WELDING ENGINEERING AND TECHNOLOGY - Welding Jigs And Fixtures - Borivoj Rihtar, B.Sc.M.E.

WELDING JIGS AND FIXTURES

Borivoj Rihtar, B.Sc.M.E.
Uniweld-strojevi, Kamanje, 47282 Kamanje Croatia

Keywords: Mechanical Jigs, mobile fixtures, manipulation devices, torque, regulation

of motors, process control, semi-automatic machines, automatic machines, Robots

Contents

1. General
1.1. Objectives
1.2. Concepts
1.3. Historical Review
2. Main types of Jigs, Fixtures and Machines
2.1. Mechanical Jigs
2.2. Auxiliary Devices
2.3. Fixtures
2.3.1. Rotators
2.3.2. Turntables
2.3.3. Welding Manipulators (Columns & Booms)
2.3.4. Racks and Welding Centers
2.3.5. Longitudinal Seamers
2.3.6. Tractors
2.3.7. Fixtures with Mutual Movements
2.3. Special Machines
2.4. Production Lines
2.4.1. Beam Production
2.4.2. Container Production
3. Conclusion
Biographical Sketch

Summary

New Markets and technological improvements requires the constant solving of new-
coming problems; either located in area of increasing measurements or enormous
production outputs, followed up with extreme Tolerances and extreme thicknesses in
both ways.

In a rush for solutions, the whole branch of producers even do not “produce” the
common names for a new product; it’s normal to find the same item under the several
names. So, it is not unusual that the terms as: jig, fixture, device, equipment, tool,
machine or unit can be used for the same!

Even without the new tasks, every handle of metal parts is unpractical and hard,
concerning their own specific weight or toughness. Invented to help the welders at the
beginning of industrial welding production, a lot of elementary jigs and fixtures are still
in use, almost without any change in form or goal. The other, sophisticated and built

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WELDING ENGINEERING AND TECHNOLOGY - Welding Jigs And Fixtures - Borivoj Rihtar, B.Sc.M.E.

with newest achievements in electronics, disengage the welders from the hard work,
improve the quality and outfit of welds.

1. General

1.1. Objectives

The solutions in a race for higher productivity with coexistent demand of top-possible
quality in a field of welded products are mainly oriented in the following directions:
 replacing of the constructive and technological solutions on the product, with
aim of using mechanized welding instead manual
 utilizing the simple manipulators for easier product positioning
 buying new fixtures, automatic or robotic machines

The decision which one of above mentioned directions to choose have to be based
primary on the quantity of the same or similar products. Recognizing the usual financial
problems as a certain limit, it is important to point on the possibility of collecting the
equipment in “step by step” way. For such approach, a complete further production
technology must be developed at the very beginning.

1.2. Concepts

Basic ideas of each Jig or Fixture are:

 providing the most preferable position to weld: “downward in V-groove”
 being helpful to the welder in mutual positioning of two different parts or two
part ends

Naturally, in a first case, than is not relevant if the weld be fulfilled manually or by use
of some semi-automatic processes (GMAW / GTAW) or fully automatic (SAW).Also,
that position provides better quality of the weld, ensuring proper gas or slag segregation.

Every Fixture ensures stable clamping of product’s parts always on the same place,
what is the main precondition for mechanized or automatic welding.

Further positive effect of Jigs and Fixtures are reduction of auxiliary workers and
Cranes, because the product will be clamped only at the beginning and released at the
end of production cycle. All the other movements are mechanized, actuated by stable or
remote controls.

Advantage of superb weld outfit in comparison with ones done in “forced” positions is
also important nowadays, when market competition challenge the producers to think
about every possible detail on the final product.

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WELDING ENGINEERING AND TECHNOLOGY - Welding Jigs And Fixtures - Borivoj Rihtar, B.Sc.M.E.

1.2. Historical Review

From the beginning of commercial welding, some Jigs were necessary to help welders
in their tasks. Either simply screw-type clamps for equalizing/centering of the parts or
sheet’s end was the very first tools.

Later, when the “real” welding production starts, the circumferential containers have
been the first ones done with new technology: welding instead forging. To rotate them,
Rotators or Rollers were invented. Driven by the electrical motor, through Reducer and
leather belts, rolls of Rotators was capable to rotate containers with one speed. That was
not too much, but always better than rolling the part on the workshop’s floor. Later, the
Positioning tables were invented for help during the welding on asymmetrical parts.

After the development of the first automatic welding system – SAW in the late 40-ies of
20-th century, the Column & Boom or Manipulator type was introduced. That Fixture
allows welding of longitudinal and circumferential welds.

Application of DC motors with regulation for each movement, allowed practically the
shape of Fixtures we find today.

Constant industrial development after the World War II, specifically in electronic,
improved the Fixtures to high level, “smart” machines as automatic or robotic ones.

2. Main types of Jigs, Fixtures and Machines

2.1. Mechanical Jigs

Major problem for manual welders stays always in fact that the arms was occupied –
electrode in one hand, protective shield in other; no space to handle with product. No
matter if it was only tack-welding or welding, there was no way to keep parts together.

A whole pile of specific Jigs has been invented to help, and here are some examples:
- sheet treated in bending machine always stays “open”; the only way to fix the ends
is by
- use of two Jigs, one a side, capable for:
a. clamping the shell’s ends tight and adjust the distance (see Figure 1);
b. adjusting the distance between the ends
- a pair of tubes is hard to held, align and tack-weld; it is simply with outside
mounting Jig, capable to align and adjust the distance (see Figure 2)
- a pair of tubes or tube and flange to held, align and weld around is possible with
inside mounting Jig with two centering tools. Opening of tools is provided by screw
and separate keys (see Figure 3)

As conclusion, all the mechanical Jigs use some screw-type adjustment of level, shape
or distance, keeping the parts still during welding.

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WELDING ENGINEERING AND TECHNOLOGY - Welding Jigs And Fixtures - Borivoj Rihtar, B.Sc.M.E.

Figure 1. Mechanical Jig for clamping / adjusting the sheet’s ends

Courtesy: “Uniweld – strojevi”, Croatia

Figure 2. Mechanical Jig for clamping / centering two tubes Courtesy: “Uniweld –
strojevi”, Croatia

Figure 3. Mechanical Jig for internal centering of two tubes or flange/tube Courtesy:
“Uniweld – strojevi”, Croatia

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WELDING ENGINEERING AND TECHNOLOGY - Welding Jigs And Fixtures - Borivoj Rihtar, B.Sc.M.E.

2.2. Auxiliary Devices

Sometimes it is not enough to use some Jig to solve the problem; on the big
constructions problem occurs in fact how to help welder to come to and stay still during
the operation, without additional efforts. For such purposes, a wide range of specialized
welding ladders, electric or hydraulic platforms or carriages was developed, helping
welders to stand firmly above the floor or to avoid crawling (see Figure 12).

2.3. Fixtures

During welding, specially machined one, there are only three possible ways to achieve
the proper weld:
A) By moving the product while Torch stands still
B) By moving the Torch while product stands still
C) By moving simultaneously Torch and product

Motorized Fixtures developed for manipulation with the product during welding can be
divided in two major groups: Rotators and Turntables (Positioners). Rotator provides
rotation of the product along the longitudinal axis, supporting product on minimum 4
points, with at least one power roll. Turntables are capable to rotate product with its
table, but depending of type, also to tilt or lift, providing the best position for welding.

Fixtures as Welding Manipulators provide the linear movement or position of one or

more Torches, while Longitudinal Seamers clamps two flat sheets or two ends of
cylindrical sheet and provide linear movement of Torch.

Fixtures known also as Machines are designed from two or more Fixtures, combining
manipulation with product and Torch, as Welding centers. Robotic cells consist usually
from one or more Turntables with one or more Robotic arms to move the Torch(es).

2.3.1. Rotators

Concerning the way of product support, there are two major types of Rotators:
conventional and self-aligning. Both types consists minimum of two items, usually
named Power and Idle units. Concerning the design, each Rotator can be stable,
manually driven on rails or with motorized drive along the rails. Division based on roll
coating knows the rubber, Vulcolane and steel rolls. Range of Diameters for Rotators
lies within limits of 60 – 10000 mm, with weights from 100 kg up to 800 tons.

Usually, all the producers of Rotators place the circumferential speed of rolls to lie in
the area between the 120 ÷ 1200 mm per minute, to cover practically all the known
speeds of welding processes. In cases with special requirements, welding speed must be
specified by Order!

Housings of Rotator’s rolls are able to slide along the main frame, to suit the different
Diameter of product. Most of Rotators are designed in a way that “half-angle” between
the vertical axis and the line from contact point to the midpoint of product have to be

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WELDING ENGINEERING AND TECHNOLOGY - Welding Jigs And Fixtures - Borivoj Rihtar, B.Sc.M.E.

from 20º up to 40º. Construction of sliding the housings can be or with several fixed
points on the frame or indefinite by use of the tool spindle.

Using Rotator, it is possible to weld manually, semi-automatic or automatically all the

circumferential welds, but also the longitudinal ones. Primary, Rotators are appointed
for containers or similar products with round cross-section, but even the other forms
could be rotated, using the additional dividable rings. Than those rings rotate upon the
rolls, but Rotator itself use only to turn the product in position.

Torque for rotation on rolls depends naturally from the product’s weight and
eccentricity, as Diameter, too. Simple Equation for Torque calculation consists from:

Weight Q (kg)
Product’s Dia. D (m)
Roll resistance f (steel = 0,0005 ; rubber = 0,007)
Eccentricity % (5 ÷ 20)
Roll’s Dia. d (m)

M  Q  f  d D  % 100  Q  d 2  kg m

It is important to notice that the products with more than 20% of eccentricity must be
balanced with mountable counterweights to provide smooth rotation! Otherwise,
unexpected slide downwards or arresting upwards can occur.

Welding the Products with extreme length can be solved with two Power units and few
Idler units for better aligning and support.

Figure 4. Power unit of 50 t “self-aligning” type Rotator, stable, Vulcolane rolls, tool
spindle adjustment of blocks Courtesy: “Uniweld – strojevi”, Croatia

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WELDING ENGINEERING AND TECHNOLOGY - Welding Jigs And Fixtures - Borivoj Rihtar, B.Sc.M.E.

For welding of containers with bigger or extreme wall thickness, it is always wise to use
self-aligning type of Rotators, because of the possible “creeping” problem. Rotators for
those purposes are equipped with additional “anti-creep devices” for compensation of
possible axial movement of product.

Nowadays, usual drives for Rotators are standard AC frequency controlled motors with
brakes, activated by remote control with 10 m cable. Usual knobs on simply remote
control box are Safety stop, direction of rotation and potentiometer for speed regulation.
On the more sophisticated remote controls, a LED – display for speed is an appendix.

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Biographical Sketch

Borivoj Rihtar has received his diploma of Engineering (Dipl. Ing.) from the Fakultet strojarstva i
brodogradnje, Zagreb, Croatia in 1979. After completing the additional studies, he became a welding
specialist (similar to today’s EWE). After couple of years spent in a construction firm, he joined the TPK-
PAN in Zagreb, Croatia in 1981. From that time he is in charge for project development and construction
of various Fixtures (until today over than 300 by himself only). In a couple of past years he starts to
instruct the welding engineers on the EWE course in the “Jigs and Fixtures” field.

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