Staircase Formwork Automation (Stringer & Riser Male)

COMPONENT STUDY

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THE COMPONENT IS A REINFORCEMENT FOR THE CONCRETE STAIRS, THE COMPONENT HAS 3 PARTS, and THE IMAGE 1 SHOWS THE COMPONENTS AND ITS VARIOUS PARTS.

COMPONENT SPECIFICATION:-

SL NO	COMPONENT TYPE	LENGTH(MM)	WIDTH(MM)	WEIGHT(KG)
1	MS SHEET	3000	380	26.789
2	RAISER MALE	145	30	0.65
3	J-CHANNEL	700	40	0.98

THE REAL PROBLEM

1) STITCH WELDING OF J CHANNEL ONTO MS SHEET.

2) PLUG WELDING OF RAISER MALE ONTO MS SHEET.

3) THE AUTOMATION FOR THIS WELDING AS CONTINUOUS WELDING MANUALLY WAS DIFFICULT, HAZARDOUS TO OPERATOR.

4) EASING OF OPERATION.

PROVIDING THE BEST SOLUTION

THE PROCESS

• THE WELDING:-
• THE WELDING IS DONE IN ORDER TO JOIN THE RAISER MALE AND J CHANNEL WITH THE SHEET WHICH WAS MADE FROM MILD STEEL.
• THE AUTOMATION WELDING WAS PROVIDED IN ORDER TO SIMPLIFY THE PROCESS.
• J CHANNEL WAS STITCH WELDED ONTO THE MS SHEET.
• RAISER MALE WAS PLUG WELDED ONTO THE MS SHEET.
• MIG WELDING WAS THE PROCESS USED IN ORDER TO WELD THE COMPONENT.
• THE WELDED PARTS IN THE COMPONENT ARE SHOWN IN THE IMAGE 2.

SOURCE

• AUTOMATION DONE USING 4 DIFFERENT STATIONS :-

1. RAISER MALE WELDING STATION.
2. RAISER MALE STACKING, PICK AND PLACE.

• CONVEYOR SYSTEM.

1. J CHANNEL STACKING, PICK AND PLACE AND WELDING STATION.

• RAISER MALE STACKING , PICK AND PLACE WELDING STATION WAS USED TO STACK THE RAISER MALES IN COLUMNS AND THEN PICK THEM FROM STACKS AND PLACE THEM ON MS SHEET AND WELD THEM USING MIG WELDING PROCESS. THE PICK AND PLACE SYSTEM WAS PNEUMATICALLY ACTUATED.

• J-CHANNEL STACKING, PICK AND PLACE WELDING WAS USED TO STACK THE J- CHANNELS AND PICK AND PLACE THEM ONTO THE MS SHEET USING PNEUMATICALLY ACTUATED VACUUM CUPS AND THEN WELDING WAS DONE USING MIG WELDING.

• 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.
• CONVEYOR SYSTEM WAS USED IN ORDER TO MOVE THE COMPONENT FROM ONE STATION TO ANOTHER.
• PNEUMATIC VACUUM PADS WERE USED IN ORDER TO PICK AND PLACE THE RAISER MALES AND J-CHANNELS.
• PNEUMATIC STACK LOCATOR WAS ALSO USED IN ORDER TO PLACE THE RAISER MALES IN PICK UP POSITION.

GOALS ACHIEVED

• AFTER CAREFULLY WORKING ON CUSTOMER REQUIREMENTS WE DELIVERED AN SPM WHICH NOT ONLY STATISFIED 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.
• 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 MAHCINE, IT HAS HELPED IN DE-SKILLING OF PROCESS.
• THE OPERATOR IS NOT UNDER INFLUENCE OF HARMFUL GASES HENCE IT SAFE GUARDS THE OPERATOR.