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CASE STUDY

Switching to ROTOCON Rotary Ground Clamp Increased Productivity by 250%

A major manufacturer of outdoor power equipment, including garden tractors, lawn trimmers, and mowers approached Meridian Laboratory with challenges they faced using conventional brushed grounds for their automated rotary welding lines. Poor grounding caused inconsistent weld quality, pitting, and a lack of weld penetration of their end products. By converting their manufacturing lines to ROTOCON MC-Series rotary ground clamps they were able to alleviate all these issues and eliminate the downtime associated with greasing and maintenance required with brushed rotary grounds – ultimately increasing output productivity by 250%.

Challenge

A major manufacturer of outdoor power equipment, including garden tractors, lawn trimmers, and mowers approached Meridian Laboratory with challenges they faced using conventional brushed grounds for their automated rotary welding lines. Poor grounding caused inconsistent weld quality, pitting, and a lack of weld penetration of their end products. By converting their manufacturing lines to ROTOCON MC-Series rotary ground clamps they were able to alleviate all these issues and eliminate the downtime associated with greasing and maintenance required with brushed rotary grounds – ultimately increasing output productivity by 250%.

Historically, the manufacturer had relied on conventional, brushed rotary welding grounds for more than 20 years in their automated rotational welding equipment.  While simplistic in design and operating principle, brushed rotary welding grounds have drawbacks associated to them including carbon build up, arc potential, duty cycle limitations, and periodic dielectric greasing is required to keep brushes maintained and functioning properly.  These drawbacks ultimately lead to more downtime, poor weld quality, and overall decreased productivity.

 

SolutionRotary Ground Clamp

After learning about Meridian Laboratory’s ROTOCON high current, rotary ground clamp MC-series, the customer was able to select from a variety of different models based on the current draw required in their rotary welding production lines.  Utilizing standard, off-the-shelf, ROTOCON MC models they were able to begin testing quickly and efficiently.  The advantages were immediately noticeable in a more stable current flow, dramatically decreased pitting, and improved weld penetration and quality.  They were able to decrease the amount of scrap products and increase output so quickly that the investment paid for itself within the first 30 days of usage.  Long term, they were able to eliminate all previously routine scheduled maintenance breaks, which were associated with greasing and replacing conventional brushed rotary grounds.  Since initial install and proof of concept, the manufacturer has now switched all of their rotary welding fixtures to ROTOCON MC-Series rotary ground clamps.

 

Key Statistics

  • Eliminated inconsistent and poor weld penetration associated with conventional brushed rotary grounds
  • Productivity increased by 250% by changing out brushed rotary grounds with ROTOCON, maintenance-free rotary grounds
  • Drastically reduced scrap end products

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