Servo Weld Gun Calibration and Tip Dresser cutter examination.
0Brand new launch of this automated resistance weld assembly line in this factory producing parts for cars. Crash / impact resistant materials of hot stamped steel hardened solid as a rock!
(Well iron is ore and a rock so yes solid as a rock!)
During weld studies and set-up for good cycle times, parts per hour output and quality with sensors and other measures to ensure every part comes out the same and with equal good quality for the customer.
The automated tip dress is like a pencil sharpener. It shaves off copper of the copper weld electrode tip / cap. Each cap / tip is hollow to allow water cooling to effectively cool the copper during welding as it gets very hot from the current of electricity going through great resistance for fusion of mating two pieces of metal together bonded forever.
The angle of the robot on all planes X, Y and Z must be achieved just right at the cutter so that the cut is even and not too much material that after so many welds the tip is dirty with material build up we have weld schedules / programs / settings that tell the machine / controller / welder / robot / plc after so many welds go to the cutting process and clean the tip and shave some material off. However during the weld study you don't want to shave too much off that during the production shifts you don't shave so much of the material you spring a leak and have your cooling water spewing out flooding the place. We also though have water savers. Valves and pressure switches digital that read the water pressure and when there is too much release in pressure this would indicate there must be a water leak somewhere and the system will then send 24volts to the water saver valve shutting off the water just in time.
So basically I am doing the job of the Weld Engineer. I did all the study myself. While that guy said he had 20 years experience working directly for WTC. The company that built all the weld controllers we were using on this weld line. MEDAR teach pendants.
This line is with Lincoln inverters / welders for MIG, Lincoln flux core wire, WTC weld controllers for resistance welding with Centerline servo actuated weld guns. Centerline shanks and shunts and Luvata caps/tips. Keyence range finding / presence sensing. Change & Dresser Corp. automated tip dressers.
THIS IS THE NOW CLOSED MARTINREA FACILITY ON FRAZHO AND GROESBECK.
Quite a few places I have worked over the years closed down their doors. If only they would have listened to their skilled trades and people who are directly working with the fire you created. Listen. Let them help lead you in the direction to success.
Day one we had issues here with the GM telling false narratives like this is THE FERRARI of lines in production and manufacturing.
He was talking out of his ass. Joel Alton.
Go back to the south bro. This is Detroit.
These lines were fragile.
They bought non-calibrated tooling for quality checks such as Harbor Freight torque wrenches.
That's how cheap this line was built and maintained.
I would ask for higher quality up to par with the standards in pieces of equipment to make repairs on stuff that just should not have already failed within the first 90 days of operations in the launch.