Tyazhmash has introduced new equipment

2024: Mill Drum Automation

TYAZHMASH At the AO "" plant Syzran , they automated the welding of mill drums and increased productivity by 4 times due to the introduction of equipment. This "Tyazhmash" together with "" Tesvel reported on February 19, 2024.

source = Tyazhmash

The introduced complex for automatic submerged welding is a column on a rail track, which moves and positions the working tool relative to the workpiece. A boom with a Lincoln Electric welding head is installed on the column. The height of the complex is more than 6 meters, which makes it possible to weld cylindrical products with a diameter of up to 5.5 meters.

Sets of roller supports that rotate cylindrical workpiece at constant speed are responsible for uniform rotation of workpiece during welding of annular seam. In addition, the installation can make a longitudinal seam, moving along the workpiece along the rail guides. The perfect quality of welded joints is provided by a special tracking system that automatically adjusts the position of the burner relative to the joint, preventing its deviation from the specified trajectory.

The complex is equipped with a flux recirculation system, due to which unalloyed flux is removed from the welding zone, filtered and reused. Due to this, its consumption is significantly reduced. In addition, the system maintains a constant temperature, which minimizes the risk of defects due to the use of wet flux.

The installation has 2 modes of operation: manual and fully automatic with horizontal and height laying of rollers during welding of circular and longitudinal seams. In the first case, during welding, the operator can adjust the position of the burner using joysticks on the control panel. In the second case, the process operation is completely carried out in automatic mode. The operator places the burner in the starting position, selects the welding program (specifies the number of passes, the burner pitch between the passes and layers, the size of the lock (overlap), etc.), then sets the installation to automatic mode and presses the "Start" button. The operation of the equipment starts, and the operator only observes. This mode is especially relevant for welding products with a large wall thickness, as it facilitates the operation of the operator, minimizes the influence of the human factor and increases productivity. Welding programs are stored in the memory of the machine in order to reduce the time for setting up equipment in the future.

The need for such an assistant is justified by the peculiarities of our production, in which bodies of rotation are often found. First of all, this complex is intended for welding mill drums. Of course, the capabilities of the equipment will be used for welding products of other directions, - said Andrey Onipko.

The installed equipment helped the enterprise solve several problems at once. First, the plant was able to quickly fulfill volumetric orders. Secondly, thanks to automation, management was able to redistribute welders to other production areas where there were not enough such specialists. Only one operator is now sufficient to operate the plant.

The automated complex for welding mill drums is our third major joint project: earlier, especially for the Syzran plant, we produced a robotic technological complex for welding and surfacing of guide vane vanes, as well as an installation for automatic surfacing of crushing and grinding equipment, - said the director of the company "Tesvel."

Sergey Morshansky drowned that for the team the project to automate the welding of mill drums became significant: they manufactured the highest welding column and integrated heavy-duty rotators (100 and 120 tons) to work with it. In order for all this large and heavy equipment to work, electronics engineers have developed software that allows automatic welding and surfacing with high accuracy. According to him, the Syzran plant does not stop there and is confidently moving in the direction of automation and robotization of various areas.