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DEPT. OF MECHANICAL ENGINEERING 2016-2017 MINOR PROJECT PRESENTATION DESIGN OF AUTOMATED WELDING MACHINE Team Members- •

DEPT. OF MECHANICAL ENGINEERING

2016-2017

MINOR PROJECT PRESENTATION

DEPT. OF MECHANICAL ENGINEERING 2016-2017 MINOR PROJECT PRESENTATION DESIGN OF AUTOMATED WELDING MACHINE Team Members- •

DESIGN OF AUTOMATED WELDING MACHINE

Team Members-

Shubham Sharma(0812me131153)

Vasu Gupta(0812me131170)

Vikas Barmase

Shubham wadekar(0812me131157)

Project guide- Gaurav Suryavanshi sir

TABLE OF CONTENTS

Determination of problem Introduction Overview Existing Devices Problems with existing devices Economics of ROI Design Of Experiment Layout References

Determination Of Project

Marke

t

Survey

Determination Of Project Marke t Survey Problem finding and analysis Compar ison with propose d project

Problem finding and analysis Compar

Determination Of Project Marke t Survey Problem finding and analysis Compar ison with propose d project
ison with propose d project
ison
with
propose
d
project

Finalizati

on Of

project

Automation and robotics are two closely related technologies. In an industrial context, we can define automation as a technology that is concerned with the use of mechanical, electronics and computer-based systems in the operation and control of production. Examples of this technology include transfer lines, mechanized assembly machines, feed back control systems, numerically controlled machine tools, and robots. Accordingly, robotics is a form of industrial automation.

AUTOMATED SYSTEMS

There are three broad classes of industrial automation: fixed automaton, programmable automation, and flexible automation. Fixed automation is used when the volume of production is very high and it is therefore appropriate to design specialized equipment to process the product very efficiently and at high production rates. A good example of fixed automation can be found in the automobile industry, where highly integrated transfer lines consisting of several dozen work stations are used to perform machining operations on engine and transmission components

AUTOMATED WELDING SYSTEM

With the rapid surge in automation and numeric control of industrial operations, it has become quite regular with machine operation like drilling, reaming, boring to be mechanized. Welding is one such operation. The project is aimed towards developing a safe, controlled and precise automated system which can be operated by a regular worker and does not require an adept programmer or a skilled worker.

OBJECTIVES OF THE PROJECT

To remove use of complex robotic arms and extra components (belts ,etc.)

To develop a structurally less complex mechanism in comparison to existing ones.

To make a cost effective alternative to existing systems.

To make an automated welding system which can be used for small scale applications.

PRESENT SCENARIO

PRESENT SCENARIO • A Standard Mobile electric arc welding robot

A Standard Mobile electric arc welding robot

PRESENT SCENARIO • A Standard Mobile electric arc welding robot

ROBOTIC ARM TYPE AUTOMATED WELDING SYSTEM

ROBOTIC ARM TYPE AUTOMATED WELDING SYSTEM
ROBOTIC ARM TYPE AUTOMATED WELDING SYSTEM

EXISTING ROBOTIC APPLICATIONS

Applications

ETR-S overlay welding installation for shipbuilding and onshore/offshore engineering Designed for weldments with cylindrical bores (boring head elements, valves, pump housings, pipelines, marine engine components).

Girder welding installation for custom vehicle construction, bridge building and industrial hangar construction Is used for MIG/MAG-welding steel and aluminum profiled girders.

EXISTING ROBOTIC APPLICATIONS Applications • ETR-S overlay welding installation for shipbuilding and onshore/offshore engineering Designed for
EXISTING ROBOTIC APPLICATIONS Applications • ETR-S overlay welding installation for shipbuilding and onshore/offshore engineering Designed for

Filter welding installation for automobile industry This is used for welding aluminum fuel filters, or expansion reservoirs for air- conditioning systems.

Finned-tube overlay welding installation for use in industrial plant Weld-cladding to protect evaporator walls against corrosion, e.g. in power stations

• Filter welding installation for automobile industry This is used for welding aluminum fuel filters, or
• Filter welding installation for automobile industry This is used for welding aluminum fuel filters, or

SPECIALIST TASK FOR INDIVIDUAL SOLUTIONS

Certain applications call for new, individual fabrication concepts. Installations which achieve perfect results and which have to start paying their way quickly, despite being exclusive “one-off” creations

Portal A rail-tracked portal unit, freely programmable in six axes, together with motorised telescoping axis for the torch head (vertical positioning). For welding large or long/tall components, e.g. in the construction of railway rolling stock or heat exchangers.

SPECIALIST TASK FOR INDIVIDUAL SOLUTIONS Certain applications call for new, individual fabrication concepts. Installations which achieve

EXISTING PROBLEMS/DRAWBACKS

  • 1. A related problem is that arc welding is often performed in confined

areas that are difficult to access, such as insides of tanks, pressure

vessels, and ship hulls. Humans can position in to these areas more readily than robots.

  • 2. One of the most difficult technical problems is the variation in the

dimensions of the parts in a batch production job. This type of

dimensional variations means that the arc-welding path to be followed will change slightly from part to part.

  • 3. Another technical difficulty is the variations in the edges and surfaces

to be welded together. Instead of being straight and regular, the edges are typically irregular. This causes variations in the gap between the parts and other problems in the way the pieces mate together prior to the welding process.

  • 4. Human welders are able to compensate for both these variations by

certain parameters in the welding process than Industrial robots provided with sensors to monitor the variations

Economics of Automated Welding System

Economics of Automated Welding System

DESIGN OF EXPERIMENT

Motion

Synthesis

DESIGN OF EXPERIMENT Motion Synthesis Design of Component Feasibility Check Manufacturing and Testing

Design of Component

DESIGN OF EXPERIMENT Motion Synthesis Design of Component Feasibility Check Manufacturing and Testing

Feasibility

Check

DESIGN OF EXPERIMENT Motion Synthesis Design of Component Feasibility Check Manufacturing and Testing

Manufacturing and Testing

PROJECT LAYOUT

o BLACK- Pinion

Stepper Motors/Rake and

o YELLOW- Bearings

RED- o BLUE- o PURPLE-

o

Upper Plate Lower Plate Arm/Torch Holder

PROJECT LAYOUT o BLACK- Pinion Stepper Motors/Rake and o YELLOW- Bearings RED- o BLUE- o PURPLE-

LIST OF COMPONENTS

Upper and Lower base plates Rack and Pinion Ball Bearing Stepper Motors Microcontroller (Atmega8/Aurduino) Motor Controller Helical Screw Torch holding Arm

REFERENCES

• https://www.robots.com/blog/viewing/advantages-and-disadvantages-of-automating -with-industrial-robots • file:///C:/Users/subham%20sharma/Desktop/minor%20project/40_0006_2601_446 51_snapshot.pdf • http://www.robotics.org/content-detail.cfm/Industrial-Robotics-Industry-Insights/ Calculating-Your-ROI-for-Robotic-Automation-Cost-vs-Cash-Flow/content_id/5285 • https://www.robots.com/faq/show/how-much-does-robot-automation-cost • http://www.solidworks.in/sw/products/3d-cad/manufacturing-cost-estimation.htm
https://www.robots.com/blog/viewing/advantages-and-disadvantages-of-automating
-with-industrial-robots
file:///C:/Users/subham%20sharma/Desktop/minor%20project/40_0006_2601_446
51_snapshot.pdf
http://www.robotics.org/content-detail.cfm/Industrial-Robotics-Industry-Insights/
Calculating-Your-ROI-for-Robotic-Automation-Cost-vs-Cash-Flow/content_id/5285
https://www.robots.com/faq/show/how-much-does-robot-automation-cost
http://www.solidworks.in/sw/products/3d-cad/manufacturing-cost-estimation.htm

THANK YOU