Automatic Welding System for Shelf Assembly

A customer contracted Banner Welder to design and manufacture an automatic welding system to fabricate a shelf assembly. This assembly is used within an appliance application. The approach we developed consisted of 2 distinct spot welding stations, an in-feed conveyor, and an exit conveyor. The semi-automatic resistance welding system would utilize two operators, to load and unload the unit at different points of fabrication. Station 1 was outfitted with 4 weld guns, an in-fed conveyor, crowding mechanism, pick and place, and pre stage nest. A servo driven belt transfer moves the part to station #2 for the finishing welding. Station 2 features 12 weld guns, with positions controlled by servo drive. Operator protection was provided for with an integrated light curtain, Opto-Touch switch, and circuit breaker. An advanced Allen-Bradley CompacLogix PLC control and PanelView 1000 with pushbutton and touch screen capabilities control the system.

The shelf assembly is constructed from stainless and galvanized steels, meeting a tight +/- .030” tolerance. Overall part dimensions are 29” x 35” x 47”, with 1 to 5 hat sections possible. Cycle time based on a 3 hat section is 20 seconds, with a 5 minute changeover time between styles. Turnaround time for this multi cell welding system was 28 weeks, supplied to the customer in Southeast United States. For more information about this custom automatic welding system or the other capabilities available at Banner please see the table below or contact us directly.

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Automatic Welding System Case Study Highlights

Case Study Name
Shelf Assembly
Case Study Description
This shelf assembly is used within an appliance application.
Capabilities Applied/Processes
Spot Welding
Auto Feeding Brackets & Hat Sections
Equipment Used to Manufacture Part
Semi-automatic Resistance Welding Line
Servo Transfer
Overall Part Dimensions
29" x 35" x 47" (note 1 hat or up to 5 hats section)
Tightest Tolerances
+/- .030"
Material Used
Stainless/Galvanized Steel
Material Finish
In Process Testing/Inspection Performed
Industry for Use

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