Solutions Through Welding Technology

NBC-9613 Actuating Rod/Pusher Rod Projection Welder

Application:

This machine automatically welds actuating rods, engine push rods or similar assemblies with balls or cups projection welded onto either or both ends of a rod. Various rod lengths and diameters and ball diameters can be incorporated into the same machine within practical design limits. Materials can be any weldable grade of steel or stainless steel. Overall length tolerance can be controlled up to +/- 0.1 mm (+/- .004") @ 1.67 CPK. Concentricity of ball to shaft can be held within 0.16 mm T.I.R. (.006") @ 1.67 CPK. Weld strength with solid balls and shapes is equal to or greater than yield strength of shaft.

Production: Using available tempering cycle, maximizing weld strength, results in rate 450 parts per hour. Without the tempering cycle, a production rate of up to 900 parts per hour can be achieved.

Typical Sequence of Operations:

Automatic bulk feeding of rods and balls
Operational automatic gauging of rod length prior to welding.
Projection weld balls onto rod at ends.
Optional Tempering Cycle.
Automatic unload of welded parts.
Auto inspection of finished length.
Automatic segregation of reject parts.

This NEWCOR Projection Weld Machine welds actuating rods, using 10mm to 12mm balls with 25mm - 35mm rod length.

Standard Design Features:

Automatic Ball Feeders: Solid balls are automatically blow fed into welder tooling. Feed system includes quick part dump with tooling changeover for different ball diameters. Balls with holes or cups are vibratory fed and oriented into the welder tooling. A four (4) hour capacity of parts is standard. Solid balls are automatically blow fed into welder tooling. Feed system includes quick part dump with tooling changeover for different ball diameters. Balls with holes or cups are vibratory fed and oriented into the welder tooling. A four (4) hour capacity of parts is standard.

Automatic Rod Feeders: Rods are vibratory fed or hopper fed, depending on rod length. The feeder features a quick dump capability for changeover of parts. A one to four (4) hour capacity of parts is standard depending on rod size. Rods are vibratory fed or hopper fed, depending on rod length. The feeder features a quick dump capability for changeover of parts. A one to four (4) hour capacity of parts is standard depending on rod size.

Dual In-line Precision Air-Actuated Weld Rams: Internally water-cooled, class #2 copper electrode holders, with internal vacuum system, secure the balls. Weld ram uses pneumatic cylinders with instrument type precision regulators. Screw type X-Y adjustment on each weld ram provide accurate positioning of balls to rod. Internally water-cooled, class #2 copper electrode holders, with internal vacuum system, secure the balls. Weld ram uses pneumatic cylinders with instrument type precision regulators. Screw type X-Y adjustment on each weld ram provide accurate positioning of balls to rod.

Automatic Rod Placer: Self-centering rod grippers automatically transfer rod from feeder escapement and place into rod electrode clamp. Self-centering rod grippers automatically transfer rod from feeder escapement and place into rod electrode clamp.

Standard Machine Layout.

Welded Assemblies before and after Tensile Test.

Part Changeover:

Basic sequence:

Quick dump of feeders for rod and balls.
Manually change electrodes for rod and ball.
Select new weld schedule.
Recalibrate with master rod.
Audit initial part run.

Part changeover for different part numbers may require change of rod, ball or both.

Optional Equipment:

Weld Checker: Integrated weld checker verifies parameters for each cycle. Out-of-tolerance condition results in automatic part rejection. If a part is found out of range, it is automatically separated from the good part stream and unload from the welder. Consecutive faults result in cycle interruption. Integrated weld checker verifies parameters for each cycle. Out-of-tolerance condition results in automatic part rejection. If a part is found out of range, it is automatically separated from the good part stream and unload from the welder. Consecutive faults result in cycle interruption.

Rod Length Checker: In-line check of part length is automatic. A out of tolerance part is automatically rejected and a new rod is fed in its place. In-line check of part length is automatic. A out of tolerance part is automatically rejected and a new rod is fed in its place.

Chiller System: Closed loop cooling water system is self contained within the machine, controlling temperature for welding and tempering cycles to provide a stable process and increase tool life. Additional benefit of the closed loop water system is elimination of plant water impurities. Closed loop cooling water system is self contained within the machine, controlling temperature for welding and tempering cycles to provide a stable process and increase tool life. Additional benefit of the closed loop water system is elimination of plant water impurities.