Project Details
MESH designed, manufactured, integrated, and started up a custom-engineered robotic stud welding cell for welding both standard capacitive discharge studs and collar studs. The cell was used to weld studs into electrical enclosures, where weld quality and stud accuracy were critical.
The cell was part of a production line and needed to weld 5 to 9 studs in under 30 seconds. Automatic servo fixturing was utilized for automatic changeover between parts.
Automation Equipment
- Custom control system with an Allen Bradley Control Logix PLC
- Four customized HBS KAH412 automatic stud guns
- ATI automatic tool changers
- Two HBS VBZ bowl feeders and four custom bowl feeders
- One HBS CDMi2402 and two HBS ARC 800 power supplies
Fixturing
- 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 met all cycle time requirements, significantly reduced WIP in the factory, and allowed the customer to move to order-based manufacturing.
- Quality: Studs were welded to within 0.008”, eliminating poorly welded stud issues.
- Uptime/Maintenance: The cell achieved an OEE of 91%, with scheduled PM taking considerably less time than required.
- Changeover Time: Instantly and 100% automatic.
- Other: MESH installed a remote access system to support the customer without requiring a factory visit.
