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Components You Will Need:
• ‘50076-07A’ Legs
• 49715-07 Spring Clips
• 5012235 Collars
• 50244-07 Bumper Brackets
• 50077-07 Toe Tabs
50077-07
Toe Tabs
49715-07
Spring Clips
50244-07
Bumper
Brackets
5012235 Collars
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Preparing To Work:
Make sure the fixtures are clean from weld spatter and B-B’s, and that the Sub Side
and Final Side are loaded as shown in Figure 1 above. If one or both sides of the
fixture are empty, contact your lead person for assistance.
Double-check to make sure none of the clamps have been left open. An open clamp
could lead to a robot collision inside the Kuka cell!
Make sure the gas is turned on with the red-lever turned upward (see Figure 2
above). The gas is completely shut off when the lever is turned downward.
Sub Side
Final Side
Figure 2Figure 1
ON
OFF
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Preparing Kuka & Welder
On the backside of the work cell,
flip the power switch on the Miller
welder to turn the unit on.
Make sure the Control Power On
light is lit on the cell’s PLC main
screen. If not, flip the Power On
Enable switch to the right while
pressing the Control Power On
button. If this light is not on, the
robot will not allow the operator to
run.
Control
Power
On
Power On
Enable
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Loading/Operating Sequence
1. Position a Spring Clip onto the magnet as shown in the top-left
picture.
2. Place the leg into the Sub Side fixture. Always close the top clamp
down first, and then the right-hand clamp second. Then, close the
Spring Clip clamp. Make sure the clip is tight against the leg!
3. Slide a Toe Tab into the tower portion of the fixture. Close the
clamp to secure the component in place.
1. 2.
3.
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Loading (cont)
5. Place a collar (machined side facing up) into the circular bushing on the Final Side
fixture. Slide the leg down through the bushing: close the clamp atop the leg.
6. Pick-up a Bumper Bracket from the bin: position the bracket on the leg with with one
hand while bringing the bracket clamp forward. The bracket should be flush and level
with the leg upon closing the clamp forward.
7. The fixtures are now loaded and ready to be cycled into the cell for welding. Push the
green “Cycle Start” button by the PLC screen button to send the part into the cell for
welding.
5. 6.
Collar Bumper
Bracket
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Cleaning/Inspect
Use a file or chisel to remove spatter
and B-B’s from the part.
Visually inspect for any holes in the
welds: if there are any holes in the
welds, stop running the cell and
contact the department lead.
There should be no ‘notches’ or burrs
on any of the welds: if there are, use a
buffing wheel or air grinder to remove
sharpness on the welds/components.
Use an 80-grit pad on the air tool.
The operator is responsible for
conducting a 1st piece inspection and
following that up with an hourly
inspection throughout the shift. There
is also a small gauge to check washer
perpendicularity 100%. See your
department lead or QC team member
for further instructions.
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Robot Torch Maintenance
The operator is responsible for entering the cell
every 100-200 pieces in order to clean the
torch and change the weld tip. Ask your
lead person for additional assistance.
1. Use a weld pliers to unscrew the cup from
the torch (counter-clockwise). Use the air
hose inside the cell to blow out any
excess spatter spray and grime.
2. If necessary, use a shop rag to wipe off
around the tip if it is overly saturated with
fluid.
3. Use the weld pliers to unscrew the old
weld tip (it is recommended to change the
tip at least every 200 parts: the hole on
the tip widens and affects the weld
location).
4. Return the cup to the torch after cleaning
or replacing the weld contact tip.
5. Close the cell door, and return to normal
operations.
