Frequently Asked Questions

By يونيو 20, 2018Industry
Spool Welding Robot

1. What are the main features of the SWR?

Semi-autonomous

Using a laser scanner, point lasers and closed-loop control systems, the SWR automatically maintains the torch to pipe distance with 0.1mm accuracy and assists the operator in seam tracking so primary focus can remain on the weld. Depending on the fit up, additional operator input may be required for seam tracking.

Collaborative

As a collaborative welding robot, the SWR is designed to meet all the safety requirements of ISO 15066; therefore, it does not require fencing or a safety cell. A Junio welder can stand beside the robot and make changes during the weld as required.

Long Reach

Among industrial spool welding robots, the SWR has the largest ratio of reach to footprint. With a footprint of 24sq ft, the SWR has a radial reach of 15’ which allows for welds in pipe modules and spools up to and including 30’.

Ergonomical

Designed for semi-automatic 1G roll welding, the SWR significantly improves the ergonomics of pipe welding by having the robot take on the heavy lifting of a consistent weave motion.

Production Monitoring

The SWR provides repeatability and reliability; The NovData logging software captures all available data for each weld pass for future analysis and reporting.

NovEye™ software

The SWR is equipped with the NovEye software which can display the weld to the operator as it progresses and records a video from each weld for analysis and future production improvements.

2. What are Collaborative Robots?

Collaborative robots (cobots) are a new family of robots which are safe to collaborate with people on a factory floor. In contrast with robots, cobots do not require a safety cell; instead they work with human operators.

Cobots don’t require to be programmed and they are very easy to work with. In addition, they are less expensive and have small footprints compared to traditional robots.

There are many generic six-axis robots on the market today including Universal Robots, Rethink Robots, YuMi and others.

3. What size of pipe can be welded with the SWR?

The base model of the SWR can weld pipes from 2” to 60”. If your pipe falls outside these specs, we can help you but need to know more about your application first.

4. Which welding process can be used?

The primary welding process is GMAW and MCAW. We use modified short-circuit on root (STT, RMD, LSC) and use modified waveform pulse processes for solid wire flux core or metal-cored wire for fill and cap passes.

TIG,  SAW and FCAW are also available as custom options. Talk to our sales team if you’d like to know more about your specific process.

5. What material can be welded with the SWR?

The SWR can weld carbon and low alloy steels, as well as stainless and nickel alloys. .

6. Does the SWR weld root to cap automatically?

Yes, the SWR has the ability to switch between weld modes without shutting off the arc.

7. Can I use my existing positioner?

In most cases yes, Novarc engineering team can help review and determine if your positioner can be retrofitted to work with the SWR.

8. What power sources can be used with the SWR?

Available power source options are Power Wave® R450, Auto-Continuum 500, and Fronius TPS 400i LSC Advanced.

9. Does the SWR come with a power source?

Yes, all units are quoted with a power source. Customers can supply their own as well, but the power source must be a specific robotic model made by either Miller / Lincoln / Fronius.

10. Does the SWR fall under robotic welding from a welding procedure standpoint?

Based on industry standards, the SWR falls under mechanized welding, given that the operator interacts with the machine and makes on-the-fly adjustments.  

11. What is floor layout required for the SWR?

The SWR takes a 4’ x 6’ floor footprint, and it does not block forklift traffic nor interfere with shop cranes.

12. How much productivity and capacity can I expect from using the SWR?

This depends on your current welding process. One SWR with an operator can produce the same output as 4 welders using SMAW, and 2 welders using manual GMAW.

13. Why does productivity improve with the SWR?

By eliminating the torch hand control, the mechanized weave relieves welder fatigue so they can expect a higher deposition rate, higher production, faster track speeds and the ability to run pre-programmed welds.

14. What is the ROI on investing in an SWR unit?

With just a few details about your operation, we’ll have your ROI calculated. (Link: https://www.novarctech.com/roi/)

15. How does the SWR fit in the production flow?

The SWR is designed to fit in pipe fabrication shops because the height does not interfere with overhead cranes. In addition, the SWR can be easily parked away to allow shop traffic to pass.

16. How long does it take to install and commission the SWR

It takes two days to install the SWR and only one day to commission it.

17. How long does it take to train an operator and what skill level should they have?

It takes (3-5) days to train an operator for both operations and maintenance.  

The operators should know the basics of welding and have some welding experience.

18. How can I monitor the production?

The SWR comes with the NovData production monitoring software that produces daily reports. The daily report includes: production time, welding time, pipe diameter and more.  It also creates a time-stamped log file with voltage, current, WFS, travel speed and all other relevant weld and motion parameters for each weld.

The SWR also comes with a camera built into its robotic arm.  With this feature, operators get a clear view from inside the groove on the HMI as each weld progresses in real time. NovEye records all videos for future analysis.

19. What shielding gas is required?

Welding shielding depends on the weld process and filler metal. Our technical team can assist you with  specific welding applications.

The SWR uses 85%  Argon 15% Co2 and a -6 wire for root to cap welding on carbon steel pipe.

20. What are the power and air requirements for the SWR?

The SWR needs 3 phase power and minimum 85 PSI compressed air. The electrical power can be any of the standard voltages between 208V and 600V.

21. How does the robot connect with the rotator?

We add servo motor to your existing positioner so the SWR would be able to control it.

23. How does the safety system work?

The SWR has built-in speed and torque monitoring systems that ensure speed and forces are within required levels at all times.

24. How much maintenance is required for the SWR?

The SWR is designed to be a robust machine. As a result, only minimal maintenance is required. Maintenance training is included with the robot training.

25. Can the SWR be moved around the shop?

The SWR needs to be anchored to a minimum 6” concrete slab. However, you can move it between previously installed base locations using overhead cranes.

26. Can the SWR be used outside the pipe shop?

The SWR is designed for indoor usage. It can be used in the field or in a work yard, provided it is protected from the elements.

27. Can you copy data from one SWR to another?

Yes, you easily copy the data from SWR to another using a USB.

28. How heavy is the SWR?

Approximately 3500 lb.  

29. What are the bevel requirements for the pipes?

Refer to Bevel requirements document.

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