Project: Industrial Friction Welder for Skid Steer

As the Lead Electrical Design Engineer at NPDC, I spearheaded the development of an industrial-grade friction welder designed for attachment to skid steer loaders. This specialized equipment was engineered to friction weld plastic pipes for use in mining operations, particularly in gold fields where durable, leak-proof pipe connections are critical.

The project required designing a robust system capable of operating at speeds up to 3,000 RPM while maintaining precise control and safety standards in harsh field conditions. The friction welding process creates strong, homogeneous bonds between thermoplastic pipes by using rotational friction to generate heat at the joint interface.

Beyond the technical development, I also served as a mentor to junior engineers on the team, providing training on electrical safety standards, PLC programming best practices, and industrial control system design principles.

Control System Components

• Velocio PLC for primary control logic and automation
• Industrial-grade relays configured in H-bridge topology
• Hydraulic solenoid valves for directional control
• Emergency stop circuits and safety interlocks
• Variable frequency drive for motor speed control
• Human-machine interface (HMI) panel for operator control

Power & Drive System

• High-torque hydraulic motor capable of 3,000 RPM
• Skid steer auxiliary hydraulic connection interface
• Pressure sensors and flow control valves
• Heavy-duty power distribution with circuit protection
• Industrial connectors rated for outdoor use

Mechanical Integration

• Quick-attach mounting system for skid steer compatibility
• Adjustable pipe clamping mechanisms
• Precision alignment guides for consistent welds
• Vibration dampening mounts
• Weather-resistant control enclosure

Electrical Control Panel Design

1. PLC Integration: Configured and programmed the Velocio PLC for automated welding sequences and process control
2. H-Bridge Circuit: Designed and implemented relay-based H-bridge configuration for bidirectional hydraulic valve control
3. Safety Circuits: Integrated emergency stop systems, interlocks, and fail-safe mechanisms per industrial standards
4. Power Distribution: Designed the electrical panel layout with proper wire management and circuit protection
5. Interface Development: Created operator control interface with status indicators and process monitoring

Control System Programming

Developed comprehensive PLC logic using Velocio's programming environment, including:

• Automated welding cycle sequences with precise timing control
• Speed ramping profiles for smooth acceleration to 3,000 RPM
• Pressure monitoring and automatic adjustment algorithms
• Fault detection and diagnostic routines
• Data logging for quality control and process optimization

Team Leadership & Training

• Led electrical design team through all project phases
• Conducted safety training sessions on electrical hazards and lockout/tagout procedures
• Mentored junior engineers on PLC programming and industrial control systems
• Developed documentation and standard operating procedures
• Coordinated with mechanical team for system integration

System Testing & Validation

Conducted comprehensive testing to ensure reliable operation in field conditions:

• Speed control accuracy testing across full RPM range (0-3,000 RPM)
• H-bridge relay switching performance under various load conditions
• Hydraulic valve response time measurements and optimization
• Emergency stop system verification and fail-safe testing
• Weld quality assessment across different pipe materials and diameters

Field Deployment Preparation

• Compatibility testing with multiple skid steer models
• Environmental testing for dust, moisture, and temperature extremes
• Vibration and shock testing during transport and operation
• Operator training sessions with field technicians
• Development of maintenance schedules and troubleshooting guides

Safety Compliance

• Conducted risk assessment per industrial safety standards
• Implemented lockout/tagout procedures for maintenance
• Verified compliance with NFPA 79 electrical standards
• Established safety protocols for high-speed rotating equipment
• Created comprehensive safety training materials for operators

Key Innovations

The H-bridge relay configuration I designed provided precise bidirectional control of hydraulic valves, enabling smooth acceleration and deceleration profiles critical for consistent weld quality. The Velocio PLC implementation allowed for flexible programming and easy field adjustments without requiring specialized programming tools.

Lessons Learned

This project reinforced the importance of robust electrical design in industrial equipment. Working with high-speed rotating machinery and hydraulic systems required careful attention to safety interlocks and fail-safe mechanisms. Leading the electrical design team and training junior engineers enhanced my leadership skills and deepened my understanding of industrial safety standards. The successful deployment of this friction welder demonstrated the value of thorough testing and documentation in creating reliable field equipment.