FUTURE TRENDS AUTOMATED WELDING IN INDIA 7 - Automated... · Tack tolerance to orbital narrow gap...

FUTURE TRENDS – AUTOMATED WELDING IN INDIA

GAUTAM BANERJEE

KAIYUAN INDIA

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P2P2

Welding-A Key Enabler to Meet Nation’s Aspiration

1.GDP stands at 7.1% growth rate target is to take to double digit in coming years.

2. Target for Manufacturing contribution to GDP is to hit 25% from present 16% by 2025.

3.Present per capita steel consumption of 59.4 Kg is much lower than global average of 254 Kg which should increase manifold.

3.Per Capita Power consumption stands at1000KWH which should have a step increase to match countries like US ,China which stands at 9 and 5 times more respectively.

4.Target is to double the Infrastructure facility in coming years, as it is presently 46% of what it should be benchmarkng developed Countries.

5.Reduce the emission level 20 %per unit of GDP (Excl.Agriculture) from 2005 level by 2020

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P3

Role of Welding in Make in India

1.Infrastructurea)Roads

b)Bridges

c)Airport

d)Buildings

3.Process

4.Transport

5.Mining

6.Oil and Gases

7.Aerospace

2.Powera)Fossil Fuel

b)Nuclear

c)Wind

d)Hydro

e)Solar


As is situation of automatic welding in India

1.In India still major deposition by Electrode & Semi

Automatic process which needs to move fast towards

Automation.

2.Robotics widely used in automobile ,Yellow goods.

But Indian Robotics market stands at 750 nos Compared

to China’s 4000nos yearly

3.Shipbuilding,Railways mostly adopting old manufacturing techniques.

4.Pressure vessels selectively use hard automation and yet to introduce high productive process barring few Organisations.

5.Not much automation in SS and AL Fabrication barring Space sector.

6.Most of the Automation is stand alone type and not much line solutions.


Challenges of welding automation

1.Percepion exists regarding lack of volume of job to justify ROI.

2.Bulk of the time goes for handling and fitting compared to Arc time. Which needs to be addressed concurrently.

3.Issue of acceptability of changed WPS by inspecting agencies.

4.Proper job preparations setup.

5.Introduction of special alloys.

6.More shifting to SS and Aluminium Alloys.

7.Growth of manufacturing economy without job crearion.

8.Availabilty of domain skilled manpower.


Technology Drivers For Welding Automation1.Gordon Moor’s law.

No of transistors doubles per square inch of integrated circuit in two years.

This allows digital signal processing chips to get miniaturised fast and cheap and allows digital closed loop control of the power sources making the dynamic charachteristics adaptable to process. Opens gate to intelligent,adaptive,communication enabled system.

2.Enhanced reliability of Switching devices like IGBTFast primary switching inverters cause fastest response, very high efficiency and reduction in size of present day welding process.This makes Welding Power Supplies Energy Efficient ,Fast acting & compact.

3.Sensors TORCH POSITION


b.Current,Voltage ,Gas Flow,Temperature -Transducers with data transmitters .

3.IOT-This will help in a big way to implement high end automation without the immediate availabity of domain knowledge.Moreover the visibility and analysis of data can help to improve the quality, productivity, cost in a big way


Drivers for welding Automation

TO HAVE A SUCCESSFUL MAKE IN INDIA INITIATIVE IT IS IMPERATIVE TO EMBRACE WELDING AUTOMATION IN A BIG WAY TO FACILITATE

1.Quality Consistency

2.Productivity

3.Total operational cost

4.Safety.

5.Deskilling

6.Become a world class manufacturing hub.

SOME SEGMENT BASED WELDING AUTOMATIONAPPLICATIONS


For Power Generation

Automation Solution ---Welding Industries

For Nuclear Job


For Pressure Vessel Industries


For Chemical Vessels

HYDROGEN REACTOR

Small Pipe Cladding90 deg Cladding

CAP seal Cladding

Flange Shield face welding machine

Vessel Strip Cladding Centre

PAD Automatic cladding

Heavy Rasping Machine

Mounted type Narrow Gap TIG

Narrow GAP SAW

NC shape Saddle Welder

Vertical Inner Cladding system

NC shape Saddle Cutter

Schematic of Hydrogen Reactors




Narrow GAP Technology for job thickness > 50mm thickness instead of conventional groove with 50 deg or 60 deg compound angle.

INCREASES PRODUCTIVITY,REDUCES CONSUMABLEs,REDUCED HEAT INPUT,LEAST DEFECT

Narrow Gap Hot wire TIG Narrow Gap SAW Narrow Gap MIG

32% 100% 117%




Hot Wire NARROW GAP TIG for thick Pipe welding

Melts theside wallsurely

10mm

Maximum100mm

16 zones for parameters control

Smooth transit on different zones

Transverse section of the job with Hot wire Narrow

GAP Technology

Tack tolerance to orbital narrow gap hot wire TIG welding

Automatic root welding (one side weld with back formation), precision as below:Gap tolerance: ≤0.5 mm；Misalignment: ≤0.5mm；Groove roughness: ≤12.5。




Hot Wire Narrow Gap TIG for thick plate welding

600mm welding, melt rate @

44g/min.

Narrow gap hot wire TIG welding for

500mm


Narrow Gap Specialized SAW torch with swing, seam tracking & sidewall tracking

Job: Thickness 50-400mmOpening at base: 18 mm & angle of 1-2 degree





Narrow GAP MIG

Wire reel

Wire feeder

Wire bend

Feed roller

2nd shield

NG torch(6mm wide)

GASWater

GAS

Double U grooveX-groove for conventional

The process save 70% wire and

75% energy, low distortion.




3D Cutting and Welding systems for the Nozzles

7 axes

Cutting of Nozzles and branch pipesWelding of Nozzles and pipes




Orbital welding system for tubes and Pipes




Dual Tungsten Cladding——State of the art technology with TIG process

Strip Cladding




90 deg cladding for Elbow


For Wind Tower industries


Offshore Wind Tower




4 edge milling work station.

Different Grooves




1+1 Shell fit up station.

Suitable for single shell with unsatisfied round.




Multi Wire SAW like Twin wire, Tandem for higher deposition.3 to 4 wires used in Pipe mills.

30

24

16

12

8

0 5 10 15 20 25 30 35

Tandem Twin + Twin

Tandem + Twin

Tandem

Twin Wire

Single Wire

Deposition(Kg/hr)

Deposition(Kg/hr)


For Process Industries


P+T seam welding with Hot Wire

P+T+ Hot Wire TIG process: Plasma torch in front for penetration and hot wire TIG followed for cover. It can increase the welding efficiency and quality.P+T+Hot wire is suitable for SS, Titanium alloy etc material welding with back side gas protection..

Thickness Plasma current TIG currentHot wire current

Wire feed speed Welding speed

6mm 270A 300A 100A 2000mm/min 400mm/min




For Process Industries


Deep Penetration TIG.

Deep penetration process (DP-TIG) is a kind of high efficiencyautomated weld process, which solves low arc stiffness, low penetration, low melt rate problems.

10mm butt joint without edge preparation/no groove required/no gap

required.


For Ship Building Industries


Panel line with OSW.


For Ship Building Industries


Laser Hybrid welding .

The combination of laser welding with another weld process is called a "hybrid welding process". This means that a laser beam and an MIG arc act simultaneously in one welding zone, influencing and supporting each other.

T Beam welding.


For Aerospace industries


Friction Stir Welding.

Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding.


For Railways industries


Robotic Welding line for the Railway Wagon

Automatic Production Line for the Side Wall of the Open Wagon Welding


For Yellow Goods industries


Robotic Welding with GMAW/ Tandem MIG


For Automobile industries


Robotic Welding in automobile


For Infrastructure industries-PEB


Pull through beam welding systems

H beam welding system with;1)Twin wire for less thick plates;2)Tandem welding for Thick plates;

3D CNC cutting solution for PEB



Intelligent monitoring system for SPM

LAN

network



Equipment real time monitoring

Data record

Fault diagnosis

Manufacture management

Technology management

Long distance debug

Data encryption


Sensor for Current, Voltage, Speed

Sensor for Part Identification

Sensor for Heat input data

Sensor for distortion

RFTRANSFORME R

Data Convert

er

Cloud server


IOT technology

CONCLUSION 1.To meet the Country’s aspiration in manufacturing domain (25% of GDP by 2025)we need to automate the entire range of Welding application on priority.

2.Need to have a world class fabrication ecosystem to cater to global requirement other than the nation.More so to capitalise on the opportunity arising out of migration of fabrication job from West and increasing manufacturing cost in Asia.

3.Replicate the success of Auto Components in other areas.

4.Organisations already in Automation space need to move to Line Solution with flexibility.

4.India can use it’s IT ability to bridge the skill gap.IOT can play a key role

5.Becoming a global hub for Shipbuilding,Railway Wagon,Pressure Vessels can create huge job opportunity.

6.Easy access to capital should be thought of for Automation thinking of the future.

7.This will be key to meet India’s pledge towards a environmentally sustainable growth.

FUTURE TRENDS AUTOMATED WELDING IN INDIA 7 - Automated... · Tack tolerance to orbital narrow gap...

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