June 12, 2017

Laser Welder

Machine No. 6375

This machine is used to weld the Can to the Header S/A after final powder load and consolidation.  The complete Igniter assemblies come from the Output Powder Loader in plastic tubes, or linear vibratory feeder from the powder loader. The machine is built around a 16 station cam driven index table. The Igniter S/A’s tubes are manually loaded into a tube unloader and the Igniter S/A’s are automatically unloaded from the tubes into a vibratory inline feeder and then loaded with the pins facing up into the index table fixtures by a parts placer. The part nest is simply a hole that the Igniter S/A is loaded into simultaneously. At the weld station, the Igniter is lifted up slightly in the nest by the bottom spindle and the top spindle comes down and clamps with whatever force is necessary to be sure the Header S/A is properly seated in the Can. 

A stepper motor then accelerates the upper and lower spindles up to 60 RPM.  The Laser Welder is fired and then the spindle rotates 400 degrees before shutting off the Laser Welder.  After decelerating to a stop, the part is unclamped and progressed to the next station by the index table.
Good parts and bad parts are unloaded at the same station and are sorted into plastic jars by multi-position parts placer that moves over a system of drop tubes.

CONTROLS – The control system uses an Allen Bradley PLC5  running a ladder logic program to control the real time sequencing of the machine.  Operator interface, data logging and any other interface to high-level devices are provided by a custom Microsoft Visual Basic program running on an Intel-powered PC using Windows NT Workstation 4.0 as the operating system.  The control system provides the following standard features as well as many others:
· Machine Status display and messages for any machine fault stops.
· Storing, loading, and editing operational parameters, by customer part number.
· Operational Mode selection.
· Production data accumulation by Year, Week, Day, Hour and Lot.
· Manual control of each output and status monitoring for each input for every station.

CYCLE RATE – 24 PPM