axle welding system - unikraft.in welding machine leaflet.pdf · axle welding system the non driven...

AXLE WELDING SYSTEM

The Non Driven Axles ( ) are used in Trucks, Trailers etc.

They are of Round, Square or Rectangular shapes. These axles are generally made by joining the

hollow middle portion to the 2 solid end portions by welding.

To ensure that the axles can take the designed load without compromising the safety, stringent

welding norms are applied. So, it is preferable to carry out this welding by an Automatic machine.

Dead Axles - as they are generally called

Contact Us:-Email:- [email protected],[email protected]:- +91-9552592593 / 9922535540Tel. No.:- 020 27452593Web.:-www.unikraft.in

UNIKraft Techno LLPUNIKraft Techno LLP

MACHINE DESCRIPTION:-UNIK has developed a fully programmed automated machine to carry out this welding.

The Machine is designed to handle both Round Axles as well as Square axles.

In case of Square / Rectangular axles, the axle is rotated on its axis & the vertical slide

moves up & down, tracing the square / rectangular profile of the Axle while rotating.

The machine can manipulate 2 MIG/MAG torches at the same time for increased productivity.

The program is set to measure one full revolution along with the required overlap and to stop

the welding & rotation simultaneously. Also the program can reposition the torch to new positions

for the first, second & third runs of welding, including weaving of the torch during welding.

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Work Address:-Gala No.62, Parmar Industrial Complex,Survey No.142/1, Chinchwad, Pune 411019.

PREAMBLE:-

AXLE WELDING SYSTEM


WELDING QUALITY IMAGES:-



For the Square Axles, during root run the torch is in inclined position to direct the welding arc force at

the root. After root run including the overlap, before starting second run, the torch automatically

comes to vertical position . The X-Y slides position the welding torch exactly at the predefined position

for each run of welding.

The torches carry out weaving during welding as per the set parameters. The axle rotation speed is

also precisely changed as per the program for the root run & the subsequent runs. After final run of

welding is completed, the welding & rotation is stopped. The welding torches retract to their home

position & job gets de-clamped automatically.

Machine SpecificationsThe machine is made on a robust base with TWO sets of X-Y Servo slides for

controlled manipulation of the 2 torches to weld square & round axle of following specifications:

· Length: - Min 800 mm to Max 3000 mm

· Square axle: 150 X 150mm, 150 X 200mm & round axle: diameter: 125mm & 150 mm

· Welding process: MIG / MAG welding

· Servomotor with drives: 4 Nos

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AXLE WELDING SYSTEM


AXLE WELDING SYSTEM PRODUCTIVITY CHARTS:-

The benefits of our well-engineered welding systems range from improved weld quality to decreased variable labor costs. The most prominent advantages are:1. Improved Weld Quality: Our Mechanized welding system improves the welding consistency and repeatability.2. Increased Output/Volume: Production weld speed is decided by the machine's capability. It does not deteriorate with Welder's fatigue. With minimized part set up time, and higher weld speeds, the output is increased.3. Decreased Scrap / Rework: Since the Welder's skill is not required, there will be less chances for the mistakes & rework.4. Decreased Variable Labor Costs: Reliance on human welders dramatically increases a manufacturer's labor costs. Welding is a Hazardous Occupation. UV Flash, fumes, Electric Shock, sparks and heat make manual welding a taxing and hazardous job. Nowadays, getting a skilled welder is becoming more difficult due to other options available for their occupation. The Human welder's skill and concentration deteriorates from the beginning of the shift towards the end of the shift. With Auto welding, the Occupational Hazard as well as the demand for a qualified welder is reduced. Insurance and accident related costs are reduced considerably.OPTIONAL FEATURES WE OFFERED WITH MACHINE AT EXTRA COST:-· Induction Pre Heating System for Pre Heating Axle upto 250 Deg. · Integration of Control panel with Welding Machine to control the Welding current & Voltage.· Weld Protection Curtain – to avoid the Hazardous UV light from affecting the other workers working nearby.

Please send your enquiries to the following address, for further details & our immediate response.

S.N.

1 1

0.3

0.3

8

8

12

40

120

1.2

1.2

4

Load the Job on the machine using dedicated jib crane

2 Clamp the Job

3Select the Program for welding from HMI as per the job size & press Cycle Start

4 Welding of Axle –one Root Run & 2 Weaving Run

5

6

Cleaning Cycle

Unload the Job on the machine using dedicated jib crane

Total Time (In Min )

Total Time (in Min for one axle-Arc + Non Value added time )

No of Axle per shift ( 8 Hour shift )

No Axle Per Days ( 3 Shifts )

OPERATION SEQUENCE TOTAL NON-VALUE

ADDED TIME (MIN.)

ARC TIME

(MIN.)

Note: - Filling up of Gas, Loading the Wire, Preheating of Axle (if required) etc are not included in our timing Calculation .Time Calculated is actual time of operation. Pre-processed axles should be stored near each station.

BENEFIT OF AUTO AXLE WELDING SYSTEM:-



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axle welding system - unikraft.in welding machine leaflet.pdf · axle welding system the non driven...

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