O", achieving the goal of "automated welding without replacing equipment or relying on EtherCAT".
Based on an actual transformation project, this paper elaborates on the technical solution centered on "analog + I/O", analyzes the technical highlights and implementation effects of the solution, and provides a reference path for the automated upgrade of similar existing welding equipment.
Ⅱ. Why Conduct Manual Welding Transformation? — Project Background and Core Pain Points
2.1 Core Pain Points
Traditional automated solutions have significant limitations in this project:
Lack of EtherCAT Communication Compatibility: The Binzel welding machines owned by Turkish customers do not have the EtherCAT digital communication function corresponding to NODHA Industrial Technology’s welding machines. However, conventional automated solutions (such as those matched with MK controllers) rely on EtherCAT communication to transmit welding parameters (e.g., current, voltage) and control commands (e.g., arc striking, arc ending). This prevents Binzel welding machines from integrating into the existing automated system, forcing them to remain dependent on manual operation.
Excessively High Cost of Equipment Replacement: If new welding machines with EtherCAT communication function are replaced to achieve compatibility, the procurement cost per unit equipment will increase significantly. Moreover, the existing Binzel welding machines still have good mechanical performance, and direct obsolescence will result in asset waste, which is contrary to the enterprise’s core demand of "cost reduction and efficiency improvement".
Prominent Bottlenecks in Manual Welding: When operating Binzel welding machines manually, parameter adjustment depends on experience, leading to poor weld consistency. At the same time, the training cycle for skilled welders is long. When order volume increases, production capacity cannot be improved quickly, which restricts production efficiency.
In response to the above pain points, the project team of NODHA Industrial Technology has established core goals:
A. Take "no equipment replacement" as the premise to minimize investment costs;
B. "Do not rely on EtherCAT communication" to bypass the compatibility problem;
C. Achieve "easy operation" and "plug-and-play"—build a reliable control link between the robotic arm and existing welding machines through "analog + digital I/O" to realize the core function of automated welding.
Ⅲ. How to Implement Manual Welding Transformation? — NODHA Industrial Technology’s Implementation Path of "Collaborative Robot + Analog + Digital I/O"
Focusing on the core goal of "by passing EtherCAT communication and adapting to Binzel welding machines", NODHA Industrial Technology takes the collaborative robot arm as the core and builds an automated control link in three steps to ensure the implementability and practicality of the solution.
3.1 Step 1: Define the Framework — Taking NODHA Industrial’s Collaborative Robot Arm as the "Control Center"
First, clarify the core logic of the transformation: use Nuohan’s collaborative robot arm to replace "manual labor" and serve as the automated control center for Binzel welding machines. It can issue commands and execute actions without relying on EtherCAT communication. Specific actions include:
a. Confirm the basic conditions of the welding machine: Review the technical manual of the Binzel welding machine to verify that it has the "external analog control" function (capable of receiving analog signals to adjust current and voltage) and the "digital I/O external control" function (capable of receiving switch signals to trigger arc striking and arc ending). This is a key prerequisite for bypassing EtherCAT communication.
b. Build the hardware link: With Nuohan’s collaborative robot arm as the core, add supporting high-precision analog output modules (for parameter transmission) and I/O signal interaction modules (for command and status feedback). Form a physical connection framework of "collaborative robot arm → analog module + I/O module → Binzel welding machine", which is completely independent of EtherCAT communication. Specific operations are as follows:
Connection between the control cabinet and power supply: Remove the aviation plug, install and connect the power cables as shown in the diagram — ① live wire, ② neutral wire, ③ ground wire — to supply power to the control cabinet.
Figure 3.1 Wiring of the Aviation Plug
After completing the wiring, install the aviation plug according to the diagram.
Figure 3.2 Installation of the Aviation Plug
Insert the aviation plug with the connected power cables into the socket according to the diagram.
Figure 3.3 Aviation Plug Connected to the Socket
Connection between the control cabinet and the robot: Locate the "teach pendant socket" and "robot socket" on the control cabinet. Insert the robot plug into the corresponding socket, then rotate the front end of the plug to the right to lock it, ensuring stable signal transmission between the robot and the control cabinet. ① Teach pendant socket; ② Robot socket
Figure 3.4 Robot Cable Sockets
Insert the robot plug into the designated socket as shown in the diagram, then rotate the front part of the plug to the right to lock it (the insertion method for the teach pendant plug is the same as that for the robot socket).
Figure 3.5 Robot Plug Inserted into the Socket
3.2 Step 2: Establish Signals — Replacing the Core Functions of EtherCAT with "Analog + Digital I/O"
This is the technical core of the transformation. Through two types of signal links, it realizes the functions of "parameter transmission", "command control" and "status feedback" that were originally undertaken by EtherCAT communication—with no need for any digital communication configuration.
A. Analog signal link: The control cabinet outputs precise control parameters, replacing EtherCAT's parameter transmission function to control the welding machine's current and voltage.
Using the analog output module, establish the conversion logic of "collaborative robot arm digital signal → analog signal → welding machine parameters": the terminal definition of the quick-connect plug is shown in the diagram.
Figure 3.6 Quick-Connect Plug
Channel 1: The 0-10V analog voltage corresponds to the current adjustment range of the Binzel welding machine (e.g., 100-300A). Linear mapping ensures precise parameters — for example, when the collaborative robot arm issues a "200A current" command, the module outputs a 5V analog voltage, and the welding machine responds accurately with an error controlled within ±2%, avoiding fluctuations caused by manual adjustment.
Channel 2: The 0-10V analog voltage corresponds to the voltage adjustment range of the welding machine (e.g., 18-40V). Similarly, linear transmission is achieved to ensure parameter stability under different welding conditions (e.g., 30V for thick plate welding, 20V for thin plate welding).
B. Digital I/O Signal Link: Control Actions, Transmit Status, Ensure Safety — Replacing EtherCAT's Command InteractionThrough the 8P quick-connect plug of the control cabinet, three types of signal interaction are realized, completely independent of EtherCAT:
8P Plug Terminals：
4P Plug Terminals：
In addition, considering the NPN/PNP polarity characteristics of the Binzel welding machine's I/O interface, the NODHA Industrial Technology team enables quick adaptation through the "output type selection switch" on the control cabinet (as shown in Figure 3.1). Simply rotate the switch with a dedicated key to switch the signal type—no need to modify the robot program to achieve signal adaptation, which significantly shortens the debugging time.
Figure 3.7 Output Type Switching
C. Safety Link: Emergency Stop and Circuit Breaker of the Control Cabinet for Dual ProtectionEmergency Situation: Press the emergency stop button on the control cabinet (No. 5 in Figure 1.1), the robot will stop moving immediately, and the control cabinet will simultaneously cut off the output signal to the welding machine, disconnecting the welding circuit.
Routine Protection: If the welding machine has an overcurrent or the robot malfunctions, the relays inside the control cabinet (No. ④ and ⑥ in Figure 3.14) will automatically disconnect the signal. At the same time, the circuit breaker (Figure 3.2) can manually cut off the main power supply to avoid equipment damage and personal safety risks.
3.3 Step 3: Start the Equipment — Simplify Operations to "Plug-and-Play"
After completing the wiring, the system can be started in only 3 steps. No professional technicians are required—frontline workers can operate it after simple training.
1、Power on the control cabinet: Toggle the circuit breaker upward (Figure 3.2) to connect the main power supply of the control cabinet, and the indicator light will turn on.After correctly connecting the power cable, toggle the circuit breaker upward to turn on the main power supply.
Figure 3.8 Circuit Breaker Operation for Power-On
2、 Power on the robot: After the power is supplied, rotate the selector switch on the front of the cabinet to the right. The indicator light will turn on, and the robot will power on and start normally. After startup is complete, if you need to shut down, rotate the selector switch to the left to reset. After the robot's enable is disconnected and it is powered off, toggle the circuit breaker downward to cut off the power supply.
Figure 3.9 Robot Power-On Rotary Switch
If a teach pendant is connected, the power-on waiting process can be displayed on the teach pendant.
Figure 3.10 Teach Pendant Displaying Power-On Process
After successful power-on and completion of the robot's enable, the teach pendant interface will display as shown in the figure below.
Figure 3.11 Robot in Completed Power-On State
Plug-and-Play Connection: Customized adapter cables and conversion joints are pre-manufactured according to the interface specifications of Binzel welding machines and wire feeders. During on-site installation, simply insert the welding torch into the wire feeder and connect the control cable of the collaborative robot arm to the welding machine's I/O port and analog module. All connections can be completed within 2 hours, enabling production on the same day and avoiding any impact on the production schedule.
3.4 Step 4: Maintain the Equipment — Simplified Inspection and Operation via the Control Cabinet
The maintenance and operation of the modified equipment are also "highly simplified" through the control cabinet:
Teach Pendant Disabling/Enabling: If the teach pendant is not required, it can be disabled via the PC software associated with the control cabinet (as shown in Figure 3.12) to prevent misoperation. For enabling, simply reconnect through the PC terminal; the process is identical to disabling and will not affect the use of the APK software.
Figure 3.12 Disable/Enable Operation of the Teach Pendant
Control Cabinet Inspection: When internal modules (such as the analog module and router) need to be checked, insert the triangular key into the cabinet lock (No. 6 in Figure 1.1) and rotate it to the left to unlock and open the door. The internal components are clearly arranged, facilitating quick troubleshooting. As shown in the figure below.
Figure 3.13 Opening the Control Cabinet
Layout of Internal Components
Figure 3.14 Hardware Introduction
IV. Transformation Achievements and Industry Value
4.1 Improved Operational Convenience
After the transformation, equipment operation has achieved "zero threshold":New workers can independently complete welding operations after only 30 minutes of training, without the need for professional programmers, reducing the enterprise's labor adaptation costs.The wireless control function of the tablet APP shortens the operation time per workstation and reduces ineffective labor for workers.
4.2 Significant Cost Reduction
Compared with the "full equipment replacement" plan:This transformation plan significantly reduces costs while making full use of the enterprise's existing equipment resources, avoiding asset waste.The welding qualification rate of the transformed equipment has increased from 92% (manual welding) to 98%, reducing rework costs caused by welding defects and creating significant economic benefits for the enterprise.
4.3 Safety and Stability Assurance
The establishment of a dual safety protection mechanism:Shortens the fault alarm response time during equipment operation to 5ms, with no safety accidents occurring.The linear transmission design of analog signals controls the fluctuation range of welding parameters within ±2%, significantly improving the flatness and consistency of weld beads and meeting the enterprise's high-quality production needs.
V. Conclusions and Outlook
5.1 Conclusions
This project successfully solved the problem that existing manual welding equipment cannot be connected to automated systems due to the lack of digital communication interfaces, through a customized solution of "analog output + I/O signal interaction".The solution does not require equipment replacement: analog signals realize precise control of welding parameters, and I/O signals complete equipment coordination and safety protection.It also optimizes operation and connection methods to achieve "plug-and-play" and "zero-threshold operation".Practice shows that the equipment transformed by NODHA Industrial Technology has met the expected goals in operational convenience, cost control, and welding quality, providing a feasible path for the automated upgrading of existing welding equipment.
5.2 Outlook
In the future, the application scenarios of this solution can be further expanded:Establish an adaptation database for analog and I/O signals for welding machines of different brands and models to realize rapid replication of the solution.Introduce the Internet of Things (IoT) technology to collect welding data in real-time through the tablet APP (such as welding duration, parameter changes, fault records), providing data support for the enterprise's production management and process optimization.Explore the combination of AI algorithms and analog control to realize adaptive adjustment of welding parameters and further improve the stability of welding quality.
By continuously optimizing the customized solution, we will help more manufacturing enterprises solve the problem of upgrading existing equipment, realize the transformation of welding automation in a low-cost and efficient way, and promote the high-quality development of intelligent manufacturing.