DEWBOT IX Welding
Welcome to DEW Robotics Welding Team 2015
The welding team is crucial to Team 1640's success. We primarily build the frame that holds the whole robot together. Our ability to weld robot frames and other parts gives team 1640 a competitive advantage over those teams that can not. Welding the robot frame results in the frame being lighter, stronger and easier to build to precise dimensions. In addition, having competent welders allows us to repair tools or equipment that would otherwise be discarded, saving time and expense
As you might expect, such a valuable skill requires knowledge and regular practice. Therefore, we have developed a program for interested students to get the neccessary training and practice so that the quality of our welding work is as good as it can be when it comes time to build the next robot.
Most of the training and practice is done in the off season by working on welding projects such as building tools, repairing equipment, or making alterations to the robots.
When students are ready, they may take a qualification test that, upon passing it, will qualify them to weld the new robot chassis independently with a minimum of oversight. The document link below describes the complete qualification process and requirements.
Above all we want the welding team to succeed, learn valuable skills, take pride in their work and contribute significantly to the success of the 2014-2015 season
Keith Williams,
Welding Mentor
Welding Team News
Links to Important Documents
Current Projects
LINKS TO IMPORTANT DOCUMENTS
File:WELDING SHOP GROUND RULES 1.doc The MIG welder is by far the most powerful machine we have at the shop. It is capable of delivering more than 9,000 watts of welding power. The danger of serious burns, eye injury, fires and electric shock is very real. The welder and spool gun are also expensive pieces of equipment that need to be treated with care. Please be familiar with the Ground Rules, as they are to be followed at all times in the welding area.
File:DEW Robotics - Welding Qualification 2013-14 v1 3.doc This document is a complete description of the DEW 1640 welding qualification process. Included are test descriptions, rules, materials, and more. Please read through it, and feel free to ask any questions about this process. We will also go over the requirements together as a team when qualification time is near.
File:Miller MIG Guidelines.pdf This document, published by Miller, the leading manufacturer of welding equipment and technology, is an excellent general guide to MIG welding.
CURRENT PROJECTS:
- 2014 Fixtures and ClampsClamping and holding the pieces that are to be welded is a crucial part of building the robot frame and any other assembly we might need to put together. As practice this fall for the welding tests, we've made a right-angle and some clamping fixtures to help.
- 2013 Robot - Jan to Feb 2013 - Currently building two robot frames for the 2013 season.
- 2013 Game Pyramid - Jan 2013 - Built one of the game pyramids to do robot prototyping and testing on.
- Welding Screen - (Dec/12) Built a screen frame to protect the eyes of our colleagues working in the machine shop area.
- Welding Table - 2012's summer's project was to build a substantial steel welding table. Various students worked on this project which was a much needed addition to our welding shop.
- Tool Cart Modification - We heavily modified a cart to accept two toolboxes, and have a work table on top. Doug and I did the welding with steel fluxcore wire.
WELDING TEAM NEWS
Wednesday, December 31, 2014:
Contratulations to Laura for passing the welding test. Laura now joins the welding team with Melia, Trevor and Marina. We have quite a strong team this year. I'm looking forward to seeing the quality of work we can deliver. br>
Tuesday, September 3, 2013:
It's that time again. Time for the welders to start practicing to be ready for build season. With a little luck, we can start tomorrow. Please read through the documents attached above. The 'MIG Guidelines' document from Miller is excellent beginning reading. We will go over the testing document together at some point so have a look at this document too.
Wednesday, May 22, 2013 SUMMER PROGRAM:
As you may know, team 1640 does quite a bit of welding, both to build the robot and other items such as the 2013 game pyramid. For those interested in doing the welding on the robot for next season, summer is the time to get started. We would like to have about 5 students join the welding team, and be well practiced and qualified by the fall. Please feel free to stop by, introduce yourself and find out how the welding program works.
I need some help tonight straightening up the welding area. Then either the veteran welders can practice, or any new prospective team members can give it a try. We will have projects to work on during the summer, so recruitment begins now.
Tuesday, February 12, 2013:
Finishing up the frame. The main frame and caterpilar drive rails for both Prime and Deux are finished. Bumper mounts have been added to Prime. Tonight we will finish up a horizontal model of the pyramid corner, for robot testing. As before, we've been stick-welding the pyramid components. if you want to give stick weldign a try, stop by.
Tuesday, February 4, 2013:
Caterpilar tracks were welded, 8 of them total. Excellent job by Kira. Next step is the top rail and cross pieces for both 'bots when they are ready.
Tuesday, January 29, 2013:
Prime and Deux frames are both equal in their state of completion. All the pivot tops have been welded. Next step is the top rails plus cross pieces on both. Also caterpilar tracks when they are cut and ready. Good job to Brad, Kira and Marina for their work on some challenging pieces.
Friday, January 25, 2013:
Congratulations to Brad for passing the welding test. The major frame elements of the "Prime" chassis have been welded. The next step is adding gussets to the frame.
Thursday, January 24, 2013:
The major frame elements of the "Prime" chassis are on the table and aligned. Tonight we should be able to weld it into a solid moveable assembly. Depending on what parts are cut, we can either start on the "Deux" chassis, or continue to add parts to "Prime".
Wednesday, January 23, 2013:
Tonight we start welding of 2 robot chassis'. Marina, Kira, Brad, this is what all that practice was for. This is your time to shine. Please let me know if you will be able to make the meeting. There will be plenty of work to do.
Tuesday, January 15, 2013:
Four days of working on the pyramid, and it's finally nearing completion. Tonight we should be able to finish the top cap. Need to weld the top rung together, and set it on top of four vertical posts at the corners of the third rung. Post length should be 10.5 inches. Top cap rungs should be 7 inches apart. Posts should protrude 2 inches out of the top gusset.
Thursday, January 10, 2013:
Congratulations to Marina and Kira for passing the welding test. Both are now certified to weld on the robot. We cut all the pipe for the pyramid, and welded three of the corner pieces. Tomorrow we will have gussets to weld into the corners, and should be able to have one corner finished.
Wednesday, January 9, 2013:
The welder is wired and ready. Welders (Brad, Kira, Marina and Patrick) need to get practice and certify on aluminum. We also need to do some test welds on the EMT pipe we will probably be using to build the 2013 pyramid. Please remember to bring baseball hats.
Monday, January 7, 2013:
The move to the Eagle warehouse is complete. Tuesday we will have the welder wired and ready. The 2013 season is shaping up to be busy for the welding team, as we will need to build one of the major elements of the game, the pyramid. On WEDNESDAY the 9th, we will have a few things on our plate. We need to get the welding area set up. Welders need to get practice and certify on aluminum. We also need to start reviewing the plans for the pyramid, and do some test welds on the EMT pipe we will probably be using to build it. Please remember to bring baseball hats.
Sunday, December 23, 2012:
Two new welding masks were purchased (Clem). By-the-way, the world didn't end.
Friday, December 21, 2012
Welders, assuming the world does not end today, the shop will continue to be operational until next week for practice and qualification. If you will be helping pack up tonight, please carve out at least an hour to do the welding test. If you will be at the warehouse any other days, please email me and I will come in to get you certified. Let's see how many of you can get certified before the welding equipment is moved next week.
Wednesday, December 19, 2012 Session
Welding screen frame needs to be cleaned up (maybe painted?) and put into use. Anyone needing something to work on could take care of this. Welders, we will be welding aluminum, and passing qualification tests. All the experience you've gained with flux-core on steel will serve you well. Please remember to bring a baseball-type hat.
Monday, December 17, 2012
Made a spooler to load small 1 lb spools from the big 13 lb spool of Al MIG wire. Cut some Aluminum practice pieces, also suitable for test pieces.
Wednesday, December 11, 2012 Session
We will finish the welding screen and start practicing on Aluminum. Welders please remember to bring baseball hats. Other things on our to do list include:
- Load some 4 inch spools with .035 Aluminum MIG wire.
- Cut up the scrap robot frames underneath the table into flats, angles and channel pieces to use for practice.
- Students also need to cut their test pieces. Might as well kill two birds...
- The welding table needs have the weld beads, lumps & bumps ground down flat.
Wednesday, December 5, 2012 Session
Marina, Kira and Patrick finished some of the filet welds (including vertical-up and overhead welds!) on the legs of the welding screen. We ran out of flux core wire, so Patrick helped set the welder up to MIG weld aluminum and got to try out MIG'ing aluminum. Each student needs to cut their test pieces for when they are ready to take the test. There is an appendix in the back of the qualification document above which lists the number and sizes of all pieces you will need.
Tuesday, December 4, 2012
Replaced 2 missing screws on the spoolgun. Cut some contact tips in preparation for Al welding with .035 wire.
Monday, December 3, 2012
Brad had a good question about the testing process. To paraphrase, Brad asked, "Can we weld multiple test pieces and submit the best one?". My thoughts are these. The test is meant to simulate a real world situation. On the real robot, you can practice as much as you want, but you only get one chance to do a weld on the robot. So the answer is 'No'. The student must identify the piece which will be evaluated (the 'final' one) before any welding begins. The testing process document (above link) has been updated accordingly. Any questions, feel free to ask.
Wednesday, November 28, 2012 Session:
Made excellent progress on the welding screen. The frame is tacked together, ready to finish weld. Good work by Brad, Marina and Kira.
