FUTURE TRENDS – AUTOMATED WELDING IN INDIA
GAUTAM BANERJEE
KAIYUAN INDIA
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P2P2
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
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Role of Welding in Make in India
1.Infrastructurea)Roads
b)Bridges
c)Airport
d)Buildings
3.Process
4.Transport
5.Mining
6.Oil and Gases
7.Aerospace
2.Powera)Fossil Fuel
b)Nuclear
c)Wind
d)Hydro
e)Solar
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As is situation of automatic welding 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.
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Challenges of welding 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.
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Technology Drivers For Welding Automation1.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 IGBTFast 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
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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
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Drivers for welding 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 AUTOMATIONAPPLICATIONS
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P10P10
For Power Generation
Automation Solution ---Welding Industries
For Nuclear Job
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P11P11
For Pressure Vessel Industries
Automation Solution ---Welding Industries
For Chemical Vessels
HYDROGEN REACTOR
Small Pipe Cladding90 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. P13P13
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. P14P14
For Pressure Vessel Industries
Automation Solution ---Welding Industries
Hot Wire NARROW GAP TIG for thick Pipe welding
Melts theside wallsurely
10mm
Maximum100mm
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. P16P16
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. P17P17
Narrow Gap Specialized SAW torch with swing, seam tracking & sidewall tracking
Job: Thickness 50-400mmOpening at base: 18 mm & angle of 1-2 degree
Automation Solution ---Welding Industries
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P18P18
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)
GASWater
GAS
Double U grooveX-groove for conventional
The process save 70% wire and
75% energy, low distortion.
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P19P19
For Pressure Vessel Industries
Automation Solution ---Welding Industries
3D Cutting and Welding systems for the Nozzles
7 axes
Cutting of Nozzles and branch pipesWelding of Nozzles and pipes
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P20P20
For Pressure Vessel Industries
Automation Solution ---Welding Industries
Orbital welding system for tubes and Pipes
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P21P21
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. P22P22
For Pressure Vessel Industries
Automation Solution ---Welding Industries
90 deg cladding for Elbow
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P23P23
For Wind Tower industries
Automation Solution ---Welding Industries
Offshore Wind Tower
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P24P24
For Wind Tower industries
Automation Solution ---Welding Industries
4 edge milling work station.
Different Grooves
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P25P25
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. P26P26
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
0 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. P27P27
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 currentHot 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. P28P28
For Process Industries
Automation Solution ---Welding Industries
Deep Penetration TIG.
Deep penetration process (DP-TIG) is a kind of high efficiencyautomated 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. P29P29
For Ship Building Industries
Automation Solution ---Welding Industries
Panel line with OSW.
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P30P30
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. P31P31
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. P32P32
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. P33P33
For Yellow Goods industries
Automation Solution ---Welding Industries
Robotic Welding with GMAW/ Tandem MIG
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P34P34
For Automobile industries
Automation Solution ---Welding Industries
Robotic Welding in automobile
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P35P35
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. P36P36
Automation Solution ---Welding Industries
Intelligent monitoring system for SPM
LAN
network
Kaiyuan Welding & Cutting Automation India Pvt., Ltd. P37P37
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. P38P38
Sensor for Current, Voltage, Speed
Sensor for Part Identification
Sensor for Heat input data
Sensor for distortion
RFTRANSFORME 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