Presentation on theme: "AUTOMATION SOLUTIONS FOR COMPLEX HOT WIRE WELDING AND CLADDING APPLICATIONS “DSP” Based Control and Power Supply Products."— Presentation transcript:
1 AUTOMATION SOLUTIONS FOR COMPLEX HOT WIRE WELDING AND CLADDING APPLICATIONS “DSP” Based Control and Power Supply Products
2 PRESENTATION OVERVIEW Present basic review of the Hot Wire Process and its usesPresent control architectures, automation interface, and process-monitoring requirementsReview several automated systems that perform critical narrow-groove welding and cladding operations.Demonstrate software solutions that provide virtual alignment to compensate for torch/part misalignment, joint feature tracking for real-time compensation of torch-to-part movement, and internal cladding of valves with intersecting bores.
3 Approximately 50% of our systems are Hot Wire HOT WIRE BACKGROUNDProcess BasicsIncoming wire is resistance heated to near the melting point via a power supply connected to the wire feed tubeWire is typically added to the rear of the poolWire typically enters the pool at a high angle >45°Process ResultsIncrease productivity by up to 8-10 timesIncreased fill rates, travel speed, and narrower joint design1/4”-1/2” root land width and 2-6° bevel angleDouble travel rates from GTA2-4 times wire feed rates (up to 300 ipm in the flat position, depending on quality requirements)Maintains GTA weld qualityAllows splitting energy between the main arc and the wire heatingPreheating the wire to the melting point makes the wire feed into the pool smootherCan provide greater control of pool size and side wall erosionProvides greater control of slope in and slope out of weld pool and wire depositionImproved control of dilution for cladding operationsApproximately 50% of our systems are Hot WireTRAVELWORK
4 HOT WIRE BACKGROUND Equipment Camera Systems Hot Wire Power Supplies for GTA or PlasmaDC SuppliesWire typically feed into the front of poolCan have wire feed synchronized with current pulseAC Supplies (mitigate arc blow)Wire typically feed into the the rear of poolVariable FrequencyImproves flow of wire into the weld poolHot Wire TorchContact for transferring current to wireGas coverage optionalVoltage / Current Control SensingPower supply vs. torch (accounting for cable losses)Camera SystemsBore Considerations (size, heat, ext. lighting)Water / Gas Cooling
5 HOT WIRE - “More Fill Faster” “GTA QUALITY AT THE SPEED OF GMA”ApplicationsImprove production rates on high volume productsReduce the total weld time for thick wall productsProduct requirements that can’t be met with GMA/SMAWCladding to reduce overall cost of productsExpensive clad on lower cost materialCladding to produce bi-metallic productsSurface protection on high strength baseCladding to repair casting or other process related defectsQuality vs Productivity6-5/8 / wallHigh Production - 15 MinutesHigh Quality - 60 MinutesBoilers and Pressure VesselsChemical Plant PipingNuclear VesselsOil and Gas Thick Section PipeOil and Gas Drilling and Production Riser PipeOil and Gas Valve ProductsMining and Exploration Products
6 HOT WIRE / AUTOMATION Advantages • Higher production rates because of continuous processing• Narrow gap bevel options / Less weld metal required• Automation provides for the ability to continuously make the root and fill passes, even if the root pass is cold wire / Higher productivity• More process consistency resulting in more consistent joints with improved weld strength, toughness / Fewer repairs• Ability to weld high strength steels and alloys / Higher component properties• Reduces human error factor / Higher quality and productivity, especially with long duration welds• Less physical strain on welders especially on long welding/cladding processes / higher quality and productivity• Less manpower/equipment for heavy wall and large diameter components / lower processing costs• Documentation / traceability / Better QA-QC• Ease of training weldersDisadvantages• More complex systems• Higher initial system cost• Higher level of control equipment is required
7 AUTOMATION SYSTEM DESIGN Establish Requirements, Develop Concepts, Model Concepts, Fabricate and Test
8 AUTOMATION CONTROL AUTOMATION CONTROL REQUIREMENTS Basic Control ParametersWeld CurrentPulsationPart / Torch Motion and PositionCoordinated motion for spiral, tapered bore, and intersecting bore claddingJog offset / overrideMulti-pass for thick sectionsSynchronized with pulsationWire Feed SpeedSynchronized with Pulsation / OscillationHot Wire Voltage / CurrentArc Voltage ControlAdvanced Control ParametersMagnetic OscillationSynchronization capabilityMechanical OscillationHot Wire FrequencyWire Nozzle PositionSensor IntegrationJoint TrackingInter-pass TemperatureIndependent Part PositionGap MeasurementOverride CapabilityVideo Monitoring / RecordingProcess Monitoring / Data Acquisition
10 HIGH PRODUCTION SYSTEMS Mult-Station Conventional Welding Applications Requiring Higher Production Rates0.125” to 0.250” Stainless SteelMulti-process / Multi-StationGTA Cold and Hot Wire FeedGirth or Plug Weld CapabilityDSP based controlMagnetic OscillationIntegrated AVCEither Z or X axisProcess Monitoring / Verification
11 MULTI-PROCESS SYSTEMS Critical property and high production requirements for sub-sea oil and gas welding applicationsPrecision Hot Wire Valve Body Welding / Bore Cladding System- Thick section hot wire processHelical bore cladding3 Station production system
12 INTERSECTING BORE SYSTEMS MULTIPLE INTERSECTING BORESSEAL PASS CAPABILITYSTRAIGHTFORWARD PROGRAMMING INTERFACEINTEGRATED VIDEOHOT WIRE BORE TORCHESBelWeld / ERC Intersecting Bore Cladding Systems for Straight and Tapered Bores - Inconel Weld Overlay
13 INTERSECTING BORE SYSTEMS MULTIPLE INTERSECTING BORESSEAL PASS CAPABILITYSTRAIGHTFORWARD PROGRAMMING INTERFACEINTEGRATED VIDEOHOT WIRE BORE TORCHESBelWeld / ERC Intersecting Bore Cladding Systems for Straight and Tapered Bores - Inconel Weld Overlay
14 NARROW GROOVE SYSTEMS GTA Hot Wire Thick Section Narrow Groove Naval ComponentsVIRTUAL CENTERINGADAPTIVE GAP CONTROLINTEGRATED DATA BASEINTEGRATED VIDEOINDEPENDENT MONITORING
15 NARROW GROOVE SYSTEMSCritical property and high production requirements for sub-sea oil and gas welding applicationsSMI Precision Hot Wire Pipe/Bore Cladding System- Thick section narrow-grove hot wire process- Helical bore cladding
16 SENSORS POSITION SENSORS Tactile Scanning Lasers Mechanically Scanned LaserClosed Loop Position ControlSingle-point proximity laserDetermines feature vs. cross seam positionAllows programmed offset from identified feature by passAllows operator offset from identified featureCan identify root gaps and modify control setpoints
18 DSP’s, Data Acquisition, & Process Monitoring Data Acquisition is the collection of the welding data. DSP’s are designed to perform this at very high rates. This high-speed data is necessary to accurately represent the process which was performed. However it can be very difficult and usually unmanageable to review large amounts of raw data.Process Monitoring is the analysis of the welding data to determine that the process was performed as programmed and the overall variation in the process. This analysis is often performed after the welding process due to the computer processing requirements. Again dedicated DSP’s are an exceptional platform to provide focused processing power for this “real-time” analysis.The results of the analyzed data, which is significantly less data, can then be transported via the network for printing, storage, etc. as a record of process performance.Sample Advent feedback without filteringSample Advent feedback with DSP filtering
19 Process Monitoring Information Dedicated DSP’s can provide “real-time” sampling, processing and analysis of welding data. The high speed analysis of the data can ensure that the process is monitored at a high rate but the data can be statistically evaluated to reduce the overall data for review and storage.Data can be analyzed in real-time to determine:Weld current pulsation and AC performanceArc Voltage consistencyTorch / Part Position and Velocity performanceStatistical Minimums, Maximums, Averages, Std. Deviations and other parametersOut-of-Tolerance Magnitudes, Positions, and Durations.This important and powerful capability allows the data to be pre-processed as the welding is being performed so that only significant and relevant “processed” data needs to be recorded.
20 SUMMARYHOT WIRE POWER SUPPLIES AND CONTROLS ARE RAPIDLY IMPROVING AND FINDING GREATER ACCEPTANCE AS THE OPTIMAL AUTOMATION SOLUTION TO OBTAINING HIGHER PRODUCTION THAN GTA-CWF PROCESSES AND/OR IMPROVED PROPERTIES OVER GMA AND SUB-ARC APPLICATIONS.CONTROL HARDWARE / SOFTWARE AND SENSOR INTEGRATION ARE EXPANDING THE CAPABILITIES OF ALL PROCESSES, INCLUDING HOT WIRE TO BE EFFECTIVELY USED FOR APPLICATIONS WITH DIFFICULT GEOMETRIES AND CRITICAL MATERIAL PROPERTY REQUIREMENTS.SOPHISTICATED, MODULAR, NETWORKED BASED SYSTEMS THAT CAN PRODUCE OUTSTANDING WELDS FOR COMPLEX WELDING OPERATIONS, INCLUDING INTERSECTING BORES, MULTI-PASS THICK SECTION NARROW GROOVE, AND TAPERED BORES ARE MORE AVAILABLE AND PROVEN THAN EVER. THESE SYSTEMS ARE PROVIDING SIGNIFICANT PRODUCTIVITY AND QUALITY IMPROVEMENTS OVER MANUAL OR SEMI-AUTOMATED PROCESSES
Your consent to our cookies if you continue to use this website.