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ULTRA-HIGH PRODUCTIVITY MAG WELDING IN AUTOMATIC HEAVY STEEL WELDING.

Objectif


The applicability of commonly used commercially available shielding gasses for different applications has been investigated and limits of the different constituents have been stipulated for optimum use of the ULTRAMAG process for different applications. A new patented shielding gas has been developed.
The applicability of different wire types in combination with the ULTRAMAG process has been investigated as well as the optimum wire diameters for different applications.

Investigation of the quantity and nature of the airborne pollutants (including ozone) emitted from the process has been performed, as well as investigations of the light and thermal radiation from the high current and arc voltage levels associated with the process. The noise emitted from the process has also been studied.

A knowledge based system for computerised planning of V-groove welding using the ULTRAMAG process has been specified and developed. V-grooves in the flat position was selected as the target for automated adaptively controlled ULTRAMAG welding. A comprehensive study has been made to collect sufficient knowledge for the development of algorithms for adaptive control of the welding parameters.

A comprehensive analysis was conducted in order to evaluate the automation potential of the ULTRAMAG process both in general and with respect to the selected area for demonstration. Based on this study, a detailed specification of the demonstration system was performed, including requirements to weld planning system, the welding controller, the sensor system and related interfaces. The different components of the prototype system have been developed or existing equipment has been modified to meet the specifications. A completely new control software, the ULTRAMAG weld controller, has been developed for control of the entire demonstration cell.

The different components of the prototype system have been integrated and tested obtaining the highest possible degree of automation in welding of T-beam assembly.

Final tests with the demonstration system, showed an average operation time per T-beam of approximately 40 minutes, including mounting of run in/out plates, backing and vertical and horizontal welding. Compared with today's production in shipyards, an overall productivity increase of 200 %, can be expected by installation of the demonstration system.
In heavy steel welding fabrication serious limitations for improvement of productivity are met in welding short multi-pass butt or fillet welds.

The objectives within the project are twofold. On the one hand to continue the development of the MAG welding process with ultra-high wire feed speed to a level where it can be introduced into heavy steel fabrication taking into account also the demands to human and environmental aspects. When applied, the process is apt to result in increased productivity by at least 2 times through the high deposition rate. On the other hand to make possible and demonstrate the automation of welding short multi-pass butt welds by use of the new MAG welding process. This requires development of a knowledge based system for planning the deposition and placement of each particular string and for control of the welding process.

For demonstration a prototype automatic equipment will be build, installed at the end-user collaborating in the project and tested and evaluated in welding short multi-pass V-grooves.

In the collaboration is integrated producers of welding equipment and shielding gases, mechatronics and welding technologists and an end-user in the ship building industry.

Appel à propositions

Data not available

Régime de financement

CSC - Cost-sharing contracts

Coordinateur

FORCE INSTITUTES
Contribution de l’UE
Aucune donnée
Adresse
PARK ALLE, 345
2605 BRONDBY
Danemark

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Participants (4)