DEPT.

OF MECHANICAL ENGINEERING
2016-2017

MINOR PROJECT
PRESENTATION
DESIGN OF AUTOMATED WELDING MACHINE

Team Members-
Shubham Sharma(0812me131153) Project guide- Gaurav
Vasu Gupta(0812me131170) Suryavanshi sir
Vikas Barmase
Shubham wadekar(0812me131157)
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
Problem
finding
and
analysis Compar
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

A Standard Mobile electric arc

welding robot
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.
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
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.
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
DESIGN OF EXPERIMENT

Motion
Synthesis

Design of
Component

Feasibility
Check

Manufacturing
and Testing
 PROJECT LAYOUT
o BLACK- Stepper Motors/Rake and
Pinion
o YELLOW- Bearings
o RED- Upper Plate
o BLUE- Lower Plate
o PURPLE- Arm/Torch Holder
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
THANK YOU