Scope of work,
To provide detailed engineering and design drawings for proposed automatic welding unit used in the assembly of cable ladders.
The parts to be welded (referred to as cable ladder/s) consisting of 2 longitudinal side rails, in either 3.0 metre of 6.0 metre lengths, placed parallel to one another, and connected via transverse ‘rung section’ in 4 different width options, 150mm, 300mm 450mm & 600mm. These rungs are positioned at 333mm centres. This equals 9 transverse rungs for the 3.0 metre lengths, and 18 transverse rungs for the 6.0 metre lengths.
The side rail sections vary in height from 75mm up to 150mm and have horizontal flanges that vary in width from 13mm up to 32mm, however the material thickness only ranges from 1.2mm to 1.6mm. Indicative drawings have been provided for all cable ladders, except for the 150mm high side rail section (to be supplied later)
The design focus should be centred around simplicity and the use of mechanical processes combined with pneumatics as opposed to robotic engineering.
With this scope in mind, a thought is to have the welding torches mounted in fixed positions that travel vertically to weld the rungs to the rails, then release (transversely) after each cycle via pneumatic cylinders, the welding jig them moves horizontally to the next weld position.
This is just an idea, and not prescriptive, the designing engineer is free to provide the best and most practical solution to ensure an economical build cost for the actual weld unit, as well as the most basic design so that parts are not subject to excessive wear, technical obsolescence and can be easily replaced with spares parts.
Components for the welding jig and sprockets required for indexing (movement) can be of any practical design, because assuming these will be made of some form of steel, all can be easily made. Where electric motors or pneumatic cylinders are required, reference should only be made to the actual size / technical requirement.
A very basic concept drawing has been included to give a brief understanding of what is required, however this should be viewed as nothing more than broadly indicative of the concept.
Your quotation for this project should be inclusive of all engineering data and detailed design drawings suitable for manufacturing purposes, as well as animated file to show exact working model.
To be considered for this work, you must be able to demonstrate previous experience in similar engineering solutions, including welding jigs / fixtures.