capacitor discharge stored energy welding machines, plate to pipe projection welding, rib type projections, mig welding, rotating fixture, capacitor discharge welding, co2 welding two machines, india

Case Study: The advantages and savings by using Artech Capacitor discharge stored energy welding machines

Application: Plate to pipe projection welding

Job Description: The plate has two rib type projections running across the entire length. This plate is welded on two pipes in a single stroke. The weld takes place at 4 points where the ribs touch the pipes.

Production requirement is 2000 jobs per day. Machine can weld 6 jobs per minute inclusive of job loading and unloading time. I.e. machine can weld 2400 jobs in a single shift of 400 minutes.

Operation required: Only one

Process replaced: Mig welding

Power cost is only 4 units for 2000 welds.

In case of manual co2 or mig welding the production of 2000 jobs per day was done by 2 skilled welders and two helpers. The sequence of operation was like the helper used to place 5 components in a rotating fixture. After the components were placed, the table was rotated for the welder to weld the plates. The welder could weld 5 components in 2 minutes. The helper would load the next 5 plates on the other side of the table till the welder completed the welding.

One set of operators could produce 2.5 jobs in a minute. That means two pairs of operators could produce 5 jobs per minute resulting into production of 2000 jobs in a shift of 400 minutes.
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	Capacitor discharge Welding	CO2 Welding Two machines
Machine cost	RS. 5,00,000	Rs. 100000/machine Rs. 200000
Power Cost	4 units/2000 welds i.e. Rs. 16 per day.	6 units/ 2000welds and two machines i.e. 12 units I.e. 48 Rs. Per day
Consumables like wire, gas etc.	None	0.20 Rs. Per welded piece. I.e. Rs 400 for 2000 jobs i.e. per shift Rs 400/- Rs. 10000/- month
Manpower required	One semi skilled person	Two skilled welder and two helpers
Manpower cost	Rs. 4000 /month	Skilled Rs.6000x2 = 12000 Rs. Unskilled Rs. 2500x2 = 5000Rs.
Rework required	None - as good as finished component after welding. No filler material is added.	60% components require removal of weld spatter thus adding another unskilled person. Cost of person Rs. 2500/-
Total monthly cost considering 25 days	Rs.4400	Rs. 30700/-
Total cost in a year	Rs. 52800	Rs. 368400/-

So total yearly savings are Rs. 315600. This real life example clearly indicates the advantages of using Artech Capacitor discharge welding machines.

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Case Study 2: The advantages and savings by using Artech Capacitor discharge stored energy welding machines

Application: Pipe to cap projection welding

Job Description: A sheet metal cap is welded on the pipe end. The joint should be leak proof and should sustain load of 2000 kgs. As the application is very sensitive all the jobs are subjected to leak test. Production requirement is 3500 jobs per day.

Process replaced: Brazing

	Capacitor discharge Welding	Brazing
Machine cost	RS. 9,75,000	Rs. 75000
Power Cost	5 units/3500 welds i.e. Rs. 20 per day.	Not applicable
Consumables	None	Rs. 0.90 per job i.e., Rs. 3150 for 3500 jobs
Manpower required	One semi skilled person	Three semi skilled persons
Manpower cost	Rs. 4000 /month	Rs.4000x3 = 12000 Rs/ month
Rework required	None - as good as finished component after welding.	30% components require rework due to leakage.
Rejection	Less than 1% due to leakage	4% due to leakage
Total monthly cost considering 25 days	Rs.4500/-	Rs. 90750/-
Total cost in a year	Rs. 54000	Rs. 1089000/-
Interest cost 12%	Rs. 117000 (12% of 975000)	Rs. 9000/- ( 12% of 75000)
Total cost	Rs. 171000/-	Rs. 1098000/-

So total yearly savings are Rs. 927000/-. This real life example clearly indicates the advantages of using Artech Capacitor discharge welding machines.

The above data is for a particular machine and application. It is given to us by our customers. The same data is not applicable to all the machines and applications.

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