COMPONENT STUDY :
Thank you for reading this post, don't forget to subscribe!THE COMPONENT IS A WATER HEATER STORAGE TANK WHERE THE CENTER PART OF THE CYLINDER( JOINING TWO PARTS OF CYLINDER)TO BE WELDED(GIRTH WELDING).
COMPONENT SPECIFICATION: –
- WEIGHT OF COMPONENT: – 5KGS APPROX.
- DIAMETEROF THE COMPONENT: – 200MM
- MATERIAL: – MILD STEEL
- THICKNESS: – 2MM
THE REAL PROBLEM :
1) NEED TO JOIN CENTER PART OF THE CYLINDER(GIRTH) WATER HEATER TANK.
2) THE AUTOMATION FOR THIS WELDING AS CONTINUOUS WELDING MANUALLY WAS DIFFICULT, HAZARDOUS TO OPERATOR.
![](https://i0.wp.com/nikitengineers.in/wp-content/uploads/2020/05/gw4.jpg?w=1200)
PROVIDING THE BEST SOLUTION
THE PROCESS :
- THE ROTARY WELDING: –
- THE WELDING IS DONE IN ORDER TO JOIN THE TWO PARTS OF THE CYLINDER.
- COMPONENT WAS KEPT AT THE FIXTURE AND THE PNEUMATIC CYLINDER WILL HOLD THE COMPONENT FIRMLY.
- TORCH WILL COME TO WELD ZONE AND COMPONENT START ROTATE TO COMPLETE THE WELD.
- SAFETY LIGHT CURTAIN WAS PROVIDED IN ORDER TO SAFEGUARD THE MACHINE AND COMPONENT IF AN UNPLEASANT EVENT OCCURS.
- MIG WELDING WAS THE PROCESS USED IN ORDER TO WELD THE COMPONENT.
![](https://i0.wp.com/nikitengineers.in/wp-content/uploads/2020/05/gw2.jpg?w=1200)
SOURCE
- AUTOMATION IS DONE USING 2 AXIS WELDING SPM: –
- THERE WERE ONE LINEAR AXES AND ONE ROTATION AXIS.
- THE TORCH IS MOVED TO THE CLOSE PROXIMITY OF THE COMPONENT IN ORDER TO CREATE WELD ARC USING Z AXIS.
- THE TORCH AXIS IS KEPT STATIONARY AND WELDING IS DONE IN A COMPLETE ROTATION OF A COMPONENT(FIXTURE).
- TO MAINTAIN CONCENTRICITY, SUITABLE FIXTURES WERE USED.
- 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.
3) EASING OF OPERATION: –
- SEQUENCE OF OPERATION IS MADE ACCORDING TO CUSTOMER REQUIREMENT WITH A SUITABLE PROGRAM.
- SEPARATE PNEUMATIC AXIS WAS GIVEN FOR COMPONENT CLAMPING.
![](https://i0.wp.com/nikitengineers.in/wp-content/uploads/2020/05/gw3.jpg?w=1200)
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 CAN PRODUCE 120 WELDED COMPONENTS IN A SHIFT IF THE CUSTOMER WORKING FOR 8 HOURS PER SHIFT (INCL LOAD AND UNLOAD TIME).
- FOUR PEOPLE WERE WORKING ON LOADING AND WELDING OF COMPONENTS WHILE NOW A SINGLE OR DOUBLE OPERATOR(S) 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.