Resistance Welding Machine Reduces Labor Costs and Saves Valuable Floor Space
Sciaky designed a special resistance welding system for a customer that manufactures steel doors in various lengths and widths. The core of the doors consist of steel sheets welded to Z-bar supports. The customer had previously used several stand-alone Sciaky press-type spot welders and manual handling methods to weld the parts in several operations.
An increase in product volume, as well as the age of the old manual equipment, prompted Sciaky to develop a plan to automate the welding of the door's skins.
A Sciaky welding study determined it was possible to weld the doors from just one side. The process involved laying the outer sheet on a fixture followed by the Z-bar stiffeners; these were welded by a series of conventional spot welds. By changing the design of the stiffeners to incorporate embossed projections, the top sheets could also be welded from the same side using a projection-type welding head. The welding system concept also offered the ability to load and unload parts from the same position, and a sliding tray fixture exchange system allowed the system to continue welding while parts were loaded and unloaded.
To accommodate the variety of lengths and widths of the doors, Sciaky devised an innovative adjustable fixture system. To generate the welds at the required rate, two resistance welding heads were mounted on a moving crossbeam carriage. The spacing of the heads were set for a particular door type, and the heads and fixture carriage automatically moved through a preprogrammed pattern using CNC control to lay down the correct pattern of spots.
The Sciaky system saved the customer valuable floor space by replacing an entire line of manual machines with a single unit. The new process also improved product quality by reducing distortion. Labor was also reduced from three operators to one.
Resistance
Resistance Spot & Seam Welders
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