3) How easy is it to weld in the fixture?
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After you have an idea of how to hold the parts where they will be, and you've checked that you can get the parts out, the next thing to review is how easy it will be to weld the parts. This means that you need to check that there is plenty of clearance around the joints to fit a welding torch AND you have a line of sight to see what you are welding. As you do this you might find out that you need to go back and revisit some of your ideas of how you were originally going to hold the parts. Depending on the welding process (MIG, TIG, Robotic, etc) the amount of clearance and line of sight you need will be different, but it's hard to make quality welds when you can't see what you are doing so this should be a high priority. Another consideration of how easy it is to weld is the position of the weld operator. You should do whatever is possible within reason to make the welder as comfortable as possible. This means that you might be making a rotating fixture, or placing it on an adjustable height table so that the welder can be in the optimum position as much as possible. They will thank you for designing an easy job for them, and you will thank them for producing quality welds.
This fixture allows the welder to sit in a chair and spin the part to always weld in the same position. Notice the use of toggle clamps to quickly remove parts after welding.
4) Can you make adjustments to the fixture?
Quality has two aspects: consistency and tolerance. If you chase tolerance you will have a hard time catching it consistently and that's not good for business. However, if you focus on consistency, getting and staying within tolerance is much easier to not just obtain, but also to maintain. I strongly recommend graphing your QC results so that you can get a visual representation of your consistency as shown on the example below. Hopefully your parts start out within tolerance, but you should plan for ways to adjust in case it doesn't.
As anyone that has ever welded knows, the parts don't like to stay where the started due to weld shrinkage. And to a large extent the fixture will help minimize the amount of deformation that you will see during welding. It is for this reason that you should design your fixture to hold the parts exactly where you want them to end up, BUT you should build in a way to adjust, and strive for consistency first. As you can see from the graph below, it took until the 10th unit to get a consistent dimension of these critical features because of small variations in the welding procedure from part to part. When focusing on being consistent, and graphing your results you will see when it is time to make an adjustment to your fixture. If you've done it right, it should be any easy fix, not a total replacement. On the project highlighted below, after part 15, we added a shim to our fixture assembly and you can see the 0.5mm change to bring our finished part to the middle of the tolerance. By focusing first on consistency and having a fixture that we could easily adjust allowed us to reduce the chances of having a failed part.
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You should focus on consistency before you focus on tolerance. It took this project 10 parts to get consistent. After consistent geometry was obtained a small change in the fixture was made at number 16 to move the geometry closer to the center of the tolerance.
Understanding the different types of welding fixtures and positioners is crucial to optimize the performance of your robotic welding system. The choice depends on the complexity of the workpieces, the precision required, the volume of production, and the level of automation needed in your operations.
Let's delve into the specifics of each type to help you make an informed decision.
Layout templates/jigs are simple, cost-effective solutions where the operator manually places and secures the workpiece in the fixture. They are typically used for simple weldments and low-volume production where high precision may not be a priority. However, these fixtures may not be suitable for complex weldments or high-volume production due to the potential for human error and slower processing times.
Semi-automatic fixtures are a step up from manual fixtures. These fixtures often include some level of automation to accurately position the workpiece. They can include features such as pneumatic clamps and automated sliders to speed up the process and reduce the scope for manual error, making them ideal for medium-volume production.
Fully automatic fixtures are designed for high-volume production where efficiency and precision are paramount. These fixtures automatically position and secure the workpiece, eliminating the need for manual intervention. They integrate seamlessly with the robot and often include sensors to verify correct positioning before welding begins.
Single-axis positioners manipulate the workpiece around one rotational axis. They are ideal for workpieces that require welds in a circular pattern or along a curved path. By rotating the workpiece, these positioners ensure the welding robot always has optimal access to the weld joint.
Multi-axis positioners offer more complex manipulation of the workpiece, rotating and tilting along two or more axes. This ability allows them to optimally position even the most intricate workpieces for the robot to weld. They are best suited for complex weldments requiring welds at multiple angles and positions.
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