Mesh Automation

Gantry Style Stud Welding Cell

Mesh Automation > Case Studies > Gantry Style Stud Welding Cell
Gantry Style Stud Welding Cell Case Study
Project Details
  • MESH designed, manufactured, integrated and started-up a custom engineered stud welding cell for welding various sized parts. The capacitive discharge stud welding process was used to eliminate back marking and spatter.
  • This machine was used to weld studs onto a stainless steel sheet metal door to attach hinges, handles and other equipment. There were no plans for refinishing the product, so aesthetics were critical.
  • The machine also utilized a camera to find corners and centers of cutout features and locate studs in relation to those features.
Automation Equipment
  • Six HBS KAH412 Automatic stud gun
  • Three HBS VBZ Bowl feeders
  • Three HBS PBZ manual feeding escapements
  • One HBS CDMi2402
  • Cognex camera
  • Custom engineered servo fixturing.
  • Fixture featured multiple grounding clamps to evenly distribute grounding spots.
  • Fluoroclad SDFC was used on parts where spatter could stick. Additionally hardened tooling was used for grounding pads.
Final Project Outcome
  • Productivity: Cell allowed the customer to get away from batch processing.  Additionally, the cell could weld studs 3 or 4 times faster than a human operator and do so more consistently.
  • Quality: Stud were welded to within 0.006”.  Additionally, poorly welded stud issues were eliminated since the machine can hold the gun perfectly square to the workpiece.
  • Uptime/ Maintenance: The cell achieved an OEE of 93%.
  • Changeover Time: Instant and 100% automatic.