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50075-07A: FLTs

Work Instructions (Welding/Robots)

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Components You Will Need: • ‘50076-07A’ Legs• 49715-07 Spring Clips• 5012235 Collars• 50244-07 Bumper Brackets• 50077-07 Toe Tabs

50077-07

Toe Tabs49715-07

Spring Clips

50244-07 Bumper Brackets

5012235 Collars

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Preparing To Work:

Make sure the fixtures are clean from weld spatter and B-B’s, and that the Sub Side and Final Side are loaded as shown in Figure 1 above. If one or both sides of the fixture are empty, contact your lead person for assistance.

Double-check to make sure none of the clamps have been left open. An open clamp could lead to a robot collision inside the Kuka cell!

Make sure the gas is turned on with the red-lever turned upward (see Figure 2 above). The gas is completely shut off when the lever is turned downward.

Sub SideFinal Side

Figure 2Figure 1

ON

OFF

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Preparing Kuka & Welder On the backside of the work cell,

flip the power switch on the Miller welder to turn the unit on.

Make sure the Control Power On light is lit on the cell’s PLC main screen. If not, flip the Power On Enable switch to the right while pressing the Control Power On button. If this light is not on, the robot will not allow the operator to run.

Control Power

On

Power On Enable

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Loading/Operating Sequence

1. Position a Spring Clip onto the magnet as shown in the top-left picture.

2. Place the leg into the Sub Side fixture. Always close the top clamp down first, and then the right-hand clamp second. Then, close the Spring Clip clamp. Make sure the clip is tight against the leg!

3. Slide a Toe Tab into the tower portion of the fixture. Close the clamp to secure the component in place.

1. 2.

3.

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Loading (cont)

5. Place a collar (machined side facing up) into the circular bushing on the Final Side fixture. Slide the leg down through the bushing: close the clamp atop the leg.

6. Pick-up a Bumper Bracket from the bin: position the bracket on the leg with with one hand while bringing the bracket clamp forward. The bracket should be flush and level with the leg upon closing the clamp forward.

7. The fixtures are now loaded and ready to be cycled into the cell for welding. Push the green “Cycle Start” button by the PLC screen button to send the part into the cell for welding.

5. 6.

Collar Bumper Bracket

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Cleaning/Inspect Use a file or chisel to remove spatter

and B-B’s from the part.

Visually inspect for any holes in the welds: if there are any holes in the welds, stop running the cell and contact the department lead.

There should be no ‘notches’ or burrs on any of the welds: if there are, use a buffing wheel or air grinder to remove sharpness on the welds/components. Use an 80-grit pad on the air tool.

The operator is responsible for conducting a 1st piece inspection and following that up with an hourly inspection throughout the shift. There is also a small gauge to check washer perpendicularity 100%. See your department lead or QC team member for further instructions.

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Robot Torch MaintenanceThe operator is responsible for entering the cell

every 100-200 pieces in order to clean the torch and change the weld tip. Ask your lead person for additional assistance.

1. Use a weld pliers to unscrew the cup from the torch (counter-clockwise). Use the air hose inside the cell to blow out any excess spatter spray and grime.

2. If necessary, use a shop rag to wipe off around the tip if it is overly saturated with fluid.

3. Use the weld pliers to unscrew the old weld tip (it is recommended to change the tip at least every 200 parts: the hole on the tip widens and affects the weld location).

4. Return the cup to the torch after cleaning or replacing the weld contact tip.

5. Close the cell door, and return to normal operations.