FUTURE TURE TR TRENDS ENDS AU AUTO TOMA MATE TED WELDING DING - - PowerPoint PPT Presentation

FUTURE TURE TR TRENDS ENDS – AU AUTO TOMA MATE TED WELDING DING IN N INDIA IA

GAUTAM BANERJEE KAIYUAN INDIA

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P2 P2

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 le of f Welding in in Make in in In India

1.Infrastructure

a)Roads b)Bridges c)Airport d)Buildings

3.Process 4.Transport 5.Mining 6.Oil and Gases 7.Aerospace 2.Power

a)Fossil Fuel b)Nuclear c)Wind d)Hydro e)Solar

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P4

As is is situ ituation of f automatic welding in in 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.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P5

Challenges of f weld lding 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.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P6

Tech chnology Driv rivers For r Weld lding Automation

1.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 IGBT

Fast 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

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P7

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

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P8

Driv rivers for r weld lding 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 AUTOMATION APPLICATIONS

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P10 P10

For Power Generation

Automation Solution ---Welding Industries

• For Nuclear Job

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P11 P11

For Pressure Vessel Industries

Automation Solution ---Welding Industries

• For Chemical Vessels

HY HYDROGEN RE REACT CTOR

Small Pipe Cladding 90 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

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P13 P13

For Pressure Vessel Industries

Automation Solution ---Welding Industries

• 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%

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P14 P14

For Pressure Vessel Industries

Automation Solution ---Welding Industries

• Hot Wire NARROW GAP TIG for thick Pipe welding

Melts the side wall surely 10mm

Maximum 100mm

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。

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P16 P16

For Pressure Vessel Industries

Automation Solution ---Welding Industries

• Hot Wire Narrow Gap TIG for thick plate welding

600mm welding, melt rate @ 44g/min. Narrow gap hot wire TIG welding for 500mm

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P17 P17

Narrow Gap Specialized SAW torch with swing, seam tracking & sidewall tracking Job: Thickness 50-400mm Opening at base: 18 mm & angle of 1-2 degree

Automation Solution ---Welding Industries

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P18 P18

For Pressure Vessel Industries

Automation Solution ---Welding Industries

• Narrow GAP MIG

Wire reel Wire feeder Wire bend Feed roller 2nd shield NG torch(6mm wide)

GAS Water GAS

Double U groove X-groove for conventional The process save 70% wire and 75% energy, low distortion.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P19 P19

For Pressure Vessel Industries

Automation Solution ---Welding Industries

• 3D Cutting and Welding systems for the Nozzles

7 axes

Cutting of Nozzles and branch pipes Welding of Nozzles and pipes

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P20 P20

For Pressure Vessel Industries

Automation Solution ---Welding Industries

• Orbital welding system for tubes and Pipes

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P21 P21

For Pressure Vessel Industries

Automation Solution ---Welding Industries

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

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P22 P22

For Pressure Vessel Industries

Automation Solution ---Welding Industries

• 90 deg cladding for Elbow

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P23 P23

For Wind Tower industries

Automation Solution ---Welding Industries

• Offshore Wind Tower

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P24 P24

For Wind Tower industries

Automation Solution ---Welding Industries

• 4 edge milling work station.

Different Grooves

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P25 P25

For Wind Tower industries

Automation Solution ---Welding Industries

• 1+1 Shell fit up station.

Suitable for single shell with unsatisfied round.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P26 P26

For Wind Tower industries

Automation Solution ---Welding Industries

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

30 24 16 12 8 5 10 15 20 25 30 35 Tandem Twin + Twin Tandem + Twin Tandem Twin Wire Single Wire

Deposition(Kg/hr)

Deposition(Kg/hr)

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P27 P27

For Process Industries

Automation Solution ---Welding 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 current Hot wire current Wire feed speed Welding speed 6mm 270A 300A 100A 2000mm/min 400mm/min 8mm 260A 260A 90A 1500mm/min 240mm/min 10mm 230A 200A 90A 1000mm/min 170mm/min

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P28 P28

For Process Industries

Automation Solution ---Welding Industries

• Deep Penetration TIG.

Deep penetration process (DP-TIG) is a kind of high efficiency automated 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.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P29 P29

For Ship Building Industries

Automation Solution ---Welding Industries

• Panel line with OSW.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P30 P30

For Ship Building Industries

Automation Solution ---Welding 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.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P31 P31

For Aerospace industries

Automation Solution ---Welding 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.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P32 P32

For Railways industries

Automation Solution ---Welding Industries

• Robotic Welding line for the Railway Wagon

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

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P33 P33

For Yellow Goods industries

Automation Solution ---Welding Industries

• Robotic Welding with GMAW/ Tandem MIG

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P34 P34

For Automobile industries

Automation Solution ---Welding Industries

• Robotic Welding in automobile

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P35 P35

For Infrastructure industries-PEB

Automation Solution ---Welding Industries

• 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

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P36 P36

Automation Solution ---Welding Industries

Intelligent monitoring system for SPM

LAN network

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P37 P37

Automation Solution ---Welding Industries

Equipment real time monitoring Data record Fault diagnosis Manufacture management Technology management Long distance debug Data encryption

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P38 P38

Sensor for Current, Voltage, Speed Sensor for Part Identification Sensor for Heat input data Sensor for distortion RF T R A N S F O R M E R Data Convert er Cloud server

Automation Solution ---Welding Industries

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.

Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P40