COMPONENT STUDY :
Thank you for reading this post, don't forget to subscribe!THE COMPONENT IS A TRACTOR TROLLEY WHICH CONSISTS OF RECTANGULAR TUBES, C CHANNELS WHICH MUST BE WELDED. (COMPONENT IMAGE IS SHOWN BELOW)
COMPONENT SPECIFICATION: –
- WEIGHT OF COMPONENT: – 5TONNES APPROX.
- LENGTH OF COMPONENT: – UPTO 3100MM
- WIDTH OF THE COMPONENT: – UPTO 1500MM
- MATERIAL: – MILD STEEL
- THICKNESS: – 1MM TO 10MM
THE REAL PROBLEM
1) INTERPOLATION WELDING OF RECTANGULAR TUBES AND C CHANNELS VERTICALLY AND HORIZONTALLY ACCORDING TO DESIGN.
2) THE AUTOMATION FOR THIS WELDING AS CONTINUOUS WELDING MANUALLY WAS DIFFICULT, HAZARDOUS TO OPERATOR.
PROVIDING THE BEST SOLUTION
THE PROCESS
- THE LINEAR AND INTERPOLATION WELDING: –
- THE WELDING IS DONE IN ORDER TO JOIN THE RECTANGULAR TUBES AND C CHANNELS TO FORM A FRAME STRUCTURE.
- COMPONENT WAS KEPT STATIONARY AT THE WELD POSITION(FIXTURE) AND TORCH AXIS WILL MOVE TOWARDS WELD ZONE.
- COMPONENT CLAMPING SYSTEM WAS PROVIDED TO LOCK THE COMPONENT TIGHTLY.
- MIG WELDING WAS THE PROCESS USED IN ORDER TO WELD THE COMPONENT.
- ARGON + CO2 MIX GASES WERE USED.
- THE BELOW IMAGE SHOWS THE COMPONENT AND THE WELD ZONE.
SOURCE
- AUTOMATION IS DONE USING 4 AXIS WELDING SPM: –
- THERE WERE THREE LINEAR AXES 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, Y AND Z AXIS).
- THE COMPONENT IS KEPT STATIONARY AND BY USING LINEAR INTERPOLATION CONCEPT, WELDING IS DONE.
- TO MAINTAIN LINEARITY, 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.
- COMPONENT CLAMPING ADJUSTING SYSTEM WAS PROVIDED TO TIGHTEN THE COMPONENT.
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 2 WELDED COMPONENTS IN A SHIFT IF THE CUSTOMER WORKING FOR 8 HOURS PER SHIFT.
- 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.