Navus Fills Niche For Adaptive Multipass Welding

Navus

A crystal clear image from the HD camera during inspection shows 0 inclusions.

Multipass adaptive welding is a signature strength of the Navus team. With the ability to weld with an adaptive process, we are able to produce higher quality joints on even the heaviest of weldments. This process has been proven on joints with over 60 passes.

Buck Barber, Sales Manager at Navus, said, “The team developed an algorithm that allows the system to adapt to changing joint parameters including width, position, and angle. In a sense, this allows us to hit a moving target. No one has put the technology together to do it quite this way.” The resulting welding process is quicker, more consistent, and of higher quality.

The adaptive robotic welding solution is also bringing consistency and speed to a process with which operators are allowed only short windows of time to work due to safety regulations. When operators must switch every 15 minutes due to hazardous conditions, a large gap is created where no value is being added to the product. Robotic systems are able to fill this gap and maximize arc-on time.

Due to the stringent ultrasonic testing requirements, testing cannot be completed until the entire joint is complete. If an inclusion is found in the root pass, the entire weld must be ground out to be repaired. The consistency of a robot minimizes such occurrences and the speed allows for quicker recovery in such a case.

With years of research and development and a certified weld inspector on staff, Navus has developed innovative strategies to meet the toughest welding challenges. From welding in all positions to producing welds that stand up to the most rigorous testing procedures, Navus has the experience, technology, and in-house testing capabilities to perfect processes.

Our multipass heavy deposition robotic solutions include:

  • A portable robotic work cell for multiple welds in multiple positions.
  • Robotic tool changes for single-torch welding, grinding, deburring, and cleaning.
  • Remote operating solutions for hazardous environments to prep joints, weld, clean, and inspect.
  • T-beam welding robotic cell that reduces production time by nearly 70%.
  • Custom weld cell with six robots to weld and clean odd-shaped 30-ton parts.

Founded in 1998, Navus Automation, Inc. is an industry leader in full-service custom machine building, welding, and integration solutions. We collaborate with many Fortune 500 companies in the automotive, military, agriculture, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety.

 

Navus To Speak at National Robotic Arc Welding Conference

Navus

Buck Barber, Sales & Marketing Manager for Navus Automation, Inc., will speak at the National Robotic Welding Conference & Exhibition (NRAWC) in Milwaukee on June 7, 2017. The conference highlights the newest tools and techniques for data driven, flexible robotic manufacturing.

Adaptive welding robots have traditionally been employed to handle low skill, repetitive tasks, from a fixed location. But with the tools and features available today for offline programming, sensing, tool changing, and remote monitoring, robotic systems are gaining the flexibility and technology needed to increase a single robot’s range of capabilities.

As an example of those advances in capabilities, Barber’s presentation at NRAWC will reveal how a remotely operated, multi-function robotic work cell makes welding in a dangerous environment more safe and efficient. The unprecedented system is designed to move the robotic welding work cell 100 feet into position in a dangerous environment while the operator works remotely from a safe location. The multi-task robot effectively preps joints, welds, provides inter-pass cleaning, and vacuums welds remotely.

Barber will be representing Navus as one of the featured industry leaders presenting on data driven flexible manufacturing with single or multiple robots, and new advances in optimizing upstream processes. This year marks the 34th anniversary of the conference. The mission of the conference has been to present new and emerging technology in the areas of welding and automation. The conference was unique from the beginning in that it did not have a call for papers but instead featured invited speakers, like Barber, based on cutting edge technologies.

With years of research and development and a certified weld inspector on staff, Navus has developed innovative strategies to meet the toughest challenges. Founded in 1998, Navus Automation, Inc. is an industry leader in full-service custom machine building, welding, and integration solutions. Navus collaborates with many Fortune 500 companies in the automotive, military, agriculture, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety.

 

Automated Multipass Heavy-Deposition Robotic Welding

Navus

One of our major contracts required welding large steel sheets for shipbuilding, which is typically a time-consuming endeavor, especially considering that the parts can weigh as much as 30 tons. However, with a multipass high-deposition robotic welding technique we were able to reduce the overall process time by about 60%.

Six ABB IRB 4600 robots, three on each side of the cell mounted on 30-meter tracks, move along using a Fronius GP tandem system. The robots work within two cells to achieve interpass cleaning, grinding, and removal of any silicate that could compromise finish quality.

The workpiece is a 2”-thick steel plate that must be flipped a total of four times for the completion of welding and cleaning between each pass. The welds require an interpass temperature of 200-300ºC, and cleaning must be completed before each pass.

Our engineers used RobotStudio to program the parts offline based on our client’s modeling software. Digital manufacturing with offline programming is essential in achieving a project of this scale.

With this system, our client was able to cut their manufacturing process from a minimum of 28 weeks to eight weeks for one key component, which reduces the overall build time per set of components by approximately 60-70%. Best of all, the increased productivity doesn’t come with any costs in quality. The robotic system has been qualified to complete UT (ultrasonic testing) class welds.

This project has been key to reaffirming our reputation for applying ingenuity to solve complex challenges and deliver customized turn-key systems solutions.

Founded in 1998, Navus Automation, Inc. is an industry leader in full-service custom machine building and integration solutions. We collaborate with many Fortune 500 companies in the medical, automotive, military, and consumer industries. Navus engineers provide exceptional robotic solutions for integrated systems that increase productivity, quality, and safety.