Automated seam welder???

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Good morning, I need an automated seam welder that can weld stainless boxes. There are (4) 2" welds on each box. I understand I'll need fixtures, etc, but don't know where to turn to have a machine spec'd out. Any ideas? Thx...CMP
Reply:Hmmm. this is your first posting.  I can see lots of questions that need to be answered before anyone will respond to you.Do you really need an "automated seam welder"?  How many boxes are you making?  (say more or less than 100,000/ year?)   If you just need a few parts, hire an experienced welder / shop to TIG the thing together and be done with it..What kind of precision do you require?  How pretty do the welds have to look?Will alternative methods work?  (spot weld, rivets, screws, crimp/seam)Why must the material be stainless steel?  What does the rest of the part look like (other attachments, other functions, painting required?  would a high tech plastic make more sense in the application?)Does the seam have to seal liquid? seal air pressure?Whats the driver here? (quality? Cost up front?  total cost for the entire duration of the project?)Why not operator welded?  Safety issue?  Cost? Consistency of weld quality?If money was no constraint, I'd be talking robot controlled MIG. If money was tight and the volume was big I'd use a custom machine with turntable, and a four bar link controlling a MIG gun.  Its only a two inch weld, right? Are you sure you wouldn't be better off jobbing this one out?What goal are you trying to achieve? (oh.. and if its not obvious.. I'm an automotive engineer, been doing this for a LONG time... )If you really want more info.. send me a sketch of your application via private message system.  I'm pretty good at estimating manufacturing costs of parts, at least in the automotive arena...  I will sign non-disclosure agreement.  --zip
Reply:Hmmm. this is your first posting.  I can see lots of questions that need to be answered before anyone will respond to you.Do you really need an "automated seam welder"? -Yeah, I think I do.How many boxes are you making?  (say more or less than 100,000/ year?)   If you just need a few parts, hire an experienced welder / shop to TIG the thing together and be done with it.-We currently employ 7 qualified welders and around 10K parts per year. I feel I'm wasting their time and talent on this part-they hate it as it is highly repetetive and requires post-welding grinding and polishing as it's a cosmetic part whcih answers a subsequent questionWill alternative methods work?  (spot weld, rivets, screws, crimp/seam)-Nope, been there, done that-they want what they want. Cosmetic, medical equipmentWhy must the material be stainless steel?  -See aboveWhat does the rest of the part look like (other attachments, other functions, painting required?  would a high tech plastic make more sense in the application?)-Nope-lab environment, must be as designed-mature design.Does the seam have to seal liquid? seal air pressure?-Liquids, causticWhats the driver here? (quality? Cost up front?  total cost for the entire duration of the project?)As above, I'd rather fixture and automate this process so my welders can work on more intricate parts. I'd also like to put a lower cost operator in front of a machine and acheive less post-weld operation to get a cosmetic part. I was in Germany last week and saw a custom machine that did exactly what I wanted. Unfortunately, the owner of the company told me that that particular mfr was no longer in biz. Bottom line was that he was getting exactly what I want,;a super-clean weld, requiring little or no post-weld work, operated by someone who needs to know very little; so I know it's out there somewhere, even if it's custom. Why not operator welded?  Safety issue?  Cost? Consistency of weld quality?-See aboveIf money was no constraint, I'd be talking robot controlled MIG. -Looking at those as well.If money was tight and the volume was big I'd use a custom machine with turntable, and a four bar link controlling a MIG gun.  Its only a two inch weld, right?-That's pretty much what I saw in Germany-to whom do I speak to make something like that.Are you sure you wouldn't be better off jobbing this one out?-Nope, not in the cards-we must control all processes from start to finish.What goal are you trying to achieve? -Get this off my welders bench and onto a process that can be run more efficiently with less post-weld grinding/polishing.Thanks for your help...CMP
Reply:Seems to me you clarified things quite well.Maybe a call to one of the welding manufacturer's?  I think I would start there & have them come out & see exactly what you need.  I bet they could build you one or at least point you in the right direction.Let us know what you decided.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:CMP have you tryed a google search? (automated welders)a few listed --try,www.amertinc.com   or www.weldlogic.comlots of other to look at .. not knowing any budget or spec you really need will be tuff to suggest one machineidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:Thx guys, I started that search/contact process Monday am, have had several responses and am working thru them. I was hoping I'd catch lightning in a bottle and hit someone here who has been there, done that! Will keep pluggin away...CMP
Reply:CMP, Thanks for your response to my questions.  Apologies for the 'tone' of my questions... it frustrating for folks to have specifics in mind then ask a really general question that nobody could possibly answer.  By the way, where are you located?  Best practice is to include your location on your profile.  How much time you got on a resolution?  Here's an idea.  Drive over to your local college.  Ask to speak to the director of engineering studies.  Tell them you have a great idea for a mechanical engineering class project.  You will pay for all materials, $1000 donation to the school upon completion.  Pizza party, tee shirts for the class at completion again, on your dime.  If not in the cards for a class project, ask for a sharp student who is interested in working as an intern for a period of time to work on such a project.  This would be an excellent project for an engineering college student.Look for rotary table with control, MIG weld gun on four bar / six bar / liner slider with stepper or encoder/motor to control motion of the MIG gun in a single axis of movement.   Motor Controller via old computer with parallel output (or arduino controller.)  Assuming hand load / unload to rotary table safety interlocks required.Not sure how you are going to approach post weld cleanup.  Goal would be none required, but who knows how well that can work.It'd be a fun project.  This would really make sense is if you think you have other potential projects in your facility that will work with future classes.  Create a good relationship with folks that can help you in the long run.  Let us know.  Oh.. and I'm trying to ask my sheet metal buddies at work who do this thing all the time, if they can recommend a supplier of such tooling..  nobody is answering their phones right now.  We're all busy, sigh.good luck, zip
Reply:In the Northeast Zip and I love the engineering idea. I actually used to lecture at our state univ to 1st year engineering students as to the applicability of their mech. eng degrees so I will call that contact. So far few have showed me anything useful, but the Lincoln rep says he might have some solutions. Keep the ideas flowing...CMP
Reply:A robot with a laser and a cold wire feeder may be a good fit for you.
Reply:I see a Weldlogic CWT-12-21 Welding Lathe for sale on Ebay.  Item number: 360395512117   Includes 300amp miller welder with autolink, etc... (Can you autogeneous TIG this product?) When I look at all the items currently for sale from that vendor, things seem MUCH higher than Craigslist prices.  I've been watching used vertical mill prices pretty closely.  I'd probably offer the guy 50% of his asking price on the Weldlogic stuff listed above, use that stuff as the basis to build your own custom stainless steel box welding machine.  Even at 50% of asking these prices are pretty expensive.zip.
Reply:Originally Posted by CMPGood morning, I need an automated seam welder that can weld stainless boxes. There are (4) 2" welds on each box. I understand I'll need fixtures, etc, but don't know where to turn to have a machine spec'd out. Any ideas? Thx...CMP