CAST-IN PLATE WELDING SOLUTION

COMPONENT STUDY

Thank you for reading this post, don't forget to subscribe!

The component a C shaped bar welded onto the cast plate, which weighs 5 kgs as a whole (the plate and bar) ,the picture shows the component and its parts (image 1).

COMPONENT SPECIFICATION :-

Diameter of the bent bar: – Ø16.

CAST-IN SIZE:-200x200x16.

THE REAL PROBLEM

1) Circular welding of 4 ends of d bars using MIG welding process.

2) The automation for this welding as continuous welding manually was difficult, hazardous to operator.

3) Easing of operation.

PROVIDING THE BEST SOLUTION

THE PROCESS

• THE CIRCULAR WELDING :-

• The welding is done in order to join the d shaped bent bars with the casting plate.
• Due to shape of the component, its rotation posed a challenge and hence while welding the torch is rotated and the component is fixed.
• Mig welding was the process used in order to weld the component.

the below image shows the component after welding.(image 2)

SOURCE

• AUTOMATION DONE USING 4 AXIS WELDING SPM:-

• There were three linear axis and one rotation axis.
• The torch is moved to the close proximity of the component in order to create weld arc using 3 linear axes(x axis, y axis and z axis).
• The torch is rotated to weld around the bent bars.
• The precision in bring the weld holes to weld zone was achieved by using locators.
• The below image shows the spm and axis used.
• The automation was done in order to de skill the process, have higher repeatability and efficiency.

• EASING OF OPERATION:-

• Sequence of operation is made according to customer requirement and the machine is made fool proof with component sensor and suitable program.
• Toggle clamps were used in order to clamp the components.
• In order to achieve repeatability the locators were used.
• The below image shows the fixture assembly.

GOALS ACHIEVED

• After carefully working on customer requirements we delivered an spm which not only satisfied the customer but made the customer happy.
• The machine is now producing 56 such welded components in a shift with the customer working for 2 shifts per day.
• Two people were working on loading and welding of components while now a single operator can work on loading and welding.
• An operator who doesn’t know welding can also operate the machine, it has helped in de-skilling of process.
• The operator is not under influence of harmful gases hence it safe guards the operator.