nsrp panel meeting · nsrp panel meeting. planning, production processes & facilities. november...
TRANSCRIPT
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Interim Products (S2459)2015 NSRP All Panel
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Robotic Welding of VCS Interim ProductsManTech Project Number: S2459
NSRP Panel MeetingPlanning, Production Processes &
FacilitiesNovember 9-12, 2015
Steven PothierEngineering Assistant SeniorGeneral Dynamics, Electric Boat Corporation(401) [email protected]
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Robotic Welding Video
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Agenda
• Project Team• Project Goals• Phase I Tasks / Phase II Tasks• Qualification Process • Robotic Welding Technology• Accomplishments• Questions
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ManTech Project TeamDale Orren – NSAM Deputy DirectorWarren Southerland – Project Manager Barry Espeseth – Project Technical Representative
Ned Kaminski – Technical LeadMimi Reis – ManTech Program ManagerDerek McKee – Engineer Erin Foster – Welding Engineer QPSteven Pothier – Engineering Asst. Sr.
Nancy Porter – Senior Project ManagerAdam Uziel – Applications Welding EngineerJosh Chance – Principal Welding Technician
Joe Blackburn – TWH 05P24 Matt Sinfield – 05P24 TADavid Lammlein – 05P24 TA
Dave Hart – LCERepresenting PMS 450
Byron Rose – PMS 397Larry Becker – BAHCharlie McNamara – PMS 450
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Project Goals / Objectives
• Create a manufacturing cell at the Electric Boat Corporation Quonset Point Facility to robotically weld interim product assemblies that cannot be welded with a mechanized process Structural welding is a major contributor to VCS construction costs.
Opportunity to improve weld preparation accuracy, component assembly and fit-up, welding processes, equipment, and span time for interim products.
Increased use of fixturing, positioning, automation, and mechanization.
Electric Boat believes the best method to reduce welding costs is to increase the number of weld joints that are welded with automated equipment.
• Target cost reduction opportunity of more than 30% in labor cost per interim products assembly
• Share improvements with other Navy shipyards
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Task 1. Identify Assemblies to Weld in the Robotic Cell
Task 2. Develop Functional Specifications for Robotic Welding System
Task 3. Purchase or Lease Robotic Welding System
Task 4. Develop Offline Programming (OLP)
Task 5. Develop Welding Processes for Assemblies
Task 6. Phase I Reporting
Phase I Statement of WorkProcure Robotic Welding System for Part Family & Interim Product Assemblies
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Task 7. Deliver Purchased System to EWI
Task 8. Develop Welding Processes for Assemblies
Task 9. Deliver Robot Welding Cell to Electric Boat Quonset Point
Task 10. Transfer Welding Processes and OLP Knowledge to Electric Boat
Task 11. Robotic Welding Procedure and Personnel Qualifications
Task 12. Identify Process Enhancements for the Welding Robot
Task 13. Develop Roadmap to Implement Robotic Manufacturing at Electric Boat
Task 14. Phase II Final Reporting
Phase II - Statement of WorkPart Family & Interim Product Robotic Welding System Process Development and System Transfer to Electric Boat Quonset Point
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Qualification Process• For each test position, two different programming methodologies were
used; adaptive and non-adaptive. Adaptive methodology - uses a pre-programmed bead plan and through-
the-arc seam tracking to complete the entire weld with the operator ensuring proper bead placement, checking inter-pass temperatures, cleaning the bead surface between passes, and performing a workmanship inspection of each weld pass.
Non-adaptive methodology - the operator programed each pass with the teach pendant individually and through-the-arc seam tracking was not used to complete the weld. The non-adaptive methodology allows the operator to observe as the welding is
performed and adjust the welding parameters and oscillation during the process.
This variant was qualified so the robot could be used to make repair welds or touch up weld joints that could not be completed in adaptive mode.
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Qualification Process
• 4 qualification plates made to Tech Pub 248 - level I requirements 1 in the horizontal (2G) position for GMAW spray – Adaptive
1 in the horizontal (2G) position for GMAW spray – Non-adaptive
1 in the flat (1G) position for GMAW spray – Adaptive
1 in the flat (1G) position for GMAW spray – Non-Adaptive
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Qualification Process
• All 4 qualification plates were subjected to and passed the requisite Tech Pub 248 testing per Section 4.5Nondestructive testing
Visual Radiography Ultrasonic Magnetic Particle
Destructive testing All weld metal tensile Transverse tensile Weld metal charpy V-notch Transverse side bend
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Robotic Welding Technology
• Wolf Robotics completed system build on May 29, 2013, at which time members of the project team participated in a System Runoff
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Robotic Welding Technology (Cont.)
• 3D Part Search – Used to find the part in reference to the virtual cell.
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Robotic Welding Technology (Cont.)
• 3D Part Search – Current is sent through the tip of the wire to sense where the part is. Finding the part in Z axis.
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Robotic Welding Technology (Cont.)
• 3D Part Search – Finding the part in X axis
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Robotic Welding Technology (Cont.)
• 3D Part Search – Finding the part in Y axis
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Robotic Welding Technology (Cont.)
• Dry Run – Dry running the programmed weld path to insure accuracy.
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Robotic Welding Technology (Cont.)
• Dry Run – Checking layer / bead placement, weave design, weld speed.
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Robotic Welding Technology (Cont.)
• Dry Run
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Robotic Welding Technology (Cont.)
• Dry Run
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Robotic Welding Technology (Cont.)
• Return to Home Position – Returning to Home will get robot up and out of the way of the part. Home is also a safe position so the Robot can move along the track safely.
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Initial Design
Accomplishments
• Robot cell was installed in Bay 4 at the Electric Boat Quonset Point Facility
Cell at Wolf Robotics prior to Shipping to EWI
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Accomplishments
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Accomplishments
• Welded Practice Plates Sample Flat and Horizontal plates
were welded and sent for Radiographic (RT) inspection for verification – Passed
Data Collection software was used to monitor all welding parameters
• Welded Qualification Plates Flat 65 kJ – Passed Flat Non-Adaptive – Passed Flat Adaptive – Passed Horizontal Non-Adaptive – Passed Horizontal Adaptive – Passed
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Accomplishments
• Robotic arc welding is currently considered a “special weld” per section 4.4.8 of Tech Pub 248 (The Requirements for Welding and Brazing Procedure and Performance Qualification).
Electric Boat qualified the robotic arc welding procedure as “Mechanized-R” in accordance with Tech Pub 248 “special weld” requirements.
• The welding procedure qualification records were submitted August 2015 for approval Working with SOSG to finalize qualification approval
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Accomplishments
• The Electric Boat submittal package included the following documents: Welding Procedure Qualification Records (WPQRs)Welding Technique Sheet (WTS)Welding Procedure Qualification PlanWelding Operator Qualification and Verification PlanFirst Article Assemblies, Validation of Similitude
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Accomplishments
• Developing qualification plate OLP, bead plans, and process parameters Gas Metal Arc Welding (GMAW) spray - flat position
Adaptive / Non-Adaptive / 65kJ
GMAW spray - horizontal position
Adaptive / Non-Adaptive
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Questions?
Steven PothierEngineering Assistant Senior General Dynamics, Electric Boat Corporation(401) [email protected]