FABRICATION OF

AUTOMATIC DOUBLE AXIS

NON-CONSUMABLE
ELECTRODE WELDING
MACHINE
 CONTENTS

S.NO TITLE
1 ABSTRACT
2 INTRODUCTION
3 BLOCK DIAGRAM
4 BLOCK DIAGRAM DESCRIPTION
5 WORKING DIAGRAM
6 WORKING PRINCIPLE
7 ARC WELDING
8 NON-CONSUMABLE ELECTRODE METHODS
9 ADVANTAGES
10 DISADVANTAGES
11 APPLICATION
12 COST ESTIMATION
13 PHOTOGRAPHY
14 CONCLUSION
15 REFERENCES

ABSTRACT:

In our project FABRICATION OF AUTOMATIC DOUBLE AXIS

NON-CONSUMABLE ELECTRODE WELDING MACHINE is beings with
an introduction to welding the various components automatically. Two-pneumatic
cylinder and solenoid valve are provided. One cylinder is for the up and down
movement, another one for arm lifting and one for the rotary motion.

It is beings with an3 introduction to welding the various components

automatically. Two-pneumatic cylinder and solenoid valve are provided. One
cylinder is for the up and down movement, another one for arm lifting .

INTRODUCTION
 Automation can be achieved through computers , hydraulics,
pneumatics etc., of these sources, pneumatics form an attractive medium for
low cost automation. Automation plays an important role in automobile.
Nowadays almost all the machines are being atomized in order to product
the human being.

The automobile vehicle is being atomized for the following reasons.

To achieve high safety

To reduce man power
To increase the efficiency of the vehicle
To reduce the work load
To reduce the fatigue of workers
To high responsibility
Less Maintenance cost

The technology of pneumatics has gained tremendous importance in the

field of workplace rationalization and automation from old-fashioned timber works
and coal mines to modern machine shops and space robots. Certain characteristics
of compressed air have made this medium quite suitable for used in modern
manufacturing and production industries. It is therefore important that technicians
and engineers should have a good knowledge of pneumatic system, air operated
valves and accessories.

A pneumatic system consists of a compressor plant, pipe lines, control

valves, drive members and related auxiliary appliances. The air is compressed in an
air compressor and from the compressor plant the flow medium is transmitted to
the pneumatic cylinder through a well laid pipe line system. To maintain optimum
efficiency of pneumatic system, it is of vital importance that pressure drop between
generation and consumption of compressed air is kept very low. In our project
FABRICATION OF AUTOMATIC DOUBLE AXIS NON-CONSUMABLE
ELECTRODE WELDING MACHINE is beings with an introduction to
welding the various components automatically.

Three-pneumatic cylinder and solenoid valve are provided. One cylinder is

for the up and down movement, another one for arm lifting and one for the rotary
motion. In the present age of mass production it is often required to automate the
manufacturing process that was conventionally done manually. The process of
joining in many applications is welding. The welding may be of Electric arc
welding, Co2 Welding, or TIG welding. The process of Electric arc welding or Co2
welding is normally done manually.

In electric arc welding after striking the arc the electrode is moved in the
direction of welding maintaining an effective arc gap, similar type of process is
done in Co2 welding. Moving the electrode along the welding line is a skill full
work and especially for circular components become much more difficult. Manual
operation though done by an expert works man will require the work piece to be
rotated about a fixed axis for good profile and homogeneous welding. Normally
this process is done manually but the rate of rotation is not ensured, hence the
quality of weld is affected.

Hence the need of a special device which can rotate the job at a fixed rate
to assist the welding process for circular components and ensure good profile and
homogeneous welding. Welding is a fabrication or sculptural process that joins
materials, usually metals or thermoplastics, by causing coalescence. This is often
done by melting the work pieces and adding a filler material to form a pool of
molten material (the weld pool) that cools to become a strong joint, with pressure
sometimes used in conjunction with heat, or by itself, to produce the weld.
NEED FOR AUTOMATION

Automation can be achieved through computers, hydraulics, pneumatics,

Robotics, etc. of these sources, pneumatics form an attractive medium for low cost
automation. The main advantages of all pneumatic systems are economy and
simplicity. Automation plays an important role in mass production. Automation
plays a vital role in mass production .For mass production of a product, the
machining operations decides the sequence of machining .the machines designed
for producing a particular product are called transfer machines.

NEEDS FOR PNEUMATIC POWER

Pneumatic system use pressurized gases to transmit and control power, as

the name implies, pneumatic systems typically use air as fluid medium, because air
is a safe, low cost and readily available fluid. It is particularly safe environments
where an electrical spark could ignite leaks from the system components. There are
several reasons for considering the use of pneumatic system instead
of hydraulic system. Liquid exhibit greater inertia than gases therefore,
in hydraulic system the weight of the oil is a potential problem. To design and
development a material handling system for automation /semi automation of
industries by using pneumatic control system, which is used for low cost
automation.
COMPRESSORS

The main function of the air compressor is to compress the air up to the
required pressure. The maximum capacity of the compressor is 10105 to 12 105
N/m2. This is a two stages or two-cylinder reciprocating air compressor. The two
cylinders are for low and high compression. The air pressure is measured at various
places by the use of pressure gauges. V-belt and pulley are used to drive the
compressor.

DYNAMIC COMPRESSORS

Positive displacement compressors work on the principle of increasing the pressure

of a definite volume in an enclosed chamber. Dynamic (turbo) compressor employs
rotating vanes or impellers to impart velocity and pressure to the flow of the air
being handled. The pressure comes from the dynamic effects such as centrifugal
force.

SOLENOID VALVE

A solenoid is an electrical mechanical device that can convert electrical

power to mechanical force and motion. It consists mainly of plunger, mostly a T
type plunger, wire or coil and a C-frame. The working principle is such that when
an electric current is passed through a coiled wire, a magnetic field sets up around
the wire. Because of coiled wire, the magnetic field would be several times
stronger around and through its center. The solenoid force is directly fed to the
spool of the direction control valve to shift it.

This force is applied through the T-plunger that is surrounded by the coil,
also called the armature. To select a proper electromagnet, the forces resisting
the actuation of the magnet, i.e. the force of friction and spring force have to be
kept at their minimum so that the electromagnet can develop a force greater than
the resultant of the resisting force. Mostly in the case of dc magnets, the body and
the armature may be made of one piece whereas the ac magnets require both the
parts to be made from thin laminated sheets to obstruct flow of eddy current and to
avoid increase of the solenoid body-temperature.

Whether one has to go for a dc or ac magnet, depends fully on the

requirement of the control system. However in majority of pneumatic direction
control valves, only dc magnets are used as the overall requirement of force and
response time is quite suitable for such application.

OPERATION OF SOLENOID VALVE

With solenoid valves, a current through a solenoid is used to implement

switching between positions. When a current flows through the solenoid, a
magnetic field is produced which pulls the laminated steel core into the coil, the
force depending on the current through the solenoid? The larger the current the
greater the force exerted.
BLOCK DIAGRAM DESCRIPTION:

RELAY:

INTRODUCTION

A relay is an electrically operated switch. Many relays use

an electromagnet to mechanically operate a switch, but other operating principles
are also used, such as solid-state relays. Relays are used where it is necessary to
control a circuit by a low-power signal (with complete electrical isolation between
control and controlled circuits), or where several circuits must be controlled by one
signal. The first relays were used in long distance telegraph circuits as amplifiers:
they repeated the signal coming in from one circuit and re-transmitted it on another
circuit. Relays were used extensively in telephone exchanges and early computers
to perform logical operations.

A type of relay that can handle the high power required to directly control
an electric motor or other loads is called a contactor. Solid-state relays control
power circuits with no moving parts, instead using a semiconductor device to
perform switching. Relays with calibrated operating characteristics and sometimes
multiple operating coils are used to protect electrical circuits from overload or
faults; in modern electric power systems these functions are performed by digital
instruments still called "protective relays".
BASIC DESIGN AND OPERATION

A simple electromagnetic relay consists of a coil of wire wrapped around

a soft iron core, an iron yoke which provides a low reluctancepath for magnetic
flux, a movable iron armature, and one or more sets of contacts (there are two in
the relay pictured). The armature is hinged to the yoke and mechanically linked to
one or more sets of moving contacts. It is held in place by a spring so that when the
relay is de-energized there is an air gap in the magnetic circuit. In this condition,
one of the two sets of contacts in the relay pictured is closed, and the other set is
open. Other relays may have more or fewer sets of contacts depending on their
function. The relay in the picture also has a wire connecting the armature to the
yoke. This ensures continuity of the circuit between the moving contacts on the
armature, and the circuit track on the printed circuit board (PCB) via the yoke,
which is soldered to the PCB.

When an electric current is passed through the coil it generates a magnetic

field that activates the armature and the consequent movement of the movable
contact either makes or breaks (depending upon construction) a connection with a
fixed contact. If the set of contacts was closed when the relay was de-energized,
then the movement opens the contacts and breaks the connection, and vice versa if
the contacts were open. When the current to the coil is switched off, the armature is
returned by a force, approximately half as strong as the magnetic force, to its
relaxed position. Usually this force is provided by a spring, but gravity is also used
commonly in industrial motor starters. Most relays are manufactured to operate
quickly. In a low-voltage application this reduces noise; in a high voltage or
current application it reduces arcing.

When the coil is energized with direct current, a diode is often placed across
the coil to dissipate the energy from the collapsing magnetic field at deactivation,
which would otherwise generate a voltage spike dangerous
to semiconductor circuit components. Some automotive relays include a diode
inside the relay case. Alternatively, a contact protection network consisting of a
capacitor and resistor in series (snubber circuit) may absorb the surge. If the coil is
designed to be energized with alternating current (AC), a small copper "shading
ring" can be crimped to the end of the solenoid, creating a small out-of-phase
current which increases the minimum pull on the armature during the AC cycle.

Simple electromechanical relay.

SOLENOID VALVE:
 A solenoid valve is an electromechanically operated valve. The valve is
controlled by an electric current through a solenoid: in the case of a two-port valve
the flow is switched on or off; in the case of a three-port valve, the outflow is
switched between the two outlet ports. Multiple solenoid valves can be placed
together on a manifold.

Solenoid valves are the most frequently used control elements in fluidics.
Their tasks are to shut off, release, dose, distribute or mix fluids. They are found in
many application areas. Solenoids offer fast and safe switching, high reliability,
long service life, good medium compatibility of the materials used, low control
power and compact design. Besides the plunger-type actuator which is used most
frequently, pivoted-armature actuators and rocker actuators are also used.

OPERATION:
 There are many valve design variations. Ordinary valves can
have many ports and fluid paths. A 2-way valve, for example, has
2 ports; if the valve is open, then the two ports are connected and
fluid may flow between the ports; if the valve is closed, then ports
are isolated. If the valve is open when the solenoid is not
energized, then the valve is termed normally open (N.O.).
Similarly, if the valve is closed when the solenoid is not energized,
then the valve is termed normally closed. There is also 3-way and
more complicated designs. A 3-way valve has 3 ports; it connects
one port to either of the two other ports (typically a supply port
and an exhaust port).

Solenoid valves are also characterized by how they operate.

A small solenoid can generate a limited force. If that force is
sufficient to open and close the valve, then a direct
acting solenoid valve is possible. An approximate relationship
between the required solenoid force Fs, the fluid pressure P, and
the orifice area A for a direct acting solenoid value is

Where d is the orifice diameter. A typical solenoid force

might be 15 N (3.4 lbf). An application might be a low pressure
(e.g., 10 pounds per square inch (69 kPa)) gas with a small orifice
diameter (e.g., 38 in (9.5 mm) for an orifice area of
0.11 in2 (7.1105 m2) and approximate force of 1.1 lbf (4.9 N)).

The solenoid valve (small black box at the top of the photo)
with input air line (small green tube) used to actuate a larger rack
and pinion actuator (gray box) which controls the water pipe
valve. When high pressures and large orifices are encountered,
then high forces are required. To generate those forces,
an internally piloted solenoid valve design may be possible. In
such a design, the line pressure is used to generate the high valve
forces; a small solenoid controls how the line pressure is used.

Internally piloted valves are used in dishwashers and

irrigation systems where the fluid is water, the pressure might be
80 pounds per square inch (550 kPa) and the orifice diameter
might be 34 in (19 mm). In some solenoid valves the solenoid acts
directly on the main valve. Others use a small, complete solenoid
valve, known as a pilot, to actuate a larger valve. While the
second type is actually a solenoid valve combined with a
pneumatically actuated valve, they are sold and packaged as a
single unit referred to as a solenoid valve.

Piloted valves require much less power to control, but they

are noticeably slower. Piloted solenoids usually need full power at
all times to open and stay open, where a direct acting solenoid
may only need full power for a short period of time to open it, and
only low power to hold it. A direct acting solenoid valve typically
operates in 5 to 10 milliseconds. The operation time of a piloted
valve depends on its size; typical values are 15 to 150
milliseconds.

INTERNALLY PILOTED
 While there are multiple design variants, the following is a
detailed breakdown of a typical solenoid valve design. A solenoid
valve has two main parts: the solenoid and the valve. The
solenoid converts electrical energy into mechanical energy which,
in turn, opens or closes the valve mechanically. A direct acting
valve has only a small flow circuit, shown within section E of this
diagram (this section is mentioned below as a pilot valve).

In this example, a diaphragm piloted valve multiplies this small pilot flow,
by using it to control the flow through a much larger orifice. Solenoid valves may
use metal seals or rubber seals, and may also have electrical interfaces to allow for
easy control. A spring may be used to hold the valve opened (normally open) or
closed (normally closed) while the valve is not activated.
A- Input side

B- Diaphragm

C- Pressure chamber

D- Pressure relief passage

E- Solenoid

F- Output side
 The diagram to the right shows the design of a basic valve, controlling the
flow of water in this example. At the top figure is the valve in its closed state. The
water under pressure enters at A. B is an elastic diaphragm and above it is a weak
spring pushing it down. The diaphragm has a pinhole through its center which
allows a very small amount of water to flow through it. This water fills the
cavity C on the other side of the diaphragm so that pressure is equal on both sides
of the diaphragm; however the compressed spring supplies a net downward force.
The spring is weak and is only able to close the inlet because water pressure is
equalized on both sides of the diaphragm.

Once the diaphragm closes the valve, the pressure on the outlet side of its
bottom is reduced, and the greater pressure above holds it even more firmly closed.
Thus, the spring is irrelevant to holding the valve closed. The above all works
because the small drain passage D was blocked by a pin which is the armature of
the solenoid and which is pushed down by a spring. If current is passed through the
solenoid, the pin is withdrawn via magnetic force, and the water in
chamber C drains out the passage D faster than the pinhole can refill it. The
pressure in chamber C drops and the incoming pressure lift the diaphragm, thus
opening the main valve.

Water now flows directly from A to F. When the solenoid is again

deactivated and the passage D is closed again, the spring needs very little force to
push the diaphragm down again and the main valve closes. In practice there is
often no separate spring; the elastomeric diaphragm is molded so that it functions
as its own spring, preferring to be in the closed shape. From this explanation it can
be seen that this type of valve relies on a differential of pressure between input and
output as the pressure at the input must always be greater than the pressure at the
output for it to work.
 Should the pressure at the output, for any reason, rise above that of the
input then the valve would open regardless of the state of the solenoid and pilot
valve

COMPONENTS

Example core tubes

Non-magnetic core tubes are used to isolate the fluid from the coil. The
core tube encloses the plug nut, the core spring, and the core. The coil slips over
the core tube; a retaining clip engages the depression near the closed end of the
core tube and holds the coil on the core tube. Solenoid valve designs have many
variations and challenges.
Common components of a solenoid valve:

Solenoid subassembly
o Retaining clip (a.k.a. coil clip)
o Solenoid coil (with magnetic return path)
o Core tube (a.k.a. armature tube, plunger tube, solenoid valve tube,

sleeve, guide assembly)

o Plug nut (a.k.a. fixed core)
o Shading coil (a.k.a. shading ring)
o Core spring (a.k.a. counter spring)
o Core (a.k.a. plunger, armature)
Core tubebonnet seal
Bonnet (a.k.a. cover)
Bonnetdiaphragmbody seal
Hanger spring
Backup washer
Diaphragm
o Bleed hole
Disk
Valve body
o Seat

The core or plunger is the magnetic component that moves when the
solenoid is energized. The core is coaxial with the solenoid. The core's movement
will make or break the seals that control the movement of the fluid. When the coil
is not energized, springs will hold the core in its normal position. The plug nut is
also coaxial. The core tube contains and guides the core. It also retains the plug nut
and may seal the fluid. To optimize the movement of the core, the core tube needs
to be nonmagnetic.
 If the core tube were magnetic, then it would offer a shunt path for the field
lines. In some designs, the core tube is an enclosed metal shell produced by deep
drawing. Such a design simplifies the sealing problems because the fluid cannot
escape from the enclosure, but the design also increases the magnetic path
resistance because the magnetic path must traverse the thickness of the core tube
twice: once near the plug nut and once near the core. In some other designs, the
core tube is not closed but rather an open tube that slips over one end of the plug
nut.

To retain the plug nut, the tube might be crimped to the plug nut. An O-ring
seal between the tube and the plug nut will prevent the fluid from escaping. The
solenoid coil consists of many turns of copper wire that surround the core tube and
induce the movement of the core. The coil is often encapsulated in epoxy. The coil
also has an iron frame that provides a low magnetic path resistance.

MATERIALS

The valve body must be compatible with the fluid; common materials are
brass, stainless steel, aluminum, and plastic. The seals must be compatible with the
fluid.

To simplify the sealing issues, the plug nut, core, springs, shading ring, and
other components are often exposed to the fluid, so they must be compatible as
well. The requirements present some special problems. The core tube needs to be
non-magnetic to pass the solenoid's field through to the plug nut and the core. The
plug nut and core need a material with good magnetic properties such as iron, but
iron is prone to corrosion. Stainless steels can be used because they come in both
magnetic and non-magnetic varieties. For example, a solenoid valve might use 304
stainless steel for the body, 305 stainless steel for the core tube, 302 stainless steel
for the springs, and 430 F stainless steel (a magnetic stainless steel for the core and
plug nut.

TYPES:

Many variations are possible on the basic, one-way, one-solenoid valve

described above:

one- or two-solenoid valves;

direct current or alternating current powered;
different number of ways and positions;

COMMON USES:

Solenoid valves are used in fluid power pneumatic and

hydraulic systems, to control cylinders, fluid power motors or
larger industrial valves. Automatic irrigation sprinkler systems
also use solenoid valves with an automatic controller.
Domestic washing machines and dishwashers use solenoid valves
to control water entry into the machine.

Solenoid valves are used in the paintball industry, solenoid

valves are usually referred to simply as "solenoids." They are
commonly used to control a larger valve used to control the
propellant In addition to this, these valves are now being used in
household water purifiers. Solenoid valves can be used for a wide
array of industrial applications, including general on-off control,
calibration and test stands, pilot plant control loops, process
control systems, and various original equipment manufacturer
applications.

ROTATRY MOTION OF PNEUMATIC CYLINDER:

Some machine actions require rotary motion for only a portion of a turn.
Using a hydraulic motor to perform a partial-turn function is expensive and it is
difficult to accurately stop a motor at a specified degree of rotation. A clevis-
mounted cylinder, attached to an arm and keyed to a shaft, produces rotary action,
but is limited to 90 or less. At 90 rotation, a cylinder/lever arrangement has half
torque or less when it starts and nears the end of stroke. To obtain partial- or
multiple-turn rotary action and/or accurate stopping of rotary output, use one of the
rotary actuators shown in this chapter. Figure 19-1 pictures the symbols for air- and
hydraulic-operated rotary actuators.

It provides simplified cutaway views of vane-type rotary actuators. The

figure depicts both single- and double-vane-types. The vanes attach to an output
shaft and have seals around their periphery. When fluid pressure on a given vane
area pushes it through the body cavity, the output shaft turns with a given torque.
The maximum rotation of vane rotary actuators is limited to approximately 280 in
a single-vane model and approximately 100 in the double-vane configuration.
 Vane-type rotary actuator.

A double-vane rotary actuator sends fluid to the push side of the opposite
vane through drilled passages in the shaft, as shown by dashed lines and arrows.
Pressurized fluid at the CW port turns the output shaft clockwise. Pressurized fluid
at the CCW port turns the output shaft counterclockwise.

Most vane-type rotary actuators operate at lower pressure and torque limits
of 2500 to 5000 in. lb. Some manufacturers do make units that operate at up to
3000 psi, with torque in excess of 700,000 in. lb.

Vane-type rotary actuators have no effective way of internally cushioning or

limiting the degree of rotation. An external method must be used to limit rotation
or cushion the load. Some manufacturers offer a valve and stroke-limiting package
that makes rotation degrees adjustable and gives variable deceleration and
cushioning. Check manufacturers catalogs for more information on these
packages.

Rack-and-pinion rotary actuator with sealed output shaft.

It illustrates one design of a rack-and-pinion type rotary actuator. This

cutaway view shows a double-rack design that has fluid in the area where the
pinion runs. This configuration requires a high-pressure shaft seal but assures that
the rack and pinion is well lubricated. With fluid piped to the CW port, the output
shaft turns clockwise. With fluid piped to the CCW port, the output shaft turns
counterclockwise. This design works best in pneumatic or low-pressure hydraulic
applications. The torque range usually does not exceed 2500 to 3500 in. lb.

The cutaway view in Figure 19-4 shows another style rack-and-pinion type
rotary actuator. This design has opposing pistons with a rack gear as the piston rod.
Fluid only enters the blind side of the piston so the pinion shaft never sees
pressure. When fluid enters one of the piston cavities, that piston moves, pushing
the rack gear to drive the pinion, and producing rotary output. With fluid piped to
the CW port, the output shaft turns clockwise. With fluid piped to the CCW port,
the output shaft turns counterclockwise.

Rack-and-pinion rotary actuator with low-pressure sealed shaft.

The rack-and-pinion design rotary actuators shown in Figure 19-4 are

available with a second rack gear and pistons mounted on the opposite side of the
pinion. This double-piston setup produces twice the torque in both directions of
rotation.

Optional stroke limiters select a precise stopping point at any degree of

rotation less than maximum. Also available are cushions that decelerate rotation
speed near the end of the stroke. Cushions are adjustable and not affected by the
stroke limiter option in the same rotary actuator. This type rotary actuator is
available with an optional hollow output shaft.
 Rack-and-pinion rotary actuators operate equally well on pneumatic or
hydraulic pressure (up to 3000 psi). They generate torque up to 200,000 in. lb for
air service, and up to 15,000,000 in. lb and higher for hydraulic service. Output
shafts turn any number of degrees up to five rotations according to piston and rack
gear size.

Simplified cutaway view of spiral -shaft rotary actuator.

It shows a simplified cutaway view of a spiral-shaft rotary actuator. (There

are several variations of spiral-type rotary actuators, but all function similar to this
diagram.) The spiral-shaft rotary actuator has a keyed, non-rotating piston with a
hollow rod. The hollow rod has a set of internal spiral grooves that mesh with the
spiral shaft. The spiral-grooved shaft only has rotational movement and extends
through the housing as an output shaft. With fluid piped to the CW port, the output
shaft turns clockwise. With fluid piped to the CCW port, the output shaft turns
counterclockwise.

One available option is a stroke limiter that allows a precise stopping at any
degree less than maximum. Also available are cushions to decelerate rotation speed
near the end of stroke. Some manufacturers make this type rotary actuator with an
integral cylinder that adds linear movement to the output shaft.

The spiral-shaft rotary actuators in Figure 19-5 operate equally well on air or
hydraulic power. They operate at pressures up to 3000 psi and produce torque up to
20,000 in. lb for air service, and up to 5,000,000 in. lb for hydraulic service.
Output shafts normally rotate 360 with more turns available on special order.

Chain-and-sprocket rotary actuator.

Figure shows a simplified cutaway view of a chain-and-sprocket rotary

actuator. It consists of a large-diameter power piston with a roller chain attached to
both sides. The roller chains go around a sprocket at both ends and attach to both
sides of a smaller isolation piston. When pressurized fluid enters a port, it pushes
against both pistons with equal force.

Because the power piston has more area, it moves away from incoming
fluid. The smaller isolation piston regenerates into the incoming pump flow. (To
find the effective working area, subtract the area of the isolation piston from the
area of the power piston.) With fluid piped to the CW port, the output shaft turns
clockwise. With fluid piped to the CCW port, the output shaft turns
counterclockwise.

ARM LIFT PNEUMATIC CYLINDER:

SLIDING LOAD:
 Cylinders perform a wide variety of applications and are often used in place
of larger, more expensive mechanical systems. One such application is when a
cylinder is used to move a high friction sliding load. Some examples of this are:
machine slides, pallet shuttle systems on automated machinery, milling machine
tables, and grinder tables. There are a number of things to consider when sizing a
cylinder for a sliding load application. These include the unit weight (load),
lubrication, and required speed.

For applications where there is light lubrication, the cylinder should provide
a thrust force capable of moving a load equal to 50% to 75% of the actual load.
Once in motion, a thrust force capable of moving 20% of the actual load weight is
adequate. Because air is a compressible medium, air cylinders should not be used
for slow or controlled feed or motion in a sliding load application. The designer
should be aware that a jerky motion will result if an air cylinder is used to perform
this type of work.

Because oil is non-compressible, a hydraulic cylinder with a metered out

speed control would be more effective. For indexing applications, from one
positive stop to another, air cylinders usually provide better response and more
rapid action than hydraulic cylinders.
ROLLING LOAD

Cylinders can be used to move rolling loads or loads which are moved on
own friction bearings. For this type of application, the cylinder should have a thrust
force capable of moving a load equal to 10% of the actual load. When using a
cylinder to move a rolling load, some means of deceleration at the end of the
Cylinder stroke should be used to prevent the momentum of the load from
damaging either the cylinder or the machine.

WORKING DIAGRAM :
WORKING PRINCIPLE

The experimental setup consist of four cylinders, all are of double acting
type. The cylinder1 is used to actuate rack and pinion assembly, piston rod of
cylinder 1is connected to rack, which is meshed with the pinion. By operating the
cylinder1, rack and pinion turns the whole assembly for 180.
 By varying the length of the rack the turning angle can be altered. Vertical
cylinder or cylinder2 is used to increase the height of the setup. The height is
limited to piston rod length.

DESCRIPTION OF ASSEMBLY

The assembly unit consists of a base block, cylinders, rack and pinion, base
plate, tie rods, solenoid valves and gripper. Cylinder 1 is mounted on the base
block with rack and pinion assembly connected with tie rods. The vertical cylinder
is mounted vertically over the base plate to increase the height with a block and
endplate provided at the end. The horizontal cylinder is mounted on the block of
the vertical cylinder horizontally to increase length of the arm with a block and end
plate provided at the end position.
The Double axis welding machine makes use of properly shaped MS alloy
electrodes in order to apply pneumatic pressure and carry electrical current through
the work pieces. Heat is generated mainly at the merging point between two sheets.
This causes the material being welded to melt gradually, thereby forming a molten
bath, known as the weld mass. The molten bath is held through the pressure
applied by the electrode tip and the encircling solid metal.
In this type of welding process, no welding rod is used. If the compressed air
goes to solenoid valve to pneumatic cylinder welding holder connected to
pneumatic cylinder which actuated by solenoid valve at the time automated welded
for metal.
ARC WELDING

Arc welding is a process that is used to join metal to metal by using

electricity to create enough heat to melt metal, and the melted metals when cool
result in a binding of the metals. It is a type of welding that uses a welding power
supply to create an electric arc between an electrode and the base material to melt
the metals at the welding point.

They can use either direct (DC) or alternating (AC) current, and
consumable or non-consumable electrodes. The welding region is usually protected
by some type of shielding gas, vapor, or slag. Arc welding processes may be
manual, semi-automatic, or fully automated. First developed in the late part of the
19th century, arc welding became commercially important in shipbuilding during
the Second World War. Today it remains an important process for the fabrication of
steel structures and vehicles

POWER SUPPLIES

To supply the electrical energy necessary for arc welding processes, a

number of different power supplies can be used. The most common classification
is constant current power supplies and constant voltage power supplies. In arc
welding, the voltage is directly related to the length of the arc, and the current is
related to the amount of heat input. Constant current power supplies are most often
used for manual welding processes such as gas tungsten arc welding and shielded
metal arc welding, because they maintain a relatively constant current even as the
voltage varies.

This is important because in manual welding, it can be difficult to hold the

electrode perfectly steady, and as a result, the arc length and thus voltage tend to
fluctuate. Constant voltage power supplies hold the voltage constant and vary the
current, and as a result, are most often used for automated welding processes such
as gas metal arc welding, flux cored arc welding, and submerged arc welding. In
these processes, arc length is kept constant, since any fluctuation in the distance
between the wire and the base material is quickly rectified by a large change in
current.

For example, if the wire and the base material get too close, the current will
rapidly increase, which in turn causes the heat to increase and the tip of the wire to
melt, returning it to its original separation distance. The direction of current used in
arc welding also plays an important role in welding. Consumable electrode
processes such as shielded metal arc welding and gas metal arc welding generally
use direct current, but the electrode can be charged either positively or negatively.
In welding, the positively charged anode will have a greater heat concentration
(around 60%) and, as a result, changing the polarity of the electrode affects weld
properties.

If the electrode is positively charged, it will melt more quickly, increasing

weld penetration and welding speed. Alternatively, a negatively charged electrode
results in more shallow welds. Non-consumable electrode processes, such as gas
tungsten arc welding, can use either type of direct current (DC), as well as
alternating current (AC). With direct current however, because the electrode only
creates the arc and does not provide filler material, a positively charged electrode
causes shallow welds, while a negatively charged electrode makes deeper
welds. Alternating current rapidly moves between these two, resulting in medium-
penetration welds.

One disadvantage of AC, the fact that the arc must be re-ignited after every
zero crossing, has been addressed with the invention of special power units that
produce a square wave pattern instead of the normal sine wave, eliminating low-
voltage time after the zero crossings and minimizing the effects of the problem.
Duty cycle is a welding equipment specification which defines the number of
minutes, within a 10-minute period, during which a given arc welder can safely be
used. For example, an 80 A welder with a 60% duty cycle must be "rested" for at
least 4 minutes after 6 minutes of continuous welding. [6] Failure to observe duty
cycle limitations could damage the welder. Commercial- or professional-grade
welders typically have a 100% duty cycle

ADVANTAGES

Low cost intelligent robot

Portable in size and Easy transportable

Since the project is based on the electronics, it is compact and swift and
response.

No external devices are used here to control it.

The medium is air; the operation of the arm movement is fast.

DISADVANTAGES :

This system operated in pneumatics, so we need air tank or compressor

APPLICATIONS :

Industrial Application Medium scale painting industries.

NON CONSUMABLE ELECTRODE METHODS

Gas tungsten arc welding (GTAW), or tungsten/inert-gas (TIG) welding, is

a manual welding process that uses a non-consumable electrode made of tungsten,
an inert or semi-inert gas mixture, and a separate filler material. Especially useful
for welding thin materials, this method is characterized by a stable arc and high
quality welds, but it requires significant operator skill and can only be
accomplished at relatively low speeds. It can be used on nearly all weld able
metals, though it is most often applied to stainless steel and light metals. It is often
used when quality welds are extremely important, such as in bicycle, aircraft and
naval applications.

A related process, plasma arc welding, also uses a tungsten electrode but
uses plasma gas to make the arc. The arc is more concentrated than the GTAW arc,
making transverse control more critical and thus generally restricting the technique
to a mechanized process. Because of its stable current, the method can be used on a
wider range of material thicknesses than can the GTAW process and is much faster.
It can be applied to all of the same materials as GTAW except magnesium;
automated welding of stainless steel is one important application of the process. A
variation of the process is plasma cutting, an efficient steel cutting process. Other
arc welding processes include atomic hydrogen welding, carbon arc
welding, electro slag welding, electro gas welding, and stud arc welding.

A non-consumable tungsten rod is used as the electrode with inert gases

shielding both the molten metallic pool and the red hot filler wire tip. Argon or

helium gas is used for shielding purposes. Argon is preferred for a wide range of

materials, and as no flux is used, corrosion due to flux inclusions cannot occur.

Almost all metals can be welded using TIG process. Dissimilar metals can also be

welded by TIG choosing the appropriate combinations. These non-consumable

tungsten electrodes are alloyed with zirconium or thorium (around 1%). Zr alloyed

tungsten is used in alternating current applications and it has high resistance to

contamination and has got good arc starting characteristics. Thoriated Ti electrodes

have high emissivity, better current carrying capacity and longer life and normally

preferred in DC welding. Pure Ti electrodes are usually preferred for AC welding

of aluminium and magnesium. The current carrying capacity is lower than that of

alloyed electrodes. The current carrying capacity of the electrode depends on the

type of shielding gas, the length of electrode, the cooling of the holders, position of

the weld type etc. If the electrode is large for specified current, the arc will become
erratic and welding will be difficult. However, selection of smaller diameter rods

would increase the chances of electrode melting.

TIG welding of stainless steel, nickel and its alloys may be carried out with

argon and 5 per cent hydrogen. The hydrogen helps to increase the arc heating

efficiency and reduce the amount of oxides formed with stainless steel. In the case

of aluminium alloys a mixture of argon and helium can be used. TIG welding can

be done in almost all positions. Metal thickness ranging 1 to 6 mm is generally

joined by TIG process. TIG is often used for root pass in pressure components and

other critical applications, as it gives a clean and accurate weldment. In aerospace

work the welds are made totally by multipass TIG welding, owing to the high

quality demanded there. Aluminium alloys are generally welded by TIG welding.

Argon is the main shielding gas with some amount of helium. Preheating of

aluminium alloys is necessary when TIG process employs AC power supply. High

alloy steels, copper, magnesium, Ni, Ti and Zr alloys can be readily welded by TIG

with AC power source. Pure inert gas atmosphere must be ensured as some of these

alloys (Ti and Zr) are highly reactive. Gas tungsten arc welding produces the

highest quality welds most consistently. It can weld all metals in any

confirguration, but is not economically competitive on heavy sections. It is most

popular for welding aluminium and stainless steel pipe for nearly all process uses

and specially in cryogenics where fusion is very necessary. GTAW lends itself to
more precise because the arc heat and filler metal additions are controlled

independently. But the process is slow and the arc travel speed is 10cm/min and

metal deposition rate 1 kg/hr. The concentrated heat input of the TIG process helps

to increase the welding speed, minimise distortion and improve the metallurgical

quality of the weld. In TIG the shielding gas (argon, helium or their mixture) gets

ionised due to high frequency voltage superimposed on the welding current. The

electrons which become free during the process of ionisation form a conducting

path between the work piece and the tungsten electrode. Thus the arc can be started

without directly touching the tungsten electrode to the work piece. In the case of

DC power supply the high frequency voltage superimposition can be cut off once

the arc is struck. In AC power, the high frequency voltage superimposition will be

required continuously to improve the arc stability in addition to the filter capacitor

to be connected in series in the output circuit. The arc voltage may range from 10-

15 V with current 50-350 amps for argon and 15-25V with current 50-350 amps for

helium shielding gas. Tungsten has high resistance to heat and a high melting point

(3410C) and is a strong emitter of electrons which provide the arc path, ionize it,

facilitating the maintenance of a stable arc. Specifications of tungsten electrode are

given in AWS A 5.12-1980. TIG welding is better suited for metal thickness of 7

mm and below. DC from a constant current type power source is used with

electrode negative to deposit a narrow deep penetration weld. While welding the
electrode tip must not be allowed to come in contact with the molten puddle. For

initiating the arc high frequency starting must be used.

PULSED TIG WELDING

Pulsed TIG welding achieves a good control of heat input. The current from DC

power source is supplied in pulses having a predetermined duration for the

peakand low values.When the current is maintained at high on-position, welding

takes place with the required penetration. During the off-position, the torch is

manipulated to correct the positioning. The electrode is kept sufficiently hot and

the ionised column is also retained so that the arc is not extinguished. In this

process deep penetration is obtained with less heat input to the joint. The pulsed

arc agitates the molten weld metal and so minimises the porosity. Pulsing produces

arc stiffness and hence avoids arc wander. Molten weld pool can be well

manipulated and, successive solidification of the nuggets avoids cracking and

burn-through. Lesser heat input improves the grain structure and the mechanical

properties of the weld. There is no need for weaving because the pulsed current is

sufficient to melt the required base metal area. Since the molten metal deposited in

each pulse starts solidifying from the periphery towards the centre, the centre

portion becomes prone to defects like segregation and shrinkage cracks. Pulsed

TIG welding is suitable for the root run of the tube and pipe welding. Thin plates
and foils can be effectively welded by this process. While joining precision parts

by pulsed TIG, rapid current rise and current decay with a high pulse repetition rate

is used. In mechanised TIG, slower rates of current rise and fall and slower current

pulse rates are used. The advantages of pulsed TIG are (a) variation in joint fit-up

can be tolerated (b) welding of sheets down to 1 mm thickness can be carried out

(c) distortion is minimised (d) position welding made easy (e) operator requires

less skill (f) mechanisation is possible (g) ideal for critical applications like root

passes of pipes, joining dissimilar metals etc. Hot wire TIG Hot wire TIG welding

is similar to ordinary tungsten inert gas welding except that the filler wire is heated

prior to the deposition, either by resistance heating or by induction heating. A high

quality weld is obtained at a high deposition rate which is controlled by adjusting

the heating current of the wire. The dilution level is low in this welding process.

Since the wire is heated before entering the welding zone, the volatile surface

contaminants of the filler wire get evaporated, thus eliminating hydrogen,

porosities, etc.

Spot TIG

Spot TIG is a process adopted to spot welding. Argon shielding is used in this

process. The current can be supplied in pulses and by proper timing spot welds

with defect free nuggets can be obtained. Circumferential seam welding of pipes
and tubes is carried out by orbital TIG welding. Welding speed must be properly

adjusted to suit variations in weld position, such as vertical-up, flat, vertical-down

and overhead. Pulsed current is also used for orbital TIG.

SOURCES

[1] Cary, Howard B.; Helzer, Scott C. (2005), Modern Welding Technology,

Upper Saddle River, New Jersey: Pearson Education, ISBN 0-13-113029-3

[2] Kalpakjian, Serope; Schmid, Steven R. (2001), Manufacturing Engineering

and Technology, Prentice-Hall, ISBN 0-201-36131-0

[3] Lincoln Electric (1994), The Procedure Handbook of Arc Welding,

Cleveland, Ohio: Lincoln Electric, ISBN 99949-25-82-2

 [4] Weman, Klas (2003), Welding processes handbook, New York: CRC

Press, ISBN 0-8493-1773-8

ADVANTAGES

Low cost intelligent robot

Portable in size and Easy transportable

Since the project is based on the electronics, it is compact and swift and

response.

No external devices are used here to control it.

The medium is air; the operation of the arm movement is fast.

DISADVANTAGES

This system operated in pneumatics, so we need air tank or compressor.

 Overload should be avoided.

Feed should be given intermittently.

Not so effective for very hard materials.

APPLICATIONS

Automobile industries.

Medium scale painting industries.

Metal working.

Shipbuilding.

Fabrication.

Casting.
 COST ESTIMATION

AMOUNT IN
S.NO DESCRIPTION QTY MATERIAL
RS

Aluminum &
1 Pnumatic Cylinder 2 1900
SS

2 Solanoid Volve 2 Aluminum 1200

3 Welding Holder 1 Braze 800

4 Frame 5kg MS 600

Control Unit & Power

5 1 Sylika 3000
Supply
6 Labour Charge 2000
PHOTOGRAPHY
 CONCLUSION

Automated welding Positioner machine for circular weld is totally satisfying the
requirements. Developed Multi axis welding Positioner with auto indexing reduces
operator fatigue considerably. Because of this automation we achieved rise in
production. At the same time there is reduction in rejection which results increase
in the profit directly
 REFERENCES

[1] Anatoly P. Pashkevich 1 , Alexandre B. Dolgui2 , Kinematic Control of

A Robot-Positioner System for Arc Welding Application Industrial
Robotics: Programming, Simulation and Applicationl, ISBN 3-86611-
286-6, pp. 702, ARS/plV, Germany, December 2006

[2] Ahmad, S. & Luo, S. (1989).Coordinated motion control of multiple

robotic devices for welding and redundancy coordination through
constrained optimization in Cartesian space. IEEE Transactions on
Robotics and Automation, Vol. 5, No 4, (Aug. 1989), 409417.

[3] Bolmsjo, G. (1987). A kinematic description of a positioner and its

application in arc welding robots, In: Proc. of the 2nd Int. Conference on
Developments in Automated and Robotic Welding, pp. 77-84., Nov.
1987, London, UK.
[4] Kay Thwe 1, Gao Gao 1, 2, Naing Thiha Soe3 Current Welding
Technology in Myanmar [Journal of American Science 2010;6(1):99-
104]. (ISSN: 1545-1003).