COMPONENT STUDY
Thank you for reading this post, don't forget to subscribe!THE COMPONENT IS A LAMP SHADE OUTER COVER, THE COMPONENTS ARE OF DIFFERENT SIZES AND WEIGHT FROM 1.5 Kg TO 6 Kgs AS A WHOLE .THE PICTURE SHOWS THE WELDED COMPONENT,WELD ZONES AND INDIVIDUAL COMPONENTS. (FIG 1)
COMPONENT SPECIFICATION:-
SL NO | A/F SIZE | TYPE | WEIGTH(Kg) |
1 | 450 | HEXAGONAL | 1.5 |
2 | 600 | HEXAGONAL | 2.287 |
3 | 900 | HEXAGONAL | 3.540 |
4 | 1200 | HEXAGONAL | 4.792 |
5 | 1500 | HEXAGONAL | 6.044 |
THE REAL PROBLEM
1) PROFILE STITCH WELDING OF INDIVIDUAL COMPONENTS.
2) THE AUTOMATION FOR THIS WELDING AS CONTINUOUS WELDING MANUALLY WAS DIFFICULT, HAZARDOUS TO OPERATOR.
3) EASING OF OPERATION.
![](https://i0.wp.com/nikitengineers.in/wp-content/uploads/2020/05/LED-PROFILE1.jpg?w=1200)
PROVIDING THE BEST SOLUTION
THE WELD
- THE PROFILE STITCH WELD :-
- THE WELDING IS DONE HERE TO JOIN 2 INDIVIDUAL PIECES CUT IN AN ANGLE TO ARRANGE AS A HEXAGON WHEN JOINED.
- AS THE COMPONENTS ARE WELDED USING TIG AND PARTS WERE INDIVIDUAL CUT PIECES WE HAD TO MAKE A FIXTURE IN ORDER TO ARRANGE THEM ACCURATELY.
- TIG WELDING WAS THE PROCESS USED IN ORDER TO WELD THE COMPONENT.
- IMAGES 1 AND 2 SHOWS SHOWS COMPONENT’S OUTSIDE AND ONSIDE WELDING RESPECTIVELY.
![](https://i0.wp.com/nikitengineers.in/wp-content/uploads/2020/05/LED-PROFILE2.jpg?w=1200)
SOURCE
- AUTOMATION IS DONE USING 2 AXIS WELDING SPM:-
- THERE ARE 2 LINEAR AXES.
- THE TORCH IS MOVED TO THE CLOSE PROXIMITY OF THE COMPONENT IN ORDER TO CREATE WELD ARC USING 2 LINEAR AXES(Y AXIS AND Z AXIS).
- THE INDIVIDUAL COMPONENTS ARE ARRANGED USING THE FIXTURE.
- THE BELOW IMAGE SHOWS THE SPM AND AXIS USED (IMAGE 3).
- THE AUTOMATION WAS DONE IN ORDER TO DE SKILL THE PROCESS, HAVE HIGHER REPEATABILITY AND EFFICIENCY.
![](https://i0.wp.com/nikitengineers.in/wp-content/uploads/2020/05/LED-PROFILE3.jpg?w=1200)
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.
- FIXTURES WITH CORRECT ANGLE GROOVES WERE PROVIDED IN ORDER TO EASILY LOCATE THE INDIVIDUAL PIECES.
- IN ORDER TO ACHIEVE REPEATABILITY THE LOCATORS WERE PROVIDED IN THE FIXTURE.
- TOGGLE CLAMPS WERE USED TO CLAMP THE COMPONENTS EASILY AND EFFECTIVELY.
- IMAGE 4 SHOWS THE FIXTURE ARRANGEMENT AND LOCATOR INCLUDED AND IT’S TOGGLE CLAMP.
![](https://i0.wp.com/nikitengineers.in/wp-content/uploads/2020/05/LED-PROFILE4.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 IS NOW PRODUCING 40 SUCH WELDED COMPONENTS IN A SHIFT WITH THE CUSTOMER WORKING FOR 3 SHIFTS PER DAY.
- AN OPERATOR WHO DOESN’T KNOW WELDING CAN ALSO OPERATE THE MACHINE, IT HAS HELPED IN DE-SKILLING OF PROCESS.
- THE COMPONENTS CAN BE EASILY LOCATED AND HENCE SIMPLIFYING THE WORK.
- THE OPERATOR IS NOT UNDER INFLUENCE OF HARMFUL GASES HENCE IT SAFE GUARDS THE OPERATOR.