More pics from work

[Rob Garner]

Well, it's been a while since I posted any pics from work.


First up: Robotic welder fixture positioners.

Material: 3/4" and 1 1/4" hot rolled plate, 4"i.d x 1/2" wall and 3 7/8"o.d x 1/2 wall d.o.m tube.

miller-matic456p
.045 er70s-6
stargon
500 i.p.m
33volts


pics 1 and 2: rough layout and surface prep
pic 3: setting the tube
pics 4 and 5: setting gussets and center web


continued next post:

[Rob Garner]

pic 6: assy. of top half.
pics 7 and 8: welding complete
pic 9: brazed copper ground lug
pic 10: fabrication complete

continued:

[Rob Garner]

pics 11-13: compleated assy.

[Rob Garner]

Next-up: trunnion roller bases for steam jacketed rotary grain dryers.

I normally build 6 of these at a time. 3 intake and 3 discharge.

pics 1and 2: drilling and tapping the end plates for 3/4 dowels and 3/4-10 bolts.
pics 3-5:coping the center piece of I-beam

cont.

[Rob Garner]

pics 6-8: setting main beams.
pics 9-10: leveling tops of beams.

cont.

[Rob Garner]

pic 11: attaching end plate.
pic 12: adding gussets.
pic 13: adding bearing mounting plates (this completes the intake bases)
pic 14 and 15: (continuing on for discharge bases) adding center cross beam and gussets.

cont.

[Rob Garner]

welding completed:

[Rob Garner]

Assembly:

[Rob Garner]

Finally, this is what the finished product is used for.

[Rob Garner]

Misc. stuff.
Sorry guys, with most of the stuff I do I can't use a dime for size comparison, I have to use a nickle or a quarter. :D

[chopper5]

very nice work:drinkup:,must be nice to make stuff like that

[Tractapac]

That looks like heavy stuff. Nice flow of work and processes there, shown nicely by the photos. One question Rob, what's the welding process? (I'm not being critical, it's just the welds have a different appearance from what I was expecting and appear to have a slight jerkiness to them. In saying that, they're still very consistent and uniform, I was wondering if it was a characteristic of the process or the rods? And I'm not trying to make you grumpy)

[Scott Young]

he is using mig. the bead profile reflects the wire manipulation. he has some beautiful work.

[Mandau]

I know that is precision work...:)

[Rob Garner]

very nice work:drinkup:,must be nice to make stuff like that

Thank you, I really enjoy building the larger stuff.

That looks like heavy stuff. Nice flow of work and processes there, shown nicely by the photos. One question Rob, what's the welding process? (I'm not being critical, it's just the welds have a different appearance from what I was expecting and appear to have a slight jerkiness to them. In saying that, they're still very consistent and uniform, I was wondering if it was a characteristic of the process or the rods? And I'm not trying to make you grumpy)

Thank you. It is mig as said below. I use a "forward and back" motion on most of the stuff I build. It just depends on the job, customer specs. etc. See video below. You can see my hand motion.

he is using mig. the bead profile reflects the wire manipulation. he has some beautiful work.



I know that is precision work...:)

Thank you both.


http://i159.photobucket.com/albums/t150/robg_010/th_powerpositionerlongweld.jpg (http://s159.photobucket.com/albums/t150/robg_010/?action=view&current=powerpositionerlongweld.flv)


I thought this was a neat pic. It shows how hot the water cooled lead gets after running a few of those long beads in succession. The smoke is comming off of the lead.

[Rob Garner]

Here are some more misc. pics.

pics 1 and 2: machining done
pic. 3: fitting deck plate
pics 4 and 5: assy. complete

[Mandau]

One more thing Rob... in the first pic... how thick and the surface diamension of the table? You scrape the table? Thanks

[Rob Garner]

more:

cast iron over-sized bore build-up.

[Rob Garner]

One of the smaller main jobs I do is prototype solid rod bending for latches,shift linkages etc. Most of them are easy enough but a few are a royal p.i.t.a. For example: this is only 1/2" rod with mild bends,but, it is bent on all three plains with a +/- 1/2 mm accuracy on all bends! :realmad:
This probably wouldnt be a problem with a cnc bender, but, this is all done by hand with a torch.
I do it in 3 steps.

[zapster]

Man O Man!!!

Nice stuff!

Don't you just love all that mill scale grinding?:(

You get all the fun jobs..:drinkup:

...zap!

[Rob Garner]

Still more:

[Rob Garner]

One more thing Rob... in the first pic... how thick and the surface diamension of the table? You scrape the table? Thanks

The table is 4' x 10' x 2" thick. I have retractable extensions on both ends that make it just shy of 14' long. Also there is a piece of 1" x 2" bar stock welded at each end to make clamping easier with some of my smaller clamps. I do not scrape the table, just go over it with my big grinder with a 9" cupped wheel. See link and pic below below:

http://weldingweb.com/showthread.php?t=17097



Man O Man!!!

Nice stuff!

Don't you just love all that mill scale grinding?:(

You get all the fun jobs..:drinkup:

...zap!

Thank you Zap. I dont mind it to much, simply because I can get even with the "mr. clean" cnc operators around me bye throwing sparks at them. :angel:

[drivethruboy54]

SAIT grinding wheels are the best, they blow everything else out of the water. Your work looks like fun, and i like the extendable table idea.

[Tractapac]

Rob thanks for the link to the video, it showed it well. Is this, in essence, similar to using a "whip" with a welding rod? Your work looks brilliant. This is all beyond the scope of my 160A mig. Just out of interest, what are the specs, settings and wire size you're using?

[Rob Garner]

Rob thanks for the link to the video, it showed it well. Is this, in essence, similar to using a "whip" with a welding rod? Your work looks brilliant. This is all beyond the scope of my 160A mig. Just out of interest, what are the specs, settings and wire size you're using?

You`re welcome. Yes, if my understanding of the "whip" method is correct,they are similar.(I do very little stick welding,save for the occasional cast repair. It is pretty sad actually, considering it is the first process I learned how to do.)

The specs. for the welder can be found in the link below. The one I use is a little older and has a differant wire feeder ( 60m series) along with a Bernard water cooler and gun. As for the settings, I rarely go lower than 28 volts and 350 i.p.m wire speed. I would say that my normal settings are between 30-33 volts and 400-550 i.p.m wire speed. Wire size is .045 er70s-6.

http://www.millerwelds.com/products/mig/invision_456p/index.php

[STwelder]

Very nice work. And from the looks of things a lot of work. Like the pics keep em coming.

[Rob Garner]

Very nice work. And from the looks of things a lot of work. Like the pics keep em coming.

Thank you.


More pics:

Broach bar storage rack for our production machine shop.


cont.

[Rob Garner]

Storage shelves.

[Rob Garner]

Modified chip hoppers.

When these were brought in, I was asked to put the casters on them without raising the overall height by more than an inch.

[Rob Garner]

Coffin handle crimper.

[Rob Garner]

Misc. stuff.

[Xtreme Fabrication]

Are you guys hiring? :p

[Scott Young]

great looking stuff!!!

[elvergon]

That´s amazing!

Thanks for the pics!

[Tractapac]

Thanks for all the pictures, Rob. Most impressive. Nice to see work like that as it's usually not easily seen.

[boatbuoy]

the guys who can tig the teeth on those broach bars for sharpening are real artists.

[jtrapper]

Thats some fun looking stuff you have there, and a good variety. Nice craftsmanship.

[Fabtec]

Hello Rob
Thank you for posting.
In your first few pictures, are those magnetic levels with an electronic angle readout? If so, who makes them?