Generator step-up and system intertie power transformers Securing high-qualit...
Final presentation
1. University Of Wisconsin – StoutCapstone 2: Robotic Welding Cell Benjamin Ferron Ryan Schleis Justin Prokash Richard Pike Jonathan Erl Matthew Henderson Nicholas Tomsyck Robert Ihrke Rolf Severtson Jacob Stephany
2. Overview:Bauer Welding and Metal Fabricators Founded in 1946 by Donald K. Bauer Specializes in tube bending, fabrication, and welding Utilizes Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW), laser cutting, plasma cutting, and multiple GMAW robotic welding cells to provide a diverse array of customers with high quality weldments Customers include: Kawasaki, Arctic Cat, Toro, Cummins, Kubota, New Flyer, and Winnebago
3. Project Scope Design and build a demonstrable semi-automatic robotic welding cell and showcase a common industrial robot application in the UW-Stout robotics lab Substantiate repeatability of the pulsed Gas Metal Arc Welding (GMAW-P) process developed in Capstone I for production use by manufacturing representative weldments in the constructed cell
4. Welding Considerations Welding aluminized steel to mild steel has been a nagging manufacturability issue at Bauer Current process uses expensive consumables (stainless steel wire, Helistar GV blended shielding gas) Current process yield is poor and joint leaks are common Pulsed Gas Metal Arc Welding (GMAW-P) process developed on test pieces in Capstone I Welding process needed to be substantiated on parts with dimensional variability typical of multiple bend tubes
5. Exhaust Pipe Assembly Representative of a part manufactured by Bauer Consists of a two-bend aluminized tube, square flange, diamond flange, and three heat shield brackets All materials donated by Bauer
6. Tailstock Assembly Supports weld fixture positioning table using a floating pillow block bearing Minimizes deflection during rotation of robot positioner to maintain positional accuracy Structurally sound Tied into robot frame Adaptable to other fixtures
7. Weld Fixture Maximizes clearance for welding torch Poka-Yoke design Mounting system adaptable to other fixtures Two fixtures allow for increased cycle efficiency
13. Control System Eaton PLC controls main operations Welding operation Pressure test Service/reset functions Eaton HMI provides a graphical user interface (GUI) Andon light indicates operation status of robot
14. Safety Enclosure Comply with industrial safety standards Requirement to run robot in full speed automatic mode Manage safety hazards Flash screens shield bystanders from weld flash Light curtain and door interlock prevents entry into cell while robot operating Enclosure is NOT a substitute for PPE
15. Safety Assessment Risk Codes Assigned Severity Before and after analysis Probability Before and after analysis Countermeasures to prevent risks
16. Cost Assessment Robot/positioner/welder $125,000 PLC Automation $7,000 Safety Enclosure $2,000 Weld Fixture $3275 Tailstock $335 Pressure Test Fixture $890 Dimensional Check Fixture $2,700 Total cost for entire cell: $141,200
17. Cost Assessment Starting Budget - $1000 Light Curtain Transmitter/Emitter - $158.00 Steel for Fixtures - $43.22 Toggle Clamps - $56.82 Pressure Sensor Heads - $87.94 Sensor Amplifiers - $222.60 Steel for Enclosure - $239.14 Cable for Control System- $72.80 Safety Signs - $59.6 Total - $940.12
18. Conclusions Substantiated that welding process developed in Capstone I is repeatable for production use on parts with typical dimensional variability found in multiple plane bent tubes Produced representative parts with excellent visual and sealing weld quality Constructed a semi-automated welding cell in the UW-Stout robotics lab around the ABB IRB-1400 robot that is safe and straightforward to operate
19. Future Recommendations Automate weld fixture to recognize part presence and clamp/unclamp components Machine mating surfaces and positioning faces to tool and die standards Incorporate additional applications and quick changeover fixture design Create a service manual with preventative maintenance
