- Utilizing a positioner can avoid inverted or vertical welding positions improving both weld quality and deposition rate
Typical T joint weld ½" fillet
30 foot long.
A poorly positioned part is limited to a 5/16" weld and requires a double pass with many restarts to meet a 1/2" weld size (AWS-D1.1).
In the 1F position, the operator can increase his .052 metal cored wire feed speed to 450-500 ipm. He can now meet code for 1/2" weld in a single pass. This eliminates the 30 or so restarts for each pass and increases deposition from 9 pounds per hour to 14½ pounds per hour. All that is changed is weld position and wire feed speed! No additional investment.
Proper weldment/assembly alignment affords better access and efficiency:
- Welding, Cleaning, Grinding, Deburring, Drilling, Bolting, Blasting
- Assemblies can be consistently positioned for manual weld, programmed welding procedures or robotic operations
Consistent repeatable welding or assembly procedures
- Reliable positioning will allow improved production time
- Repeatable assembly processes support reliable production and manpower schedules
Higher productivity and reduced consumables
- The example above illustrates an increased weld deposition rate from 9 to 14½ pounds per hour - this is a 37.9% improvement in welding productivity
- Reduced time to position and reposition assemblies
- Improved welds reduce consumable consumption
Proper use of other capital assets
- Cranes, fork trucks or other lifting equipment is not tied up supporting weldments and can be used in other material handling functions
Improved ergonomics and reduced risk
- Welding or assembly procedures can be positioned for easy access by the worker
- Reducing employee fatigue improves production, employee morale and reduces injuries
- Securely positioned assemblies reduce assembly and repositioning hazards
Higher throughput and profits
- Fixed base or adjustable base positioners have boosted plant throughput 35% or more
- Increased plant throughput will offer significant profit advantages