FUTURE TURE TR TRENDS ENDS – AU AUTO TOMA MATE TED WELDING DING IN N INDIA IA GAUTAM BANERJEE KAIYUAN INDIA
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 P2 P2 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Role le of f Welding in in Make in in In India 1.Infrastructure 2.Power 3.Process a)Fossil Fuel a)Roads 4.Transport b)Nuclear b)Bridges 5.Mining c)Wind c)Airport d)Hydro 6.Oil and Gases d)Buildings e)Solar 7.Aerospace P3 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
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. P4 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
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. P5 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
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 P6 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
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 P7 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
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. P8 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
SOME SEGMENT BASED WELDING AUTOMATION APPLICATIONS
Automation Solution ---Welding Industries For Power Generation For Nuclear Job P10 P10 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Pressure Vessel Industries For Chemical Vessels P11 P11 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
HY HYDROGEN RE REACT CTOR Small Pipe Cladding 90 deg Cladding Vertical Inner Cladding system Flange Shield face welding machine NC shape Saddle Cutter CAP seal Cladding Schematic of Hydrogen Reactors Heavy Rasping NC shape Saddle Welder Machine PAD Automatic cladding Vessel Strip Mounted type Narrow Gap Narrow GAP SAW Cladding Centre TIG
Automation Solution ---Welding Industries For Pressure Vessel 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 32% 100% 117% Narrow Gap SAW Narrow Gap MIG Narrow Gap Hot wire TIG P13 P13 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Pressure Vessel Industries Hot Wire NARROW GAP TIG for thick Pipe welding Maximum 100mm 16 zones for parameters control Smooth transit on different zones Melts the side wall 10mm surely Transverse section of the job with Hot wire Narrow GAP Technology P14 P14 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
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 。
Automation Solution ---Welding Industries For Pressure Vessel Industries Hot Wire Narrow Gap TIG for thick plate welding Narrow gap 600mm welding, hot wire TIG melt rate @ welding for 44g/min. 500mm P16 P16 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries 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 P17 P17 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Pressure Vessel Industries Narrow GAP MIG Wire reel Wire feeder GAS Water Wire bend GAS Feed roller 2 nd shield NG X-groove for Double U groove torch(6mm conventional The process save 70% wire and wide) 75% energy, low distortion. P18 P18 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Pressure Vessel Industries 3D Cutting and Welding systems for the Nozzles Welding of Nozzles and pipes Cutting of Nozzles and branch pipes 7 axes P19 P19 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Pressure Vessel Industries Orbital welding system for tubes and Pipes P20 P20 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Pressure Vessel Industries Dual Tungsten Cladding —— State of the art technology with TIG process Strip Cladding P21 P21 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Pressure Vessel Industries 90 deg cladding for Elbow P22 P22 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Wind Tower industries Offshore Wind Tower P23 P23 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Wind Tower industries 4 edge milling work station. Different Grooves P24 P24 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Wind Tower industries 1+1 Shell fit up station. Suitable for single shell with unsatisfied round. P25 P25 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries For Wind Tower industries Multi Wire SAW like Twin wire, Tandem for higher deposition.3 to 4 wires used in Pipe mills. Deposition(Kg/hr) Single Wire 8 Twin Wire 12 Tandem 16 Tandem + Twin 24 Tandem Twin + Twin 30 0 5 10 15 20 25 30 35 Deposition(Kg/hr) P26 P26 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
Automation Solution ---Welding Industries 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. . Hot wire Thickness Plasma current TIG current Wire feed speed Welding speed current 6mm 270A 300A 100A 2000mm/min 400mm/min 8mm 260A 260A 90A 1500mm/min 240mm/min 10mm 230A 200A 90A 1000mm/min 170mm/min P27 P27 Kaiyuan Welding & Cutting Automation India Pvt., Ltd.
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