Right set of data and correct analysis saves a lot of resources

By OEM Update Editorial January 3, 2022 5:21 pm

Automation will upgrade or reskill the welder to become an operator. Also, it is trying to replicate human intelligence.

Automation is transforming welding technologies, your opinion? 

Automation is a tool available to enhance the productivity, repeatability and quality of welding. It can also de-skill the process and make it easier to get high quality production. 

Certain technologies can transform productivity when connected with Automation. For example TiG welding is considered a slow process with typical manual welding speeds of up to 60mm/min , so for a 1 metre long weld joint of 8 mm thick plates, it may require 4 passes or a total weld length of 4 metres. When we use SWAT (SigmaWeld Accelerated Tig) with an automated long seam solution, the same 1 metre length 8mm thick weld joint can be welded with speeds of 400 mm / min that too in a single pass. This means you would weld the same joint in under 2.5 minutes. This in manual tig would have taken 66.6 minutes. This is transformation. In certain technologies, automation can elevate the end result drastically, but not necessarily for all. 

Your views about the upcoming manufacturing outlook for 2022 in the country? 

India is well on its way to become a part of the 5 trillion dollar economy, manufacturing will play a vital role in getting to that milestone. The current global dynamics put India in a strong position to capitalise on the growth trajectory. There is a great scope of the Indian SMEs to export , we need to gear up for better productivity and quality. If we can meet the timeline that Chinese firms commit, Indian firms will stand a better chance at bagging the export orders. We as Indian SMEs must gear up to meet global standards of quality and timely delivery. This will be possible with the help of productivity enhancing tools available today for the manufacturing sector. Welding will play a vital part, we at SigmaWeld have focused on helping the industry attain higher productivity with welding automation, SWAT and Induction Heating Solutions for preweld, post weld, pwht, Heat Straightening and Shrink fitting applications. All these are time taking processes where we have been able to reduce the cycle time by 40 percent and increase operator efficiency and productivity multi-fold. 

Please talk about your technology solutions offered to the welding automation sector. And, brief us about welding inverters and applications. 

SigmaWeld offers inverter based solutions for all ARC, TIG, MIG, SAW applications. We also provide complete solutions for productivity enhancement for our customers through automation (Special Purpose Machines or Robotics) in TIG and MIG welding applications. We have developed Auto Tig Heads which can be easily retro-fitted on existing setup like column, boom, seamers to quickly turn around the productivity and without increasing the capex spent. Our SWAT (SigmaWeld Accelerated TIG) is a game changer in the welding of Stainless Steel, Titanium, Nickel Alloys and many other materials used in Aerospace , Food ,Pharma , Dairy and Nuclear applications. It increases the productivity of GTAW by more than 10 times. Some of our clients have completed their projects before time as welding was done much quicker and better. We have welded 6 metre long , 6mm thick Nickel Alloy plates within 15 minutes which earlier was a 2 Shift job. Not to mention it requires a fraction of the consumable to complete to join compared to the manual process. 

SigmaWeld Induction Heating Solutions for Pre heating, Post Weld, PWHT and Shrink fitting are saving loads of time and money when it comes to preheating applications. A lot of time is taken in ensuring the right preheat temperature for thicker welding jobs, many times dependency is on operators such as gas burners to ensure the temperature, it becomes difficult to avoid hot spots. Induction based solution takes minutes to do the job and specially since the heat is generated within the metal (Eddy Current losses) it is very efficient and quick. The environment around the heating pad doesn’t get heated making the operator very comfortable and efficient. 

We also have our SigmaWeld Pro Series which are modular welding inverters with 100 percent duty cycle and have special programs for Welding various materials. These can be easily connected with any robotic or automation solution. 

Also, IMTEX is the primer exhibition showcasing the latest technologies available for the manufacturing sector. We expect 2022 to be no different. It will surely have an exposure for all to produce, quicker, better and cheaper.

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Welding machines when used in manual applications have a utility factor of 60 percent or less as the operator has to take breaks often. During that period the equipment also gets time to cool down. However, with modern manufacturing moving towards automation solutions , the systems will be able to work much longer without the need for a break. The power sources must have a higher duty cycle (100 percent) to give better efficiency and working. Our SigmaWeld Pro Series is a modular concept specially focused on high productivity with maximum duty cycle and easy monitoring of internal temperatures and other parameters right on the operator screen. 

For example our SigmaWeld Alex power sources at 100 percent duty cycle GTAW welding inverters. Many of our clients in India and Middle East use them for days at a stretch on the automated cladding setup, without having to stop or the need to buy higher capacity machines. These same machines are also used in Tube Mills for getting more throughput and lower power consumption. 

How automation and robotics contribute to welding solutions for better finishing, precision and aesthetics? 

Automation and Robotics have the ability to do the repeated tasks with great ease. As the process is mechanised. So it can give repeated results hours at length. Automation is trying to replicate human intelligence. A skilled operator while welding knows if there is a gap (irregular) he will adapt his welding style to cope up with the error in fit-up. Automation usually works on the Junk in Junk out concept. The input needs to be good and repeatable for the output to be equally good. 

With high speed welding heat input can also be controlled better and result in better finishing and aesthetics. 

Is automation in welding and cutting processes a threat to human-machine interface affecting jobs? 

I do not think so, people will be needed to run the automation, however it will try to take out the possibility of error, ease the job of the operator and increase efficiency of work. In fact, automation will upgrade or re-skill the welder to become an operator. 

Challenges and opportunities of implementing Industry 4.0 for welding processes is cost a critical factor? 

Data is the next gold. Having the right set of data and the correct analysis of it can save a lot of money , time and resource. What is important to know what to capture and what to monitor in Industry 4.0. It may seem a little more expensive upfront, but if it can help eliminate repair, reworking the investment in industry 4.0 will recover itself very quickly. 

Adaptation to Industry 5.0 becoming a valuable platform for optimising processes to improve production? Your views. 

Collaborative working between humans and automation (robots) will make learning, training easy. As the adaptation grows, the technology will become more viable and definitely help in improving productivity at reduced costs.