MECHANISATION AUTOMATION - Esab

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Figure 9. Orbital narrow-gapwelding. The operator controlsthe welding process via amonitor receiving the imagefrom a camera mounted ontothe welding head.Figure 10. Monitoring of welding parameters using theWeldoc WMS 4000 computer programme.A compact printer is also available for documentation,for example, printing of welding current, voltage, travelspeed and wire feed speed, measured sector-specificallyand bead-specifically during the welding.Operators need to be qualified!Users of mechanised welding systems must be qualifiedto a special standard, EN 1418*, and not only to EN287which is the qualification standard for manual welders. InEN 1418, the user is referred to as the ‘operator’ - not the‘welder’. Note that the operators standard also includes amandatory “theory” test to verify the operator’s knowledgeof the functioning of the welding station.* EN 1418: Welding personnel - Approval testing of weldingoperators for fusion welding and resistance weldsetters for fully mechanised and automatic weldingof metallic materials.About the authorJuha Lukkari joined ESAB OY in Finland in 1974 aftergraduating from the Helsinki University of Technology. Hehas held several positions and is currently head of technicalcustomer service.For more information contact: juha.lukkari@esab.fiESAB Welding Process Centre facilitiesimproved with new locationESAB’s Process Center in Gothenburg– the company’s primary center forapplication research and training inEurope – has moved to a new locationon the same premises.The move, to a more convenientposition closer to the welding laboratories,had been long considered,but became necessary with thearrival of the new laser-hybridcell which required considerablespace. All diciplines involved inapplication research and trainingnow enjoy short communicationlines and the new lay-out ensures amore efficient use of the facility.For more information contact:larserik.stridh@esab.seThe laser-hybrid installation at the new Process Centre in Gothenburg, Sweden.6 • Svetsaren no. 1 • 2005
Light mechanisation.Easy and cost-efficient with ESABBy: Juha Lukkari, ESAB Oy, Finland.Light mechanisation of welding involves the use of small, easy to use, and comparativelylow-priced equipment to move the welding gun, generally making use of small tractorsand carriers on rails that can be connected directly to existing MIG/MAG power sources.ESAB supplies a full range of equipment and consumables.Also see page 11 for a story on the Dutch pipeline fabricator, NACAP, applying lightmechanisation on a section of Europipe.Why light mechanisation?The most obvious reason for light mechanisation is toobtain a higher productivity in the form of more weldedmeters per time unit. The duty cycle is higher than inmanual welding and the travel speeds and depositionrates obtained are also greater.A typical application is fillet welding in PB position.A human welder will experience great difficulties incontinuously handling a welding gun at travel speedsin excess of 50 cm/min, but a small tractor can easilyachieve 100 cm/min or more. In manual welding, theendurable welding current limit is perhaps about 300 A,but machines can easily withstand 300-350 A.As a result, the deposition rate when using, forexample, metal-cored wire OK Tubrod 14.12 (AWSE70C-6M, EN T 42 2 M M 1 H10), increases to as highas 6-8 kg/h.Light mechanisation holds more advantages than ahigher productivity, however, that can individually, ortogether, justify an often modest investment.• Improved work conditions and safety. The physicallystrenuous work is transferred to the machine and thewelder is charged with setting and controlling theprocess - enjoying ergonomically improved conditions.• The quality of the weld is often better and moreconsistent. Optimal welding parameters are maintainedthroughout the entire length of the weld, and starts andstops - always potential defect points - are avoided.• Improved weld appearance. The appearance of, forexample, mechanised welded stainless steel welds,can be so good that architects even utilise them as acosmetic feature on the outside of fancy office buildings- actually the case in Helsinki !Design welds with eye to mechanisationTo enable the welding to be mechanised, it must betaken into consideration at the construction design stage.Long straight welds without obstacles along the way areeasy to mechanise. Fillet welds are always more attractivethan butt welds from the mechanisation point of view.Svetsaren no. 1 • 2005 • 7
Page 1 and 2: THE ESAB WELDING AND CUTTING JOURNA
Page 3 and 4: Orbital-TIG - a great wayto join pi
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Page 9 and 10: Figure 4. Manufacturing of stainles
Page 11 and 12: Railtrac flexible tool for Dutchpip
Page 13 and 14: Submerged arc welding of steelsfor
Page 15 and 16: onshore wind towers, whereas the to
Page 17 and 18: Results of mechanical testingThe we
Page 19 and 20: Figure 1. Welding tool with seam tr
Page 21 and 22: Retrofitting of automaticwelding Sy
Page 23 and 24: Mechanised welding of pipelinesBy:
Page 25 and 26: such as that from a rutile flux-cor
Page 27 and 28: Cutting technology in shipbuildingB
Page 29 and 30: Status of plasma cutting.In the que
Page 31 and 32: Improved productivityin automated a
Page 33 and 34: A CENTURY OF INNOVATION16-pound (7
Page 35 and 36: NOMAD finalisedFigure 1. The bridge
Page 37 and 38: OrigoMag C150/C170/C200/C250A recen
Page 40: ESAB ABBox 8004 S-402 77 Gothenburg

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