Design and Development of an Automated Metal Inert Gas/ Metal Active Gas Welding Machine

Abstract

Automated welding is the most preferred welding technique when it comes to construction of welding sheet metal of various thickness.The MAG welding machine has a relay switch to control ON/OFF operation of welding torch. The essential feature of the process is the small diameter electrode wire, which is fed continuously into the arc from a roller of wire which installed on welding machine . The base metal used for welding is carbon steel. The Methodology which was used prior to the automated system included Welding which was done by means of hand held Welding guns. This method had less accuracy and precision as compared to the automated system of weld ing. The process consumes more operating time and it requires large no of workers for production as increase in man power directly effects on produc tion rate and production cost as well as profit margin. Also, the production processes like welding technique which was implemented had safety issues. The automated method was proposed to getting high welding quality and accuracy ,in addition increase the productivity of welding and safety worker. Through this project, the focus is to completely eliminate human contact dur ing welding which will no doubt be safer but will also be more efficient. The machine is used to weld work pieces in flat position since higher deposition rates are achieved in this position and is a convenient approach. The machine system will be able to implemented any contour in 2D profile that is gener ated over a program user interface (CAD). Electronic devices such as stepper motors and driver board are interfaced with break out board. The break out board PMDX-122-1200 is used to signal the stepper motors to rotate while deciphering the G-code. In this project, the emphasis is given on design calculation and structural analysis. the design model implemented by using solid work software and analyzed the design by using ansys software. Setup makes use of four stepper motors of 5.4 N.m capacity for efficient movements in three axes. After fabrication and testing for Automatic welding machine for small scale to large scale industries are optimized the cost. In addition to that the quality of the weld is also quite paramount therefore using an technique for automatic welding and Industrial implementation of Automation improves productivity as well as profit margin per component. This project efficiently helps to fully automate the process of Welding. The project will provides the practical description of the components implemented in the control system along with the flow of working of various components.