COMPONENT STUDY

THE COMPONENT IS IN A CYLINDRICAL STRUCTURE WHERE SMALL PORES WERE GIVEN THROUGHOUT, WHICH ACTS AS AN AIR FILTER.

THE REAL PROBLEM

1) TWO ENDS OF THE SHEET IS BEEN ATTACHED AND CLAMPED MANUALLY. THEN LINEAR WELDING IS DONE OVER IT TO FORM A CYLINDRICAL SHAPE.
2) BASE CAP IS TACKED ALREADY WHICH MUST BE FUSED FULLY WITH WELDING.
3) THE AUTOMATION FOR THIS WELDING AS CONTINOUS WELDING MANUALLY WAS DIFFICULT, HAZARDOUS TO OPERATOR.

PROVIDING THE BEST SOLUTION

THE PROCESS

1) THE MESH FILTER WELDING:-
• THE WELDING IS DONE IN ORDER TO FUSE THE AREA TO FORM A CYLINDER.
• TWO WELDING STATIONS ARE THERE IN THIS SYSTEM TO WELD LINEAR PART AS WELL AS CIRCULAR ONE.
• COMPONENT WAS KEPT STATIONARY AT THE WELD STATION AND TORCH WILL MOVE LINEARLY TO COMPLETE ONE WELD.
• IN ANOTHER STATION, TORCH WILL BE STATIONARY BUT THE COMPONENT ALONG WITH FIXTURE WILL ROTATES TO COMPLETE CIRCULAR WELD.
• COMPONENT CLAMPING ADJUSTER SYSTEM WAS PROVIDED.
• TIG WELDING WAS THE PROCESS USED IN ORDER TO WELD THE COMPONENT.

SOURCE

2) AUTOMATION IS DONE USING 4 AXIS WELDING SPM:-
• THERE WERE THREE LINEAR AXES AND ONE COMPONENT 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 AXES).
• THE COMPONENT IS KEPT STATIONARY AND TORCH AXIS WILL MOVE ALONG WITH THE COMPONENT TO WELD LINEAR IN ONE WELD STATION.
• IN ANOTHER STATION, TORCH WILL BE STATIONARY BUT THE COMPONENT ALONG WITH FIXTURE WILL ROTATES TO COMPLETE CIRCULAR WELD.
• TO MAINTAIN CONCENTRICITY SUITABLE FIXTURES WERE USED.
• THE BELOW IMAGE SHOWS THE SPM.
• 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.
• TWO DIFFERENT PROGRAMS WERE GIVEN IN THE SYSTEM IN ORDER TO WELD LINEAR AND ROTARY
• COMPONENT CLAMPING ADJUSTING SYSTEM WAS PROVIDED TO TIGHTEN THE COMPONENT.
• PROVISION WAS PROVIDED IN ORDER TO MOVE THE TORCH BACK AND FORTH AND ROTATION PROVISION WAS ALSO PROVIDED.
• THE MINIATURE OF THE MACHINE CAN ALSO BE MADE ACCORDING TO THE SIZE OF THE COMPONENTS.