Category: Oil and Gas

FANUC America Features Robotic Plasma Cutting System for Metal Pipe from ARC Specialties

 

From FANUC America:

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 Open House in Houston, Texas: October 19th and 20th, 2016

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.

Demonstrations at this event will include:

  • M-20iA/25 with FANUC Flex Gripper 3D Bin Picking
  • New M-900/280 Rigid Robot
  • CR-35iA Load/Unload
  • Robodrill with LR-Mate Load/Unload
  • M-1iA High Speed Battery Handling
  • LR-Mate 200iD/4S Relay Inspection
  • M-20iA/25 with IRVision Fenceless Assembly System

www.fanucamerica.com

+1 888-FANUC-US

Robotic Hardbanding System

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.

Features

  • 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.

 

 

July 28th | Lunch and Learn | Featuring Talks and Demos on Hydrogen in Shielding Gas, High Deposition Welding, and Welding Contact Tip Life Extension

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 lindsay@arcspecialties.com will receive a packet of the new long-life contact tips from ARC Specialties on the day of the event.
Material Covered at the July 28th Lunch and Learn:Due to falling oil prices, the industry has endeavored to do more with less. ARC Specialties has recently completed work in three areas of interest in Hot Wire GTA Welding: 1.) the use of hydrogen blends in shielding gas, 2.) high deposition welding and 3.) contact tip life extension.1. Hydrogen Shielding GasThe thesis is that the use of 98%Ar 2% H2 shielding for GTA Hot wire ERNiCrMo-3 “625” welding reduces defects and improves productivity. Most 625 defects are oxide inclusions. Hydrogen has a strong affinity for oxygen, so it acts like a flux to reduce oxides from part, wire and shielding gas contamination. There is industry resistance to use hydrogen gas for shielding as 625 overlay is specially intended to mitigate hydrogen induced cracking.However, ERNiCrMo-3 is not a low hydrogen filler material at 8.5ppm hydrogen. Hydrogen in the wire accounts for 90% of the diffusible hydrogen in the weld, when welding with 98Ar 2%H2. Pre- and post-heat reduce diffusible hydrogen by 30%. In the worst case scenarios, with no pre-heat, immediate quench and holding in liquid nitrogen, there is only .9ml/100g in the weld metal. This is less than half of the most stringent published low hydrogen specification. Full weld procedure qualification tests were conducted on both argon & argon/hydrogen weld tests to demonstrate that mechanical properties are not affected. Finally, using a microscopic examination technique, the team has quantified weld quality to show that weld quality improves with hydrogen blends.

2. High Deposition Welding

Many manufacturers GTA Hot Wire Clad at 80 IPM (2 m/min) with .045” (1.2 mm)  wire. This deposition rate is 2 lbs /hour (.9 kg/hour).  ARC is working to improve on this in three ways. The first is to simply increase deposition while welding with argon in the 2 G position. ARC Specialties has pushed wire feed speeds up to 300 IPM (10 m/min) resulting in 8 lbs/hour (3.6 kg/hr) in production with a single wire. The team has also developed single layer procedures which meet the <5% Fe standard and pass <250 Vickers HAZ hardness after post weld heat treatment. Finally, ARC Specialties has achieved 10 lbs./hr (4.5 kg/hr) with a single layer welding at a 45 degree angle. The following 4 procedures were recently qualified, passing base tensile & impact, weld side bends, weld chemistry, and hardness HRC & Vickers, with both 1175 degrees F for both 4 and 12 hour PWHT.
Deposition rate in pounds/hr. Number of total layers Iron content % Welding Position PWHT 1175F (635C)
6 1 2.6 2 G 4 and 12 hours
8 1 3.1 2G 4 and 12 Hours
6 2 3.6 2G 4 and 12 Hours
10 2 4.1 45 Deg
  1. and 12 Hours

3. Contact Tip Life Extension

High deposition welding necessitates high wire speeds, which degrade tip life. Standard copper contact tips tested at 8 lbs/hour wear at a rate of .0036”/lb. Several other tips materials were tested with wear ranging from .00220” to .00025”/lb (best). Testing also determined that typically, .01” of wear will necessitate an adjustment in contact tip position to maintain correct wire to puddle alignment. New tips from ARC Specialties are able to operate for 5 hours without adjustment when welding at 8 lbs/hr, a 1600% improvement.
Tip Type Wear (inches/lb) Time before .01” wear position adjustment at 8 lbs/hr
Standard Copper .0036 34 minutes
ARC Alloy Tip .00025 5 hours (10 X improvement)

Introducing ARC Gen-2 Extended-Life Wire Guides & Contact Tips

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 lindsay@arcspecialties.com.

Caspian Sea Oil & Gas Show 2016: ARC Specialties Represents the Latest in Manufacturing Automation in Baku, Azerbaijan

On June 1 – 4th, 2016, members of the ARC Specialties sales team showed expo attendees the latest in manufacturing automation at the Caspian Sea Oil & Gas show in Baku, Azerbaijan. The President of Azerbaijan, His Excellency Ilham Aliyev, opened the exhibition with remarks about state of the oil and gas industry in Baku, as well as their positive outlook on the cooperation between the United States of America and Azerbaijan.