International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN(P): 2249-6890; ISSN(E): 2249-8001 Vol. 6, Issue 4, Aug 2016, 9-24 © TJPRC Pvt. Ltd DESIGN AND ANALYSIS OF WIRELESS WELDING ARM VIPUL M VASAVA 1 & PARTH B PRAJAPATI 2 1Assistant Professor, Department of Mechanical Engineering, Ipcowala Institute of Engineering & Technology, Dharmaj, Gujarat, India 2Research Scholar, Department of Mechanical Engineering, Ipcowala Institute of Engineering & Technology, Dharmaj, Gujarat, India ABSTRACT Now a day in this fast growing industrial age every company needs speed in manufacturing to cope up with the customer’s requirements. Every industrialist cannot afford to transform his unit from manual to semi automatic or fully automatic as automation is not that cheap in India. The basic objective of this project is to design low cost Wireless welding arm which can be utilized in any industry for welding purpose. This Wireless welding arm is requiring 3 axial programming and controller. Wireless welding arm can be used in welding process by controller and the structure is designed in such a way that it is Wireless for welding process. Flexile welding arm would be used mainly where May human is not able to work. Example,Under water and underground welding. Robots play a vital role in all the activities Original Article Article Original in human life including industrial needs. In modern industrial manufacturing process consists of precise and fastest proceedings. Human operations are needed to perform a variety of tasks in a robotic system such as set-up, programming, trouble shooting, maintenance and error handling activities KEYWORDS: History of Welding, Recent Problems in Welding, Problem Specifiacation, Design Calculations, Robot Dynamics Creo Model, Analysis Received: Jun 19, 2016; Accepted: Jul 01, 2016; Published: Jul 13, 2016; Paper Id.: IJMPERDAUG20162 INTRODUCTION The history of industrial automation is characterized by periods of rapid change inpopular methods. Either as a cause or, perhaps, an effect, such periods of change in automation techniques seem closely tied to world economics. Use of the industrial robot, which became identifiable as a unique device in the 1960s, along with computer-aided design (CAD) systems and computer-aided manufacturing (CAM)systems, characterizes the latest trends in the automation of the manufacturing process. These technologies are leading industrial automation through another transition, the scope of which is still unknown. A major reason for the growth in the use of industrial robots is their declining cost robot prices dropped while human labour costs increased. Also, robots are not just getting cheaper, they are becoming more effective—faster, more accurate, more Wireless. If we factor these quality adjustments into the numbers, the cost of using robots is dropping even faster than their price tag is. As robot become more cost effective at their jobs, and as human labour continues to become more expensive, more and more industrial jobs become candidates for robotic automation.Modern industrial robot controls are build as multi-processor controls due to the multitude of parallel calculations and control functions. Figure shows the internal structure of such a control. Individual assemblies which are designed for special jobs and equipped with an own micro-processor are linked with the host computer via the system bus. The host controls and coordinates the actions of the components based on the operating system and the robot program. Examples of such www.tjprc.org [email protected] 10 Vipul M Vasava & Parth B Prajapati assemblies, which are mostly installed on individual printed boards, are e.g. the axes computers. They are responsible for calculation of movement and for control of power unitsper axisare available which control speed and position of each axis. Figure 1: Industrial Robot Control A Robot welding is a specific new application of robotics, although robots were first introduced into US industry during the 1960s.The use of robots in welding did not take off until the 1980s, when the automobile industry began to use robots for spot welding. Since then, both the number of robots used in industry and the number of their applications has grown greatly. Till 2005, more than 120,000semi or fully automated robots were in use in North American industry, about half of them for welding. Growth is initially limited by high equipment costs, and the resulting restriction to high- production applications. In 2014, FANUC America Corp. introduced a low cost arc welding robot which proved beneficial for small manufacturers with a cost-effective robotic arc welding solution. Robot arc welding has started growing quickly just recently, and already it holds about 20% of industrial robot applications. The major components that constitute the arc welding robots are the manipulator or the mechanical unit and the controller, which acts as the robot's “Brain”. Manipulator used to move the robot, and the design of these robots can be categorized into few common types, as SCARA and Cartesian coordinate robot, which uses different coordinate systems to direct the arms of the machine. The robot is able to weld a pre-programmed position, guided by machine vision, or by a combination of the two methods. Vast benefits of robotic welding makes it importance such that industries accept it to make it a technology that helps many original equipment manufacturers increase accuracy, repeat-ability, and throughput The technology of signature image processing has been developed since the late 1990s for analyzing Electrical data in real time collected from automated, robotic welding, thus enabling the optimization of welds. The robot parts as shown in the figure below. Impact Factor (JCC): 5.7294 NAAS Rating: 2.45 Design and Analysis of Wireless Welding Arm 11 Figure 2: Robot Parts Recent Problems in Welding Modern manufacturing era faces two main challenges: improved quality at lower price and the need to improve productivity. These are the vital requirements to keep manufacturing plants in developed countries. Other very important characteristics of the manufacturing systems to survive the market are flexibility and agility of the manufacturing process, since companies are required to deal with a very fast growing market involving products having very short life-cycles due to worldwide competition. Consequently, manufacturing companies are needed to respond to market requirements efficiently, keeping their products competitive. This requires a very efficient and controlled manufacturing process, where option is automation, computers and software. a huge number of products require welding operations in their assembly processes. The welding process is Complex, difficult to parameterize and to monitor and control effectively. We have visiting a workshop of an industry and observe that it is difficult task for welder to welding a job or two metals. It should more take care during welding. It is also dangerous to welding while it affects eyes and also breathing problems in that environment. Sometimes due to shake hands of worker during welding it can't weld perfectly and it may occur imperfections in welding and it results into failure. In those cases it is very useful to done welding by a robot. This is the reasons why we are using a welding robot which is as follows: • Manganese in Welding Fumes Biggest on–the–job risk is open contact to the manganese contained in fumes that are produced during welding. Manganese is able to cause very serious damage to the brain and nervous system. Many workers who are in direct contact with welding fumes suffer from Parkinson’s disease, a major problem affecting movement and balance. They tend to develop “Manganese,” a disease closely related to Parkinson’s that also makes it difficult to walk and move properly. Both manganese and Parkinson’s disease cause tremors, shaking, and loss of muscle control. These conditions can become more severe as time passes. • Other Harmful Metals in Welding Fumes When the welding rod used is either base metal iron or mild steel, iron oxide may be produced in the welding fumes in addition to manganese. Breathing in iron oxide can damage nasal passages, throat, and lungs. Working with stainless steel produces fumes having nickel and chromium and caused to face problems like asthma. Nickel can make illness worse. www.tjprc.org [email protected] 12 Vipul M Vasava & Parth B Prajapati • Hazardous Coatings Welding on some plated or painted metals may be especially hazardous. If cutting a metal that has been coated with paint which contains lead, it may produce welding fumes having lead oxide. Inhaling these welding fumes can cause lead poisoning, a condition in which worker becomes weak and develop anemia (a low red blood cell count). Lead also harms your nervous system, kidneys, and reproductive system • Heat, Light, and Mechanical Injuries Arc welding uses ultraviolet light. If welding is carried out near solvents containing chlorinated hydrocarbons, the ultraviolet light can react with the solvents to form phosgene gas, which is deadly in even small amounts. Spécifications Weld penetration is the distance that the fusion line fills the weld metal below the surface of the material being welded. Incomplete root fusion is defined as the weld material fails to fuse one side of the joint in the gap. Incomplete root penetration arises when both sides root region of the joints are prepared with typical imperfection. An Excessively Thick Root Face in a Butt Weld Too Small A Root Gap Misplaced Weld Power Supply Too Low Arc Input too Low Figure 3: Specification Material/Tool Required There is number of choices are available for to selecting the building materials for Wireless ram. But not every material is a good choice. There are some materials or tools which are as follows: • CAD Software Impact Factor (JCC): 5.7294 NAAS Rating: 2.45 Design and Analysis of Wireless Welding Arm 13 • Thin sheet metal • Cardboard • Sheet metal • Steel Robot Dynamics This will gives a brief idea about Design of Wireless arm including parameters used in design.