by Steven Noel
Reliability Engineer / Group Leader
Batesville Casket Co.
The Batesville Casket Assembly Plant located in Batesville, Indiana has two Seam Welders in their fabrication department. These Seam Welders are resistance welders that are designed to weld a continuous weld that holds the casket bottoms in place while making an air tight seal. Each Seam Welder runs proximity 27 units each hour and is in use for up to 10 hours each day throughout the week.
When a seam welder starts failing due to insulation failure you start seeing poor welds which in some cases don’t show up until the unit is built and vacuum tested prior to ship out. At this point to make repairs to the casket is costly due to disassembly and removal of the interior to gain access to the bottom.
Furthermore if one of the Seam Welders were to fail during production it would reduce production by 50%. The lead time for making this type of repair is two to three hours causing production losses estimated at eight to ten thousand dollars.
These Seam Welders are 16 volt DC / 20,000 amp resistance welders so being very low voltage and high amperage any insulation breakdown will cause the foot and lower wheel to overheat and eventually fail.