annual assembly welding development 1 - vtt.fi · ¾2 hnb port extensions ¾port stub ... annual...

Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 1

What is the difference between

Remote Handlingand

Handlingand

?

Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 2

What is the difference between

Office Engineerand

Workshop Engineerand

?

Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 3

In the toiletthethe

Workshop Engineer

first washes his hands

and then does the job

Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 4

When something goes wrong in

Remote Handlingyou cannot use your hands

Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 5

When something goes wrong in

Remote Handlingyou cannot use your hands

as you canin

Robotic HandlingRobotic Handling

Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 6

ITER Vacuum Vessel Welding

Development Package

Presentation based on the

Participating organisations:

VTT, Lappeenranta University of Technology, Hollming Works Oy, Tekes

Presented by: Pertti Pale

Date 2.6.2010

Place Annual Fusion Seminar VTT Tampere

7VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

Place Annual Fusion Seminar, VTT, Tampere

The ITER Vacuum Vessel Assembly

• 9 VV sectors• 27 upper port structures

9 port stub extensionsextensions18 port extensions

• 22 equatorial port structures

14 standard ports1 DHNB port t iextension

2 HNB port extensionsport stub extension4 NBI ducts

• 9 divertor port structuresp3 RH port extensions2 RH / diag port extensions4 pumping ports 

8VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

The ITER Vacuum Vessel Assembly

• 9 VV sectors• 27 upper port structures

9 port stub extensionsextensions18 port extensions

• 22 equatorial port structures

14 standard ports1 DHNB port t iextension

2 HNB port extensionsport stub extension4 NBI ducts

• 9 divertor port structuresp3 RH port extensions2 RH / diag port extensions4 pumping ports 

9VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

ITER CALL

ITER CALL

ITER CALL

ITER CALL

T i l S li Pl tTypical Splice Plate:• Length  2,40 m• Cross section 60 x 100 mm• Mass 130 kg

14VV Assembly Welding DevelopmentCherbourg 18.5.2010 Pertti Pale

Thermal Shield

Rib

Outer Shell Sector A

Rib

Outer Shell Sector B

Rib

Inner Shell Sector A

Rib

Inner Shell Sector BTool

Triangle Support Structure

Tool Arm

Tool Arm connection to the Robot

15VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

Thermal Shield

Rib

Outer Shell Sector A

Rib

Outer Shell Sector B

Robotic Functions:PREPARED      in several positions and structures•Welding•NDTRib

Inner Shell Sector A

Rib

Inner Shell Sector BTool

•NDT•Machining•Measurement•Positioning•Thermal Shield Joining•Repair•Cleaning•Transport

Triangle Support Structure

Tool Arm

•Transport•ViewingADHOC           in several positions and structures•Actions related to misalignment of sectors•Actions related to jams•Actions related to non‐satisfactory operations (eg. welds, NDT, measurement, positioning)

Tool Arm connection to the Robot

16VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

A combination of

• Magnitude

• Complexity

• Robotic tooling

• Methods

• Requirements

17VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

MagnitudeMagnitude• Total weld LxB = 2500 m x (40...60mm)

Welding• Thickness 40...60 mmc ess 0...60• All positions• Limited space• Operation distance• Robotic remote handling• Problem points• Problem points• Repair

NDT• Thickness 40...60 mm• Limited space• Operation distance• Robotic remote handling• Problem points

He Leak Testing• Limited space• Limited space• Operation distance• Robotic remote handling• Problem points

In‐Wall Shieldingg• Limited space• Operation distance• Robotic remote handling• Problem points

18VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

• HIGH dynamic machining force ‐ for cutting, weld repair and weld preparation ‐ 6 kN

• HIGH accuracy  ‐ for positioning, measurement, welding and NDT – 0,1 mm

D i St ti D i

• LOW mass/size of robot  ‐ for mobility, limited space and parallel operation of several robot systems – 1000 kg

PayloadDynamic

work force

Static repeata-

bility

Dynamic repeata-

bility

Robot mass Mounting

Motoman HP600 600 kg 0,5 mm 2400 kg

Kuka KR 240 240 kg 0,12 mm 1267 kg FloorKuka KRKuka KR

1000 1000 kg 0,2 mm 4690 kg Floor

Kuka KR 500 500 kg 0,15/0,3 mm 2350 kg Floor,

ceilingABB IRB

6650S 145 kg 0,14/0,28 mm 2175 kg Shelf

OTC AX-V500 500 kg 0,5 mm 3000 kg FloorF MFanuc M-

2000iA 900 kg 0,3 mm Floor

Fanuc M-900iA 350 kg 0,3 mm 1720 kg

Floor, ceiling,

angle, wall

Movable on

19VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

LUT ITER IWR 600 kg 600 kg <0,1 mm 0,1 mm 890 kg

Movable on rails, all angles

<‐‐‐‐‐‐‐‐ 1 m ‐‐‐‐‐‐‐‐‐‐>2350 kg

<‐‐‐‐‐‐‐‐1 m ‐‐‐‐‐‐‐‐‐>890 kg

KUKA 500‐2 LUT ITER IWR

Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 20/12

Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 21/12

Robust mass production ‐‐‐ abt 90%

Non‐robust individual production ‐‐‐ abt 10%

• Design to serve mass production

• Requirements to allow mass productionq p

• Robotic Tooling to serve mass production and individual production

• Methods to serve mass production

22VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

1. Installation of tooling2. Definition and fabrication of Splice Plates3. Preparation of weld area for longitudinal welding4. Positioning of Splice Plates5. Confirm ok for welding operation startg p6. 1st Pass Weld + UT + He Leak Test7. 2nd to Final Pass Weld + UT8. Preparation (incl. machining) of weld area for 

transversal welding9. Confirm ok for welding operation start9. Confirm ok for welding operation start10. 1st Pass Weld + UT + He Leak Test11. 2nd to Final Pass Weld + UT12. Cleaning13. AcceptanceIn the case of defects:In the case of defects: 1. Machining 2. Rewelding 3. UT 4. For the root weld: also He leak test 

23VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

Timing excercise

Case 1 – NG TIG• Weld length 2500 m• Plate thickness 40 ... 60 mmW ld h d NG TIG G 400 600 3

Timing excercise

• Weld method: NG TIG  Groove area 400 ... 600 mm3• Weld volume abt 2500 m x 500 mm3 = 1,25 m3• Filler material 10 ton• Welding speed per station 0,5 kg/h• Arc time ratio assume 30%• Required time for 1 station = 10 ton/(0 5 kg/h)/30%=60000 h = 8 aRequired time for 1 station = 10 ton/(0,5 kg/h)/30%=60000 h = 8 a• Required time for 4 stations = 2 a

• Required time for 8 stations = 1 a

Case 2 – Laser Hybrid• Weld length 2500 m• Plate thickness 40 ... 60 mm• Weld method: Laser Hybrid  Groove area in average 200 mm2• Weld volume abt 2500 m x 200 mm3 = 0,5 m3• Filler material 4 ton• Welding speed per station 2 kg/h• Arc time ratio assume 30%

• Required time for 1station = 4 ton/(2 kg/h)/30%=6000 h = 1 a

24VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

Development Programme Package

LAB• Experience• Infrastructure: space, technical environment, resources

ROBOTIC TOOL, HANDLINGROBOTIC TOOL, HANDLING• Existing system• Supporting team

WELDING, NDT• Industrial capabilities• Industrial capabilities• R&D capabilities

DESIGN, REQUIREMENTS• To be reconsidered during the Development Programme

25VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

/

Development Programme Package

LAB ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ROViR/VTT, TUT• Experience• Infrastructure: space, technical environment, resources

ROBOTIC TOOL, HANDLING ‐‐‐‐‐‐‐‐‐‐IWR/LUTROBOTIC TOOL, HANDLING  IWR/LUT• Existing system• Supporting team

WELDING, NDT ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐VTT , industry• Industrial capabilities• Industrial capabilities• R&D capabilities

DESIGN, REQUIREMENTS• To be reconsidered during the Development Programme

26VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale

ITER CALL

LUT ITER IWRAnnual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 28

LUT ITER IWR