How To Design Automatic Welding Jig

Added: 2026-05-31

[00:00:00]Today I will introduce you to the design of an automatic welding machine. For automatic welding, we have here an automatic rotating jig. We will use a 40W motor to control the rotation of this turntable.

[00:00:20]This rotary table is designed so that you attach the object to be rotated, and then the motor controls the rotation of the table, causing it to flip. When it flips, the motor controls the desired welding position. It's possible that this motor can control rotations of 90, 180, or even 360 degrees. I'll be using an engine paired with a sleek, planetary gearbox.

[00:00:55]What's wrong with it? Because this welding process requires a very large torque, we need to use a gearbox to increase the torque.

[00:01:06]As we can see, our system will have the motor connected through a gearbox and then transferred through gears. The smaller gear will mesh with the larger gear.

[00:01:16]Yes, because we need to do it that way. Because we need to reduce the number of revolutions significantly. For example, my motor will have 3000 revolutions per minute. But according to the problem statement, we only need to rotate 10 revolutions per minute, so what should we do? First, we have to put it through a gearbox. To reduce speed, we can find a 1/30 gearbox, so 3000 revolutions divided by 30 equals 100 revolutions. Then, using this large gear, we can reduce it by another 1/10. What does that mean? To reduce a speed of 100 revolutions per minute to 10 revolutions per minute, we need to use this gear meshing system. The gear ratio increases by another 1/10. Now let's take a look at the structure of this device.

[00:02:16]Ah, at this position, it would be a gear, but it's not an ordinary gear; it's what I usually call a gear. We often call this a turntable or gear wheel. It can rotate and spin around.

[00:02:30]For this, we just need to buy the standard parts and then install them ourselves. Because it's standard, it will integrate for us.

[00:02:37]We buy them and assemble them ourselves. That's like the bracelet I'm wearing. That ring will fix it in place.

[00:02:44]Fix that ring in place and this gear will rotate. Then we fix the gear and this outer part onto the flip panel for our device. So, when the small gear of the motor rotates, it controls the rotary table, causing it to rotate. That 's the principle used for rotating and flipping to weld this material. Okay, now let's take a look at the design of this side. On this side, there will also be a connecting rod that will be fixed and fitted by one or two bearing slots.

[00:03:21]So, on this side, the shaft will be fitted into a bearing housing.

[00:03:31]I can buy this shaft, or more simply, this bearing shaft, for easier assembly; it's readily available on the market. Besides, to save costs, we can use this type of shaft. Alternatively, you could also use ball bearings in this area, but in my opinion, ball bearings are the better choice for this section.

[00:03:52]Yes, because this type is very cheap and simple, and it's also easy to assemble since it comes in a certain quantity.

[00:04:03]And we can use this shaft as a hollow shaft, like the one I'm using here, which is an 80-degree shaft.

[00:04:16]We can make a hollow shaft, and then we can see the difference between a solid shaft and a hollow shaft. I can say that in this design, the torque of a solid shaft and a hollow shaft are almost equivalent, so to save on weight, we can use a hollow shaft in this area.

[00:04:42]On this side, we can use a method to secure it by using a retaining ring here. The shaft retaining ring here is used to secure this shaft in place. And at the top, we'll design a hanging loop, which we'll call a hook. Why design here? That's so that when we assemble it, we can lift our necks because this part is very heavy. Down below, we have to go down a slide or something similar. Why use sliding rails? Because of my design, I can configure it to be short or long. So, when my wallet is short, I can put it in, and when it's long, I can pull it out.

[00:05:32]It will slide up at the track, and when I need to extend it, I can lock this track. That's the overall summary. Thank you for watching. Thank you. M.