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TRANSCRIPT
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Welding AutomationWelding Automationfor the Alberta Marketfor the Alberta Market
Presented at:
The Southern Alberta Institute of TechnologyWelding Automation Forum
June 24, 2008
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing• Innovative
fixturing• Innovative part
positioning• Innovative
fixture loading• Flexible
Automation• Consistent part
tolerances
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing• 3 step mfg.
process• 3 robot stations• Many part types• Flexible
Automation• Consistent part
tolerances
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing• 1,000 plus parts• 1 robot program• Human
Machine Interface (HMI)
• Flexible Automation
• Consistent part tolerances
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Metal Cored Wire at WorkMetal Cored Wire at Work
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing• Operator
friendly HMI• Laser Vision• Flexible
Automation• Definable part
variations
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
““I Can See!!I Can See!!””
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
The Round Stuff The Round Stuff ……
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
The Round Stuff The Round Stuff ……Near infinite variation of part (spool) definition:
– Pipe diameter– Pipe dimensional tolerance (out-of-round)– Pipe surface condition– Added components (flanges, elbows, tees, etc.)– Pipe and fitting weld preparation– Spool length– Spool eccentricity– Spool loading and counter-balance requirements– Number of same spool assemblies welded
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
The Round Stuff The Round Stuff ……A tough application for Robotic Automation:
– Robot vision and laser tracking systems are good, but near infinite part variation …
– Options:• Manual Welding• Basic Automated Welding• Orbital 1G Welding• Hybrid Automated Welding
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Manual WeldingManual Welding• Flexible to
accommodate almost any variations
• Battle with skilled labor shortage
• Difficult to meet demanding schedules
• Variable operator factor
• Slow to adapt to new processes
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Basic Automated WeldingBasic Automated Welding• Reduced operator fatigue• Enables non-stop, multipass
welding• Allows for use of high
deposition processes (eg. SAW)
• Systems are generally large in size and fixed in their location
• Extra part handling typically required
• Control systems limited to direct operator inputs (little to no programmability)
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Orbital 1G GMAW/FCAWOrbital 1G GMAW/FCAW
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Orbital 1G GMAW/FCAWOrbital 1G GMAW/FCAW• Ideal for fixed
position weldments
• Lengthy set-up time
• Difficult to justify for 1G rotated weldments
• Does not accommodate certain spool configurations
• Relatively heavy and cumbersome
• Excellent real-time function control with minimal program storage
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Hybrid Automated Welding System (HAWS) Hybrid Automated Welding System (HAWS) • A fully programmable robot (root to
cap) allowing real-time operator intervention for part deviations
• Infinitely programmable weld parameter and torch manipulation for a weld joint
• Fits in a standard spool shop’s welding station
• Welds wherever a man can 1G weld• Works with existing positioners• Start to arc in about a minute• 30’ reach• HMI user interface• Portable within shop space• Self-contained (including optional
monitoring systems)
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
H.A.W.S. H.A.W.S.
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
HAWS Early Stage HAWS Early Stage …… SAIT ProjectSAIT Project
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
HAWS Early Stage at RoboweldHAWS Early Stage at Roboweld
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
System and Test Weld Pictures, Videos, and Weld Test Data
H.A.W.S. H.A.W.S.
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Welding Automation Forum – Calgary, AB - Tuesday June 24th, 2008
Conclusion Conclusion • Robotic welding is well suited for Alberta
based manufacturing.• Hybrid welding systems are well suited
Alberta based pipe spool fabricating.• The technology is either here or pending,
when will you jump on board?• Manufacturers, fabricators, and their end-
users must work together to ensure the validity of profitable and productive welding for Alberta’s future.