COMPONENT STUDY
Thank you for reading this post, don't forget to subscribe!THE COMPONENT IS A LEVER ASSEMBLY, WHICH WEIGHS 0.320 Kgs AS A WHOLE .THE PICTURE SHOWS THE PARTS OF THE COMPONENT
COMPONENT SPECIFICATION:-
- WEIGHT OF COMPONENT:-0.3 Kg
- WEIGHT OF BALL JOINT :-0.009Kg
- DIAMETER OF THE BALL :-Ø10 MM
- HUB WEIGHT : – 0.049 Kg
- HUB DIAMETER (OD) :- Ø26.43 MM
(ID) :- Ø15.5 MM
THE REAL PROBLEM
1) CIRCULAR FILLET WELDING OF HUB ONTO THE LEVER.
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 FILLET WELD:-
- THE WELDING IS DONE IN ORDER TO JOIN THE HUB ONTO THE LEVER BODY AT THE UNDERSIDE.
- IT IS EASY TO ROTATE THE COMPONENT HENCE TORCH WAS KEPT STATIONARY AT THE WELD POSITION AND COMPONENT WAS ROTATED TO WELD.
- TIG WELDING WAS THE PROCESS USED IN ORDER TO WELD THE COMPONENT.
- THE IMAGE SHOWS THE COMPONENT AND THE WELD ZONE.
SOURCE
- AUTOMATION IS DONE USING 3 AXIS WELDING SPM:-
- THERE WERE TWO LINEAR AXIS AND ONE ROTATION AXIS.
- THE TORCH IS MOVED TO THE CLOSE PROXIMITY OF THE COMPONENT IN ORDER TO CREATE WELD ARC USING 2 LINEAR AXES(X AXIS AND Z AXIS).
- THE COMPONENT IS ROTATED USING THE ROTARY.
- TO MAINTAIN CONCENTRICITY SUITABLE FIXTURES WERE USED.
- THE 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 WITH A SUITABLE PROGRAM.
- LOCATION PILLARS WERE GIVEN TO LOCATE THE HUB.
- ROTATING TOP LOCK WAS GIVEN IN ORDER TO LOCK THE COMPONENT IN FIXTURE.
- THE DOWEL HOLES WERE PROVIDED IN FIXTURE TO CONCENTRICALLY LOCATE THE FIXTURE AND FACE PLATE.
- PROVISION WAS PROVIDED IN ORDER TO MOVE THE TORCH BACK AND FORTH AND ROTATION PROVISION WAS ALSO PROVIDED.
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 1152 SUCH WELDED COMPONENTS IN A SHIFT WITH THE CUSTOMER WORKING FOR 8 HOURS PER SHIFT.
- 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.