Heinrich

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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 Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing• Innovative

fixturing• Innovative part

positioning• Innovative

fixture loading• Flexible

Automation• Consistent part

tolerances

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Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing

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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 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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Metal Cored Wire at WorkMetal Cored Wire at Work

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Welding Robotics Welding Robotics –– Alberta ManufacturingAlberta Manufacturing• Operator

friendly HMI• Laser Vision• Flexible

Automation• Definable part

variations

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““I Can See!!I Can See!!””

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The Round Stuff The Round Stuff ……

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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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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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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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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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Orbital 1G GMAW/FCAWOrbital 1G GMAW/FCAW

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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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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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H.A.W.S. H.A.W.S.

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HAWS Early Stage HAWS Early Stage …… SAIT ProjectSAIT Project

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HAWS Early Stage at RoboweldHAWS Early Stage at Roboweld

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System and Test Weld Pictures, Videos, and Weld Test Data

H.A.W.S. H.A.W.S.

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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.

Heinrich

Business

alberta marketpresented

positioning innovative

welding automationfor