Mechanic and pneumatic Design of a welding device for automated laser welding in a laser welding

machine

The fixture device for Welding / welding device consists of 2 parts, that has to be designed:

• Fixture device for positioning the parts with pneumatic clamps

• The turning base table

We need a complete design in Solidworks and aslo a Bill of Material for all standard parts. We also
need a documentation (Drawings, pneumatic schematics). After your job we just want to
manufacture the parts an assemble them. The construction must be robust, cost effective. We will
weld approx. 500.000 pcs on the device.

Fixture Device:
The divice has to clamp 3 Parts. The main housing and on every side a reinforcing bracket. The
centering/positioning of the parts to each other has to be done by the use oft he holes that are in
both parts.

The position o f the welding lines can be seen on the reinforcing brakets. They are created as slotted
holes in the 3D model. The fixture device should cover most oft he part that is next to the welding
seams to prevent any demage by weld splatters.

It is also necessary that the parts next tot he welding seams are designed cost effective and easy to
change. We think that those parts have tob e replayced time by time. The parts close to the welding
seams has tobe made out of copper. The cheapest/best way would be if we have some sheetmetall
copper parts (thickness 2mm) with holest o screw on to the clamps and device.

The force that we need to push the the brakets and to the housing is about 1500N

In out test fixture device we opened the claps and closed the claps a several time to make sure that
the bracket will move into the corner oft he housing.

Turning base Table:

In the production we want to use two fixture devices in exchange. One is in the machine for welding
the other one will be outside the machine and gets unloaded and reloaded. To manage this we need
a rotary table.

The Distance between the fixtures on the table should be 1000mm

In the middle we need a fixed(not turning) safty wall with small openings where the fixtures can go
through the wall.

We think the easyiest way to drive/turn the table ist o use pneumatic.

The Distance between floor and fixture should be 1000mm

Example:
 This showes an example of such a turning table. But this one is not mobile. It has a fixed
stand and also the wall is turning. We want a mobile solution on wheels with the posibility to
fix tot he ground. Please design also fixtures fort he ground and a centering solution fort he
mobile turning table.

- The Safety oft he table should be realiced by two-hand operation.

Milestones:

- Sketches Design Idea - Draft - So that we can see what your main approach is. 500€
- Construction Data in SolidWorks 2020 - 1500€
- Bill of material 1000€
o All pneumatic parts Festo/SMC oder Misumi.com Artikelnummer
o All standard parts (bearing, screws,….) EU/German DIN ISO parts
- Drawing for manufacturing 2000€
- Exploded views for Assembly

Exemplary welding devices.

Our test device: