Automatic Welding Fixture for Special Purpose Mechanism

Abstract

In recent times, manufacturing industries have increasingly prioritized automation to enhance efficiency and precision. This project focuses on designing a fixture for a rotary welding machine using a Special Purpose Machine (SPM) to improve accuracy and productivity in mass production. The fixture is specifically designed to secure components while performing rotary welding of a circular rod over a lever. Maintaining high accuracy in manual welding processes is challenging, particularly in mass production. This project addresses that challenge by introducing a new fixture design that ensures precise angular positioning and rotary movement, achieving an accuracy of 0.1 mm—all without the use of robotic automation. In the field of welding engineering, where high-quality, cost-effective production with maximum efficiency is crucial, this fixture-based approach offers a reliable, scalable, and economical alternative to robotic welding systems. The proposed design ensures consistent weld quality while reducing manual errors, making it an ideal solution for industrial welding applications.

Introduction

Welding is a key metal-joining process that melts base materials and uses filler to form strong joints, differing from soldering and brazing which do not melt the base metal. Traditional methods like forge welding have evolved into modern, automated systems using energy sources such as electric arcs, lasers, and friction.

In manufacturing, automation in welding enhances consistency, precision, and efficiency, which manual welding lacks. This project proposes a semi-automated rotary welding system with a special-purpose fixture designed to hold round rods and levers in place, rotate them precisely, and carry out accurate welds.

The system incorporates:

• Mechanical Design: Hardened materials, servo motor-driven rotary system, and rigid clamping.

• Sensor Integration: Position, rotational, and temperature sensors for precision and safety.

• Control System: PLC-based automation with HMI for monitoring.

• Safety Mechanisms: Auto-shutdown and overload protection.

Fabrication involves cutting, bending, and assembling metal, with CNC-controlled tools and human/automated input.

The project methodology covers problem identification, conceptual design, data gathering, CAD modeling, material selection, and performance testing.

Key Results:

• Weld accuracy improved to 0.1 mm (vs 0.5 mm manually).

• Cycle time reduced by 35%.

• Energy use lowered by 15%.

• Defects dropped from 8% to 2%.

• Operational setup time decreased by 40%.

Future Scope:

• Higher productivity through multi-tasking robots.

• More consistent and precise welds.

• Reduced material waste.

• Improved workplace safety by reducing human exposure.

Conclusion

An automated rotary welding system with a special-purpose fixture that improves accuracy, efficiency, and cost-effectiveness is successfully demonstrated in this study. The technology offers a flexible and scalable solution for industrial applications by preserving accuracy in large production without depending on robotic automation. Welding fixture activities enhance alignment procedures and expand knowledge of automated fixture mechanisms, while sensor-guided control and rotational synchronisation are combined to guarantee constant weld quality. Additionally, the fixture improves accuracy, boosts productivity, and shortens cycle time by reducing errors brought on by inadequate labour skills, making it an essential part of contemporary automated welding systems.

References

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Copyright

Copyright © 2025 Parth Janjal, Sahil Kutafale, Tejal Durge, Ranveer Patil, Sakshi Pedhekar, Aditya Mundada, Samiksha Patil. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.