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AUTOMATION SOLUTIONS FOR COMPLEX HOT WIRE WELDING AND CLADDING APPLICATIONS DSP Based Control and Power Supply Products.

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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 uses Present control architectures, automation interface, and process-monitoring requirements Review 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 HOT WIRE BACKGROUND zProcess Basics yIncoming wire is resistance heated to near the melting point via a power supply connected to the wire feed tube yWire is typically added to the rear of the pool yWire typically enters the pool at a high angle >45° zProcess Results yIncrease productivity by up to 8-10 times xIncreased fill rates, travel speed, and narrower joint design x1/4-1/2 root land width and 2-6° bevel angle xDouble travel rates from GTA x2-4 times wire feed rates (up to 300 ipm in the flat position, depending on quality requirements) yMaintains GTA weld quality yAllows splitting energy between the main arc and the wire heating yPreheating the wire to the melting point makes the wire feed into the pool smoother yCan provide greater control of pool size and side wall erosion yProvides greater control of slope in and slope out of weld pool and wire deposition yImproved control of dilution for cladding operations Approximately 50% of our systems are Hot Wire WORK TRAVEL

4 HOT WIRE BACKGROUND Equipment zHot Wire Power Supplies for GTA or Plasma yDC Supplies xWire typically feed into the front of pool xCan have wire feed synchronized with current pulse yAC Supplies (mitigate arc blow) xWire typically feed into the the rear of pool xVariable Frequency Improves flow of wire into the weld pool zHot Wire Torch yContact for transferring current to wire yGas coverage optional zVoltage / Current Control Sensing yPower supply vs. torch (accounting for cable losses) Camera Systems Bore Considerations (size, heat, ext. lighting) Water / Gas Cooling

5 HOT WIRE - More Fill Faster GTA QUALITY AT THE SPEED OF GMA zApplications yImprove production rates on high volume products yReduce the total weld time for thick wall products yProduct requirements that cant be met with GMA/SMAW yCladding to reduce overall cost of products xExpensive clad on lower cost material yCladding to produce bi-metallic products xSurface protection on high strength base yCladding to repair casting or other process related defects zQuality vs Productivity 6-5/8 / wall High Production - 15 Minutes High Quality - 60 Minutes Boilers and Pressure Vessels Chemical Plant Piping Nuclear Vessels Oil and Gas Thick Section Pipe Oil and Gas Drilling and Production Riser Pipe Oil and Gas Valve Products Mining 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 welders Disadvantages 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 Parameters Weld Current Pulsation Part / Torch Motion and Position Coordinated motion for spiral, tapered bore, and intersecting bore cladding Jog offset / override Multi-pass for thick sections Synchronized with pulsation Wire Feed Speed Synchronized with Pulsation / Oscillation Hot Wire Voltage / Current Arc Voltage Control Advanced Control Parameters Magnetic Oscillation Synchronization capability Mechanical Oscillation Synchronization capability Hot Wire Frequency Wire Nozzle Position Sensor Integration Joint Tracking Inter-pass Temperature Independent Part Position Gap Measurement Override Capability Video Monitoring / Recording Process Monitoring / Data Acquisition

9 Power Supply Control Module CAN BUS Pendant/ Operator Display AdditionalControl Power Supply Gas Solenoid Fault Sensors Current Sensor Linear Slide/ Servo Motor/ Encoder Voltage Sensor Servo Motor/ Encoder Linear/ Rotational Linear Slide/ Servo Motor/ Encoder Wire Feed/ Servo Motor/ Encoder AVC Control Servo Axis Control (Travel) Mech Osc. Control Wire Feed Control XM Modular Architecture

10 HIGH PRODUCTION SYSTEMS Mult-Station Conventional Welding Applications Requiring Higher Production Rates z0.125 to Stainless Steel zMulti-process / Multi-Station yGTA Cold and Hot Wire Feed yGirth or Plug Weld Capability zDSP based control zMagnetic Oscillation zIntegrated AVC yEither Z or X axis zProcess Monitoring / Verification

11 Precision Hot Wire Valve Body Welding / Bore Cladding System - Thick section hot wire process -Helical bore cladding -3 Station production system Critical property and high production requirements for sub-sea oil and gas welding applications MULTI-PROCESS SYSTEMS

12 INTERSECTING BORE SYSTEMS BelWeld / ERC Intersecting Bore Cladding Systems for Straight and Tapered Bores - Inconel Weld Overlay oMULTIPLE INTERSECTING BORES oSEAL PASS CAPABILITY oSTRAIGHTFORWARD PROGRAMMING INTERFACE oINTEGRATED VIDEO oHOT WIRE BORE TORCHES

13 BelWeld / ERC Intersecting Bore Cladding Systems for Straight and Tapered Bores - Inconel Weld Overlay oMULTIPLE INTERSECTING BORES oSEAL PASS CAPABILITY oSTRAIGHTFORWARD PROGRAMMING INTERFACE oINTEGRATED VIDEO oHOT WIRE BORE TORCHES INTERSECTING BORE SYSTEMS

14 NARROW GROOVE SYSTEMS GTA Hot Wire Thick Section Narrow Groove Naval Components oVIRTUAL CENTERING oADAPTIVE GAP CONTROL oINTEGRATED DATA BASE oINTEGRATED VIDEO oINDEPENDENT MONITORING

15 SMI Precision Hot Wire Pipe/Bore Cladding System - Thick section narrow-grove hot wire process - Helical bore cladding Critical property and high production requirements for sub-sea oil and gas welding applications NARROW GROOVE SYSTEMS

16 SENSORS POSITION SENSORS zTactile zScanning Lasers zMechanically Scanned Laser yClosed Loop Position Control ySingle-point proximity laser yDetermines feature vs. cross seam position yAllows programmed offset from identified feature by pass yAllows operator offset from identified feature yCan identify root gaps and modify control setpoints

17 AUTOMATION INTERFACE Interface Demonstration

18 DSPs, Data Acquisition, & Process Monitoring zData Acquisition is the collection of the welding data. DSPs 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. zProcess 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 DSPs are an exceptional platform to provide focused processing power for this real- time analysis. zThe 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 filtering Sample Advent feedback with DSP filtering

19 Process Monitoring Information zDedicated DSPs 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. zData can be analyzed in real-time to determine: yWeld current pulsation and AC performance yArc Voltage consistency yTorch / Part Position and Velocity performance yStatistical Minimums, Maximums, Averages, Std. Deviations and other parameters yOut-of-Tolerance Magnitudes, Positions, and Durations. zThis 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 SUMMARY zHOT 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. zCONTROL 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. zSOPHISTICATED, 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

21 AMET z22,000 sq.ft. Manufacturing/Development Facility zGTA / GMA / Plasma Development/Production Systems zCircuit Board Design / Automated Electronics Manufacturing zAutomated Machine Shop Capabilities z42 Engineering and Technical Personnel

22 AMET DSP Controller Products XM Controller Multiple Channel Position based Process Monitoring Easily Expandable Advent Controller Multiple Channel Position Based Coordinated Motion Integrated Data Monitoring Integrated Video VPC 450 Variable Polarity Power Supply High Speed Power Module Inverter 450 Amp 100% Duty Cycle Intelligent DSP Controls DC/VP/AC/Mixed VP Modes of Operation Local or Remote Control


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