Valen Fittings manufactures specialist butt weld fittings for the oil and gas sector from a wide range of exotic materials – currently 37 materials are used, none of which are ferrous.  The fittings are generally used in critical applications, usually offshore or in the ‘hot spots’ of oil and gas refining processes.

A wide range of sizes are covered, typically from 8 inch to 48 inch diameter.  Some fittings require a welder to weld continuously for up to 15 minutes.  Len Sandford, Managing Director of Valen, explains, “Valen is renowned for its quality of product and in particular its speed of order turn round which is exceptional for the sector.

“We continuously aim to improve productivity but because of the many fittings, types of material, range of thicknesses and low volume call off, we don’t have the luxury of being able to implement basic welding robot principles.  Our aim is always to adapt our existing manning skills so we can maintain the quality and reduce operator strain.”

Working with welding automation specialist Pentangle Engineering, Valen firstly addressed the issue of accurately plasma cutting part finished pressings.

A Fanuc Robotics M-16 iB, inverted on a jib is used to plasma cut edges and then to cut a weld preparation angle along the same edge.

“We realised that the system would require considerable development to accommodate the variances that would be presented to the robot.  No two pressings are ever the same because of the thickness and shapes we are producing,” continued Len, “Pentangle quickly grasped the requirement and produced a real time measurement solution using lasers and feedback voltage from the plasma cutter to provide realtime adaptive control.”

Pentangle developed  the system to allow the robot to find the start point initially then offset its frame  to compensate.  During initial cutting, the plasma voltage is constantly measured and used to control the torch height and path. This ensures precision cuts typically to within 0.5mm tolerance.  A laser sensor was built in to the plasma head by Pentangle to control the cut of the secondary, but equally critical, weld  preparation angle and maintain a constant 3 mm ‘land’ along the root face.

The robot has allowed the operator to be removed from the immediate work area of the inherently dirty operation and production time has typically been reduced on a thick 24 inch pressing from  around 1½ hours to 10 minutes.

Robot two is used to weld prepared sections, utilising a 6 axes FANUC Robotics ARC Mate 120-iC positioned with a single axis manipulator.  The cell uses a high resolution camera to observe the weld, and a joystick controlled slide system,  which is mounted on the 6^th axis of the robot, to allow weld torch adjustments during the welding process.

Each complete weld can take up to 12 runs to complete.  During each run, the operator is able to view sidewall fusion and weld bead alignment on a monitor. By using the joy stick to jog in 0.5mm increments, he is able to make fine adjustments to the weld torch during welding.

Concluding, Len explains, “The quality of the weld still reflects the individual skill of the operator, but the overall appearance of the
robot-finished weld seams has improved markedly.

“Our overall productivity has improved since the installation of the robots. They provide more consistency and the quality they deliver is faultless.  From a project point of view we knew what we wanted to achieve – we didn’t want a large team looking after  each cell -  we wanted a simple one man operation that allowed our existing skilled  operators to have a simpler, safer, cleaner, and less stressful way to work – and we believe we’ve achieved that.”

It is ideally suited for motors controlled by variable frequency drives (VFDs) running pumps, fans, high-speed spindles, and other equipment in severe-duty applications such as mining and the processing of pulp/paper, food, pharmaceuticals, chemicals, and water/wastewater.  Commonly used to save energy, VFD’s induce motor-shaft currents that can damage bearings, completely wiping out any energy cost savings.

Standard bearing seals only keep out contamination and prevent leaks, but the Garlock SGi diverts harmful currents safely to ground, bypassing the bearings entirely and extending motor life. The patented AEGIS FiberLock Channel built into the Garlock SGi permanently secures circumferential rows of conductive micro fibres, preventing their dislocation and the resulting accidental contamination of the bearing.

The micro fibres themselves, proven in hundreds of thousands of installations to protect bearings from harmful currents, are engineered for flexibility to prevent breakage and ensure that the SGi will last for the service life of the motor.

Designed for long-term total bearing protection, the SGi also provides an IP56 non-contact isolation seal that withstands dust and powerful jetting liquids. It replaces contact lip seals and traditional bearing isolators commonly used in industrial applications and withstands operating temperatures from -30°C to 149°C (–22°F  to 300°F). The unit is available for motor-shaft sizes ranging from 22.2mm to 152.4 (0.875 ins to 6 ins) in flanged, flangeless, and custom configurations.

Working with their education partner, South Staffordshire College, Norgren began the selection process back in May this year and, so popular is the Apprentice Scheme, over 150 applications were received.   From a shortlist of 12 strong candidates there followed a detailed selection process finishing in the appointment of the four apprentices.    

“The apprentices join an elite group of individuals that have excelled and in some cases progressed through the business to senior management team positions,” explained Alan Topping, Norgren’s Engineering Manager.  “After a busy first week going over fundamentals of factory life, together with Health and Safety, they are now progressing through an intensive first year.  This involves spending time with all departments and achieving a basic level of understanding in each –  for three years their time will be spent with 2 days a week at college and 2 ½ days at Norgren.

“Apart from developing these apprentices around our own manufacturing processes we are also addressing an ever widening skills shortage in the UK’s engineering sector.  These skills are a vital element to keeping manufacturing and jobs in the UK.”

Norgren is a global leader in pneumatic motion and fluid control technology and manages its own product application advanced training programme called Norgren University.  Linking the apprentice programme to Norgren University will also address shortages of skills in product application and design.

Increasingly aware of mobile integration of services by universities around the UK and the exponential use of smartphone apps by students, Lancaster University set out to see what was available.  Options included developing locally from an open source web-based solution that downgrades to a mobile browser, a proprietary app from a virtual learning environment (VLE) provider and campusM™.

Complete management buy-in for the need to implement, as quickly as possible, assisted the process to select the most suitable option without delay.  campusM™ was selected as a fully featured product that allowed flexibility of integration and a fast deployment time of within 12 weeks.

Chris Dixon, Head of Service Delivery and Operations, Lancaster University, explains, “campusM™ stood out for us as it needed very little local development resource and it could meet our tight deadline for Fresher Week availability.  The product has clearly been developed around experience and understanding of university needs and has a range of ‘out of the box’ apps like campus map locations, pocket guide, library integration and timetable.  The campusM™ developers confirmed that as long as they were provided with data, or if Lancaster required them to help writing data, it would be complete within the 12 weeks – and it was”.

“In addition we bought the App Extension Kit (AEK) which further increases the flexibility of campusM™.  It allows us to write our own custom apps but using the campusM™ framework.  We’ve already launched our own student finance applet which allows students to analyse their outstanding credit payments and invoices, and we’ve also developed a bus timetable applet which takes data from Traveline providing locations of nearest bus stops, arrival times and routes.”

The AEK allows the University to develop one set of code for custom apps and the campusM™ framework allows it to run on any of the campusM™ mobile platforms including– Apple iOS®, Blackberry® and Android – and the web.  Running as a web based version, as well as mobile, keeps on-line registration straight-forward for students.

“The focus throughout has remained on enhancing the students experience and from the initial commitment to use campusM™ we have involved students in its delivery,” continues Chris Dixon, “User focus groups have been held to understand what is required and what needs to be developed for the system.  We are still implementing new custom applets as a result of these focus groups – a recent development is an applet that integrates the timetable with the sports centre so that squash courts, for instance, can be booked.

“It will be interesting for us to understand with the use of new campusM™ back office analytics what are the most used apps and which are the most popular platforms including the use of web over the mobile platforms.  It’s still early days for Lancaster University with this new facility and we’ve yet to realise more useful apps but campusM™’s flexible frameworks such as ‘Alerts’ provide the opportunity to further improve organisational functions and enhance our students’ experience.”

Comprising a combination of raw materials and using a patent pending fibre core, THERMa-PUR™ is easier to handle than conventional high temperature gasketing which use steel cores.  THERMa-PUR™ is available in a wide range of configurations including sheet, Kammprofile and corrugated metal gaskets.

Laboratory testing has proven THERMa-PUR™ provides efficient sealing when thermally cycled in temperature up to 1,000°C and, because of its non-oxidising formulation and fibre core, provides improved weight loss characteristics compared to other high temperature materials.

THERMa-PUR™ has hydrophobic properties making it safe to hydro test the system to full pressure and temperature. The new material does not stick to flanges making release easy and saving time.

Specialising in contract manufacture for the medical, optics and electronics industries, Carclo Technical Plastics injection moulds the main body of a multi-compartment cuvette and, adding value for its customer, performs an assembly operation before delivery.

Engineered by plastics automation specialists Hi-Tech Automation, a delta configuration robot, the FANUC Robotics M-1ia robot, was selected for the application.  Required to handle a weight of less than 5gm, the 1Kg payload M-1ia presented the most suitable solution.

Currently the assembly cell has been developed as a stand-alone cell with manual loading and unloading, of the cuvette, to an indexing turntable.  As production levels ramp up, the process may be made leaner by integrating the assembly cell with a robotically enabled moulding cell.

The component assembled to the moulding is a flexible filter strip delivered to the robot by a feed roller and cutter.  A camera positioned in front of the moulding measures the position and size of the filter and feeds back corrective dimensions to the feed roller / cutter to correct when required.

Alan Hogan, Manufacturing Engineer at Carclo Technical Plastics, explains, “The FANUC Robotics M-1ia robot does more than just place the filter into the moulding; we use the full flexibility of its six axes to actually manoeuvre the part into place.  Additionally the robot’s controller is controlling the whole cell and in particular a seventh axis which controls the dimension of the part.

“The vision system is integral to the controller and allows the robot to effectively adapt its programme by controlling the seventh axis. “

The M-1ia robot allowed Hi-Tech Automation to design a highly compact cell – weighing in at only 17Kgs and just 421mm wide the robot takes up no more room than a human operator working on a conveyor line.  A removable stand ensures that the M-1iA is easily integrated into the cell or removed for maintenance.

Control of the entire cell is through the FANUC Robotics intelligent R-30iA controller with integrated functions including iRVision, Robot Link and Collision protection.  In the event that the robot is integrated into the moulding cell the camera would be located into a housing provided in the robot body to position a camera above the wrist of the M-1ia.

FANUC robots are currently used in Carclo’s existing moulding facility in Mitcham, Surrey, where a FANUC Robotics M-10ia demoulds a similar component while two LR Mate robots pack the component into trays.

Alan Hogan continues, “We now use six axis robots rather than Cartesian unloaders because they are much more flexible and cost effective.  Hi-Tech Automation, in their role of FANUC Robotics Strategic Partner for plastics applications, has come up with some innovative solutions to our needs including the operator pendant we use which makes resetting the arm a simple task requiring minimal robot knowledge.”

Products machined from large solid blocks of aluminium often suffer with reduced strength properties, potentially leading to catastrophic failure during service.  Alloy Heat Treatment (AHT), the UK’s leading subcontractor in heat treating aluminium, provides for restoration of optimum strength properties to proof machined products using re-heat treatment, inspection, testing and release to the required temper.

AHT has the capacity to heat treat automotive and aircraft products up to 2.5m x 2m x 1.9m and 5 tonnes gross weight in its state-of-the-art drop bottom facility, located at its 70,000sq ft Dudley site.  In addition to providing straight forward heat treatment to manufacturers and machinists, AHT also offers both hardening and softening heat treatments to material stockists and suppliers who have difficulty in sourcing material in the required temper.

As components become increasingly complex, AHT plays an increasingly important part in its aerospace and automotive customers’ supply chains.  A quench distortion correction function, termed as “setting”, endorsed by Nadcap, automotive OEM’s and suppliers is just one added value option provided by AHT.

Setting provides for freshly quenched products to be manipulated to customer supplied checking aids or to specified machining tolerances. The setting process is further supplemented by a refrigeration process, allowing for storage of freshly quenched products at temperatures as low as -29^oC (which retards natural age hardening that prevents setting), permitting distortion correction to be undertaken without detriment, in accordance with prime contractors and OEM’s specifications.

Endorsed by NADCAP accreditation and approval by major aerospace  and automotive manufacturers, the AHT Team is always available to discuss customer requirements and understand individual requirements.

Image – Post heat treatment – component on setting fixture

A 150 ton FANUC ROBOSHOT moulding machine will be integrated with two robots – one robot, a side arm unit, will be deployed separately from the other, a FANUC Robotics M-10ia.  Carrying out post moulding operations, the six axes M-10ia robot will simultaneously control two additional axes of the side arm robot which will de-mould an 8 impression tool.

Utilising FANUC Robotics’ Dual Check Safety (DCS) position and speed check software this cell will use separate safety circuits.  DCS is an option of the FANUC robot’s controller that allows the arm to be restricted to specific zones, and the speed to be closely monitored, effectively safeguarding itself.   With less safety hardware required, workcells can be designed to be more compact, simpler and leaner.

In addition to the 150 ton moulder, FANUC ROBOSHOT will show its 100 ton machine which will be producing a polycarbonate pint glass demoulded and placed into to a laser marking machine by a FANUC Robotics M-20ia robot. The glass will then be placed to an out feed conveyor.

Both materials return strong results in ASTM standard tests while the higher performing Style 4000 has already achieved BS7531 Grade X approval.   Classified as general purpose use, the materials are asbestos-free gasketing sheet manufactured from a blend of aramid fibres and elastomeric binders.

Suitable for use with water, steam, oils and petrol, solvents and gases, makes the materials ideally suited for use in the petrochemical, oil and gas, pharmaceutical and food sectors.

The material allows good recovery rates – ASTM F36 for Style 2500 is 40% and for Style 4000 is >50% – ensuring high levels of torque retention.   High efficiency sealing, in particular for Style 4000 with ASTM F37B Nitrogen gas leakage at 0.5 ml/hr, makes the materials ideal for gas and steam where joint integrity is essential.

Garlock claims that continuous investment in its global resources and value engineering of the materials has allowed it to produce in quantities demanded of a general purpose material and at competitive prices.  The material is available through local gasket cutters or direct from Garlock GB.

A quirky demonstration of the FANUC LR Mate’s ability to count one pound coins has a serious side to it.  The robot uses a vision system to locate randomly placed coins and place them into a piggy bank while counting them in the process.

Relative to increases in operational costs, FANUC are keen to point out that robots have decreased in price over the past 20 years, making them highly affordable.  With high duty cycle FANUC Robotics robots available from £16K – £17K, one year returns on investment (ROI) begin to look realistic and even more so when three shifted.

PPMA will see a complete cross-section of FANUC Robotics robots being demonstrated including the M-3ia and M-1ia delta arm robots for high speed pick and place tasks, the small high speed LR Mate robot and palletising robots for handling payloads up to 700 Kg.

FANUC’s Strategic Partners focus on specific areas of automated packing and handling using FANUC Robotics robots – exhibiting and demonstrating will be Pacepacker Services, Abar Automation and Smurfit Kappa Machine Systems.