ABSTRACT
Robots are part of our mechanical industry everywhere automation is transforming the industrial face. This project is an attempt to improve the cycle time of available automated welding robot in production line. The main aim of the project is to reduce the cost and increase the productivity on a particular production line by studying and analyzing based on various production parameters. Welding robot we are working with is Panasonic Tawers G2 1400.Part we are working with is UCA(Upper Control Arm). Its a part of front axle, used in automobiles. Presently the robotic arm uses excess number of aerial points and tiching points. This leads to increase in the cycle time of the welding process which is useless. By studying the command monitor and analyzing the live welding process, improvement can be done in the welding process. After reducing cycle time we faced problem of line balancing. Welding is joining process where heat is involved so even cooling is also necessary to avoid distortion in part. This problem is addressed by increasing electrode wire diameter from 1.2mm to 1.6mm. Initial results solves the problem of line balancing and also welding consumable weight per part is reduced without compromising strength of component.1.6 mm electrode wire is under validation.
In coming months we are trying the same methods to optimize at two more workstation which currently manufactures LCA Lower Control Arm(RH and LH).
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