STATOR PLUG WELDING SOLUTION

COMPONENT STUDY

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THE COMPONENT IS A STATOR, WHICH WEIGHS 250 Kgs AS A WHOLE (WITH THE COIL AND OUTER SHELL) .THE PICTURE SHOWS THE COMPONENT AND HOLES TO BE WELDED. (FIG 1)

COMPONENT SPECIFICATION:-

• WEIGHT OF OUTER COVER:-19.15-21.75 Kgs
• WEIGHT OF CORE : – 220 Kgs.
• LENGTH OF OUTER COVER:-
  i) 467 MM.
  ii) 427 MM.
  iii) 357 MM.
  iv) 315 MM.

• DIAMETER : – Ø444 MM.
• CORE LENGTH                   :-
  i) 150MM.
  ii) 190MM.
  iii) 230MM.                                        

• CORE DIAMETER :- Ø 434MM

THE REAL PROBLEM

1) PLUG WELDING OF 4 HOLES USING TIG WELDING PROCESS.

2) THE AUTOMATION FOR THIS WELDING AS CONTINOUS WELDING MANUALLY WAS DIFFICULT, HAZARDOUS TO OPERATOR.

3) EASING OF OPERATION.

PROVIDING THE BEST SOLUTION

THE WELD

• THE PLUG WELDING :-
• THE WELDING IS DONE IN ORDER TO JOIN THE OUTER SHELL WITH THE INNER CORE WHICH WAS MADE FROM MILD STEEL.
• DUE TO WEIGHT OF THE COMPONENT, ITS ROTATION POSED A CHALLENGE AND IT IS OVER COME USING CERTAIN SUPPORT STRUCTURES.
• TIG WELDING WAS THE PROCESS USED IN ORDER TO WELD THE COMPONENT.
• THE BELOW IMAGE SHOWS THE COMPONENT AFTER PLUG WELDING.(IMAGE A)

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 WELD HOLES IS BROUGHT TO WELD ZONE USING THE ROTARY.
• THE PRECISION IN BRING THE WELD HOLES TO WELD ZONE WAS ACHIEVED BY USING LOCATORS (ONE PNEUMATIC LOCATOR AND ONE MANUAL LOCATOR)
• 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.
• ROLLERS WERE PROVIDED IN ORDER TO EASE THE PROCESS OF LOADING AND UNLOADING AND BALL TRANSFERS WERE PROVIDED IN ORDER TO EASY THE ROTATION.
• IN ORDER TO ACHIEVE REPEATABILITY THE LOCATORS WERE USED.
• THE BELOW IMAGES SHOW THE ROLLERS (IMAGE C), BALL TRANSFERS (IMAGE D) AND ROTARY (IMAGE E).

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.
• 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.