Tuottavuutta automatisoidulla hitsauksella. Olli-Pekka Holamo

Transcription

1 Tuottavuutta automatisoidulla hitsauksella Olli-Pekka Holamo

2 Content Kemppi Oy Why automate/mechanize welding? Levels of automation in welding How to find correct solution? Investment- what to consider Kemppi offering for robotic and automated welding applications 2

3 3 Who we are?

4 Kemppi Oy Founded in 1949 by Martti Kemppi Private family-owned company with the third generation in charge Mrs. Teresa Kemppi-Vasama Executive Chairman of the Board, Kemppi Oy Mr. Antti Kemppi Executive Chairman of the Board, Kemppi Group Oy Over 600 employees in 13 countries Global revenue 112M (2016) Headquarters in Lahti, Finland 14 subsidiaries CEO Ville Vuori 4

5 Globally local Headquarters in Lahti, Finland 2 production facilities: in Finland and India 25 nationalities within Kemppi 260 repair workshops Deliveries to over 70 countries worldwide KEMPPI SUBSIDIARIES DISTRIBUTORS 5

6 6 Why automate?

7 Why mechanize/automate? 1. Competition continuous improvement required Cost reductions Shorter delivery times No compromises on quality 2. Capability to fulfil end customers requirements Technically demanding products and customer segments: off-shore, oil industry, nuclear power plants, process industry, pharmaceutics etc. Lack of skilled welders 7

8 Why mechanize/automate? Benefits for end customer: Gets high quality products with competitive costs and delivery times. Better service from manufacturing company. Benefits for manufacturing company: Higher arc on time ratio = more welds per day / welder Optimized welding parameters = maximized productivity / welder 8 Higher deposit rate (kg/h) Higher welding speeds (m/min) Consistent quality of welds = less defects = less waste on repair time and material. Consistency in welding times = strict cost control and easier production scheduling results in utilizing the resources better Benefits for welder: Better ergonomics Higher work safety level: less impact from open arc, welding fumes, heat etc. Job changes from execution towards supervising the process : welders unique know-how can be focused on arc and producing quality

9 Why automate? Change of ways of working + Kemppi process benefits = Maximizing value added part during working day Arc on time ratio from working time % Manual welding 30-60% Automated & Mechanized welding + Process = benefits. Example: Wise Fusion + 30 % to welding speed % Productivity 9

10 Why automate? Light mechanization is the most cost efficient way to improve productivity Cutting costs for produced weld kg with only small increase on equipment investment Relative cost for welded kg 10

11 11 How to automate?

12 How to automate? Levels of automation Automated and continuous sensing of welding conditions with instant feed back to process control Adaptive welding Solutions with suitable sensors and adaptive algorithms Automated movement of the torch for one or many welds (speed and path). Automated correction of the TCP location during welding. Exact weld locations can be automatically searched. Movement of the torch is mechanized for one weld (speed and path). Automated or semiautomated correction of the TCP during welding. Movement of the torch is mechanized for one weld (speed and path). manual correction of the TCP during welding. All parameters controlled manually (excl. Mechanized wire feed) 12 Automated welding Mechanized welding Manual welding Robotic welding Welding automates TIG Orbital welding Advanced carriage models with motorized slides and sensors Carriages with or with out rails - Straight welds - Circumferential welds Positioners+ fixed torches Manual welding offering

13 Typical solutions Moving the arc Kuvalähteet internet 13

14 Typical solutions Moving the work piece Kuvalähteet: internet Manipulators Not in Kemppi offering portfolio 14

15 15 Investment?

16 Investment What to consider? Equipment cost Training costs Labor cost Implementation time = when the target productivity level can be achieved (see. next slide) Life cycle costs Benefits from optimizing processes - effects also up and downstream from actual welding operations Management and supervision work costs Quality management costs (inspection, documentation) Costs from inadequate quality repair cost Customer relations imago, capability to deliver Flexibility capacity when needed 16

17 Meaning of ease of use Time used per weld [min] Every new weld requires learning and testing The surface under the learning curve shows how much time (=money) is wasted each time when new weld type or product is ramped up in production before target welding time level has been reached. With good, easy to use, equipment, the curve is steeper and starts from lower lever each time -> savings are achieved through the whole life span of the equipment. Target time per weld [min] 1 n Weld nr. [-] 17

18 Kemppi in robotic welding 18

19 Robot welding cell where is Kemppi Workpiece positioner Robot arm with welding equipment package* Mechanical safety system Robot controller Electrical safety system, incl. emergency stop User interface (teach pendant) 19

20 Robot welding cell where is Kemppi Welding equipment Robot welding system end customer price ranges from to Euro or higher. Average being around Euros. Welding equipment cost in system only approx % from total investment, but critical for success/productivity 20

21 History of Kemppi robotic welding power sources Thyristor Analog I/O control Wirefeed & voltage Inverter -> Synergic control -> Internal digital communication-> Digital I/O control-> Fieldbus-> Pulse curves TCS -equipment Web browser UI System setups via software Arc welding package PS Pro KempArc A

22 Kemppi solutions 22

23 Complete arc welding function package for robotic welding from KEMPPI 23

24 Kemppi offering 2018 Robot welding Only main items listed here, for full offering pls. refer to additional material A7 MIG Welder 350/450 Digital Interface KempArc Pulse 350/450 Digital Inteface KempArc Synergic 500 Digital Interface KempArc Pulse 450 Analog Interface KempArc Synergic 500 Analog Interface KempArc Pulse TCS Power source code A7 MIG POWER SOURCE A7 MIG POWER SOURCE KEMPARC PULSE KEMPARC PULSE KEMPARC SYN AN AN KEMPARC PULSE TCS Wire feeder code A7 MIG WIRE FEEDER 25-LH-EUR (Euro ver.) A7 MIG WIRE FEEDER 25-LH-PP (PowerPin ver.) DT400 (Euro ver.) L DT400 (Euro ver.) DT410 (PowerPin ver.) DT400 (Euro ver.) L DT400 (Euro ver.) DT410 (PowerPin ver.) DT400 (Euro ver.) L DT400 (Euro ver.) DT410 (PowerPin ver.) DT400 (Euro ver.) L DT400 (Euro ver.) DT410 (PowerPin ver.) DT400 (Euro ver.) L DT400 (Euro ver.) Water cooler code A7 Cooler Cool X KempCool KempCool KempCool KempCool KempCool 40 Welding gun Packages for A7 MIG Gun 500 w A7 MIG Gun 500 -g Packages for A7 MIG Gun 500 w A7 MIG Gun 500 -g Packages for A7 MIG Gun 500 w A7 MIG Gun 500 -g Packages for A7 MIG Gun 500 w A7 MIG Gun 500 -g Packages for A7 MIG Gun 500 w A7 MIG Gun 500 -g (Binzel, Dinse, TBI tandem) Ref. pic.

25 Wire feeder Torch cable bundle length according to robot type Euro version Power pin version Gas cooled version Water cooled version Adapter flange according to robot type and torch clamp type Kemppi Gun mount Euro version Power pin version Wire hose with liner and connectors A7 Wire Feeder 25 Hollow wrist version Collision detector version - Robot mount T1 Bracket for Wire feeder with bolts, according to robot type Dummy version: - Robot mount T3 Robot interface Fieldbus module according to robot type Interconnection cable Cable clamps Standard version Collision detector version - Robot mount T2 Dummy version: - Holding bracket T4 Welding power source Kemppi Welding Gun Neck A7 MIG Welder 350 A7 MIG Welder 450 Wire coil mounting (bob holder) with attachment bracket, cover and floor stand Wire conduit with snap connectors for wire drum 25 Water cooler A 7 Cooler Cool X Torch cleaning unit Gas cooled version: - A7 MIG Gun 500-g (22º, 35º, 45º) Water cooled version: - A7 MIG Gun 500-w (22º, 35º, 45º)

26 Kemppi equipment in welding system Kemppi scope of supply Integrator scope of supply Cable assembly Flange for 6th axis Robot controller with fieldbus card and I/O connections Robot arm Safety system Contact tip Gas nozzle Contact tip holder Gun neck Liner for cable assembly T1 gun mount CABLES: - Interconnection cable bundle - Earthing cable Socket for power cable Mounting bracket for Wire feeder Wire feeder Wire conduit Feeder roller kit Welding power source with robot interface unit and power cable (without socket) Water cooling unit Fieldbus module Fieldbus EDS file Fieldbus cable Programming work Fieldbus configuration Other components: - Workpiece positioner - Fixtures - Material flow intgration - Additional tools - Programs - Etc. Bobbin holder (with floor stand) Stand for power source Programming work IO mapping 26 Welding application software Gun cleaning unit Integration guide

27 Kemppi Wise-processes 27

28 Appendix A7 MIG Welder 350/450 calculation: WiseFusion in robotized welding Welding production figures Manufacturer: Contract manufacturing workshop Products: Boom structures for container cranes Joint: T joint, throat thickness 5 mm Welding: Mechanized MAG welding, duty cycle 50 % Number of welders: 10 welders x 2 shifts per day = 20 welders Man hours per year: 20 welders x 1800 hours per person a year = man hours/year Welding cost: 2,5 /meter (including labor cost, filler material, shielding gas, energy, equipment etc.) Present technology Arc-on time: h x 50 % duty cycle = h/year Amount of welding: h x 0,6 m/min (welding speed) x 60 = 648 km Benefit with WiseFusion Amount of welding : h x 52 % x 0,72 cm/min (welding speed) x 60 = 809 km Benefit: 809 km km = 161 km = 25% more welding Value of the benefit: 161 km x 1000 x 2,5 /m = 402,5 k Benefits of WiseFusion in this application 20 % higher welding speed than in conventional spray arc welding (60 cm/min -> 72 cm/min) 4 % higher arc-on time because no need for arc length adjustments (50 % -> 52 % duty cycle) 25% more welding / year 28 Date

29 Kemppi processes: WiseThin+ Excellent welding characteristics for welding plate thicknesses mm Higher welding speed than in traditional shot arc welding WiseThin+ is a MIG/MAG welding process 131, 133, 135, 136 or 138 according to standard EN ISO Example: In overlap welding high welding speed and small deformations are the benefits Wire ER70S-G/G3Si1 D = 1,0 mm Shielding gas Ar+8-25%CO2 Base material EN S235JRG2 t = 1 mm Welding position PA Wfr= 2,7 m/min v = 1,2 m/min

30 Kemppi processes: WisePenetration WisePenetration offers a constant penetration even when stick-out is changing during welding. -> Cost effective solution to avoid continuous need for height adjustment 30

31 Kemppi processes: RGT RGT (Reduced Gap Technology) is a narrow gap welding solution from Kemppi, which can be applied up to 30 mm welds from one side without any special equipment. Arc on time Arc on time, 45 o : 810 s Arc on time, 20 o : 505 s Difference 305 s, welding time 38% shorter Wire consumption Weld cross section area, 45 o : 372 mm 2 Weld cross section area, 20 o : 281 mm 2 Difference 91 mm 2, savings in wire consumption 25% 7 passes 5 passes Traditional RGT 31

32 Kemppi processes: Welding of root pass In case of MIG-welding, proper weld groove preparation enables mechanized welding of the root pass with WiseRoot+ process and thus achieve benefits which were earlier out of reach. 32

33 Unique Kemppi Features 33

34 Kemppi A7 MIG Welder 350/450 Touch Sense Ignition example results Touch sense ignition feature provides longer life time for contact tips After 5000 ignitions with TSI (total number of ignitions 25000) : - All 5 contact tips were intact/ok After 5000 ignitions without TSI (total number of ignitions 19500): - 3 Contact tips were intact/ok - 2 were damaged and could not perform 5000 arc starts Welding parameters : PMIG 1,0 mm Ss, Ar + 2 % CO2 (S03), 3,6 m/min Wire: Elga CromaMig 316LSi Ø 1,0 mm Stick out: 15 mm Base material: 4 mm 316L Ignition direction: Perpendicular to plate Touch sense ignition resulted in increase of 28% in number of successful ignitions because of: - less spatter generation, - less harmful short circuits and - lower ignition pulse level. With Touch Sense Ignition Without Touch Sense Ignition 34

35 A7 MIG Welder 350/450 seam tracking As a standard feature, A7 MIG Welder provides a signal for Through the Arc Seam Tracking (TAST). The signal is transmitted via fieldbus communication to the robot controller. Benefits: Reliable tracking also with Kemppi s pulsed MIG and double-pulsed MIG processes Cost savings and simpler robot cell design, because no additional hardware is required at the robot controller end 35

36 A7 Web User Interface - New era for accessibility and management Access to power source from external computer via Ethernet with a regular web browser User management and login Memory channel configuration Fieldbus configuration Logbook monitoring and download Welding system settings Emergency stop configuration Gate door switch configuration Setup panel functionality Online meters Welding parameters Backup and restore 36

37 Web User Interface - New era for accessibility and management 37

38 Web User Interface - New era for accessibility and management 38

39 Web User Interface - New era for accessibility and management 39

40 Other ways to improve 40

41 Kemppi offering 2018 MIG mechanization Only main items listed here, for full offering pls. refer to additional material A5 MIG Rail system 2500 A3 MIG Rail system 2500 A5 MIG Orbital system 1500 MagTrac F61 Carriage A5 MIG RAIL CARRIAGE A5 MIG RAIL CARRIAGE ES A5 MIG RAIL CARRIAGE ES DD A3 MIG RAIL CARRIAGE A5 MIG ORBITAL CARRIAGE A5 MIG ORBITAL CARRIAGE ES MAGTRAC F 61 Welding Gun MT51MWC PMT MN 32C MMT 42C MT51MWC PMT MN 32C MMT 42C MT51MWC PMT MN 32C MMT 42C MT51MWC PMT MN 32C MMT 42C Welding power source and wire feeder FastMig M FastMig X Wise Processes FastMig M FastMig X Wise Processes FastMig X FastMig M Wise Processes FastMig M FastMig X Wise Processes For circumferential welding outer D [mm] > 1500 mm with bent rails mm with rings Ref. pic. Kemppi mechanization and automation solutions / OPH

42 Conclusions Everywhere companies invests continuously on mechanization and automation Avoid partly optimizing your manufacturing processes -> Do not purchase equipment, invest on solutions Equipment, process, training, continuous service and support and development Mechanization + process know-how + product know-how = winning combination Sometimes you have to change the ways of working so that equipment can be utilized in the most efficient way 42

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