I’m a long time advocate of narrow gap welding. The advantages are tremendous, but the challenges are too. A 5″ thick standard V Butt weld with a 75 degree included angle has five times the weld volume of a 1″ wide 5″ Square Butt. This means a narrow gap joint would have five times less weld wire, five times less arc time, much less distortion. And fewer defects because every inch of weld that you don’t make is an inch you don’t have to inspect and possibly repair.
Why isn’t narrow gap the standard technique for welding heavy sections? Because the technical challenges of welding vertical walls in confined spaces are huge. For good sidewall fusion, the arc must impinge on the walls. Otherwise, you risk lack of fusion defects at the bond line. Our new Narrow Gap Hot Wire Torch features a servo tungsten electrode oscillator to point directly at the sidewall. That is only half the battle. The wire must follow the tungsten. We did just that using a second independent servo this allows us full control of arc and the filler wire position. Finally, we use our HOT ONE AC constant voltage hotwire system to double the deposition rate, which cuts weld time in half.
FANUC America Authorized System Integrator ARC Specialties designs and builds custom manufacturing machinery and automated systems including systems for metal welding and cutting, material handling, pick and place, test equipment and other custom applications. In this robotic system, ARC Specialties utilizes a FANUC M-710iC/20L robot to perform plasma cutting for 40-foot long sections of metal pipe.
First, a full-length pipe moves from a notched workplate to an automated infeed conveyor system. The automated in-feed conveyor indexes the pipe into the headstock cutting area, where the pipe is automatically positioned into place by chuck jaws. The system has five sets of chuck jaws that can be manually changed to accommodate pipes of varying diameter – from 0.75” to 24” in outer diameter. The six axis FANUC M-710iC/20L robot, equipped with a quick tool changer, picks up either an OAC or PAC torch from the quick tool change station. The robot uses touch sensing, as well as laser sensing to locate the nozzle parts and the pipe.
Once the pipe has been located the FANUC robot proceeds to first make a bevel cut. The headstock contains a robotic aux axis motor package and pop-up turning rolls that rotate the pipe in coordinated motion with the robot as it makes the cuts. After the bevel cut, the robot proceeds to plasma cut small and large holes into the pipe. The robot uses FANUC Constant Path, which allows it to maintain the same path regardless of static or dynamic speed override changes.
The system features simple setup – An operator simply inputs the desired cut dimensions into the HMI, presses the Go button, and the robot executes the cut. ARC Specialties’ cutting software generates robot code to execute the desired cuts based on the operator’s input, and the HMI is able to save and store these part programs. Once the FANUC robot is finished cutting, the pipe parts roll onto a gravity-fed pipe rack where they are removed from a notched work plate and finished pipe rack manually.
FANUC America Authorized System Integrator ARC Specialties transform manufacturing processes into high-quality, high-production and high profit operations. To learn more, please visithttp://www.arcspecialties.com.
FANUC Robotics in Houston, Texas is hosting an Open House on October 19th and 20th. As an integrator of FANUC Robotics, the team at ARC Specialties will represent the latest in robotic and automated manufacturing technology at this event.
The Technology Workshop will include sessions on ROBOGUIDE/Offline Programming, CNC Technology and General Motion Applications, and CNC Aftermarket Support and Maintenance Overview.
This Robotic Hardbanding System is an automatic welding machine that is used for applying tungsten carbide to tool joints and pipe. The project was completed in Summer 2016, and is available for purchase from ARC Specialties in Houston, Texas.
A dry run in the video demonstrates the torch movement during the weld program.
Included here is a 3-jaw-self-centering manual actuated chuck.
This Robotic Hardbanding System uses touch sense to calculate the diameter of the part.
The system then changes the speed of rotation of the part to match that diameter.
The laser in this system is used to show where the first bead will be welded on the part.
The torch cleaning station automatically cleans the nozzle, applies anti-spatter, and can be programmed to clean at any interval.
The carbide refill station includes semi-automatic feeder calibration and a water-cooled carbide nozzle integrated into the torch gas cup.
Robotic cells built by ARC Specialties may be customized with other robotic applications like TIG or MIG welding, plasma cutting, plasma transfer arc welding, and other manufacturing processes.
When: Thursday, July 28th at 11:30 am – 2:30 pmWhere: ARC Specialties, 1730 Stebbins Drive | Houston, Texas 77043Cost: FreeRSVP: The first 25 companies to RSVP to firstname.lastname@example.org will receive a packet of the new long-life contact tips from ARC Specialties on the day of the event.
The first 25 companies to sign up for ARC Specialties Lunch and Learn on July 28th, 2016 will receive a complimentary sample packet of these Extended-Life Wire Guides / Contact Tips. To RSVP for the July 28th Lunch and Learn, please email email@example.com.