iccr presentatie 2015
TRANSCRIPT
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DRUM WELDING IN THE 21 ste CENTURY
Erik Verhoeven, managing director of Arplas Welding bvba
New Technology Leads the Future of Steel DrumsGLOBAL SOLLUTIONS
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Erik Verhoeven
Worked for Newcor Bay City since 1979
Worked for Arplas since 1986
In charge for development of a new type welder in
1996
Founded Arplas Welding BVBA in 2003
Part of machine building group since 2013
General manager of Arplas Welding bvba
In charge of technical development and sales
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HistoryNewcor started building drum welders in 1933
Newcor builds the first ever trough feed drum
welding
machine, copied by others
Arplas takes over activities of Newcor in Europe. Arplas closes down plant in 2003, for financial
reasons.
Arplas Welding is grounded in Belgium.
Arplas Welding becomes daughter company from
Perdaen d’Hooghe, a renowned Belgian machine
builder, with full in house manufacturing capabilities
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New offices in Belgium
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Side seam drum welding machines
High / Medium speed drum welder
HSP 800H and HSP 800M
Low speed drum welder LSP 300
Hand fed drum welder LSP 125
Pail welder PSP 900
Boiler welding machine BMS 240
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HSP 800 High speed
drum welder
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LSP 300Medium speeddrum welder
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PSP 900Medium sizedrum welder(Pailwelder)
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LSP 150 Semi automatic
drum welder
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Developments of Arplas in recent years:
New weld control SyncronAC developed in 2003
New type welder developed in 2007,for low speed;
our LSP 300.
Redesigned HSP drum welder for higher speeds
and lower maintenance in 2009.
Touch screen computer integrated in welder.
New medium size drum welder developed in 2014
Continuous adapting of welders to customers
specifications and needs.
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Technological advantages of modern welders
Drawn copper conductorsStainless steel heads
Cast copper conductorsCopper heads
Cast copper has a 20 to 30% Higher electrical resistance.Drawn copper guarantees a power saving of up to 15%
NEW OLD
Weld heads and conductors
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Technological advantages of modern welders
NEW OLD
Hour glass roll necklace16 Massive stainless steelLess skiddingNo wear
3 Bronze cast chrome plated HGRExpensive manufacturingSkiddingHigh wear and chipping
Hour glass rolls
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Technological advantages of modern welders
NEW
OLD
All drives by timing belts• Less wear• Full insulated• Less maintenance
• Complicated mech. Systems• Pollution of welder• High maintenance
Belt drives
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Technological advantages of modern welders
NEW OLD
Electric driven pusher• Auto speed setting• Auto length setting• More controlled speed
Pneumatic pusher• Manual settings• Poor speed control
Pusher system
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Technological advantages of modern welders
NEW OLD
Weld head drive• 2 electronic coupled motors• Standard gear boxes• No touch feature for smooth welds
• Single motor.• Many shafts and couplings• Custom made gearboxes
Weld head drives
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Technological advantages of modern welders
NEW OLD
• Smoother introduction of drum• Less bumping of lower head• Higher weld speed possible
• Less control on weld start.• Lower weld speed
Weld head angel
Weldhead under 45 degrees angel Weldhead under 90 degrees angel
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Technological advantages of modern welders
NEW OLD
New electrode copper
Ekectrode in CuCoNiIIbe• Harder copper quality• Lower electric resistance• Longer life time
Electrode in CuCrZr• Softer than CuCoNiIIbe• Lower electric resistance• Shorter life time.
Type electrode Number drums Price electrode
(2 pieces)
Price replacement Cost per 1000 drums
CuCrZr 280 mm 106 000 510 Euro 540 Euro 9,90 Euro
CuCrZr 300 mm 229 000 610 Euro 540 Euro 4,90 EuroCuCoNiBe 280mm 238 000 824 Euro 540 Euro 5,73 EuroCuCoNiBe 300mm 514 000 994 Euro 690 Euro 3,27 Euro
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Technological advantages of modern welders
NEW OLD
Thermal shrinked elektrodes
Thermal shrinked electrode• Only outer ring replaced (Cheaper)• Better electrical connection• No O rings or water leaks• Very easy to do.
Bolted electrodes• Complete electrode replaced• Electrical connection by bolts• O rings for water tightness.
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Technological advantages of modern welders
NEW OLD
Touch screen computer• Menu system for all settings• Trouble shoot menu• Fast identification of quality issues• Main company computer communication
Push button operator panel• All manual settings• No trouble shooting
Operators communication
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Technological advantages of modern welders
NEW OLD
SyncronAC weld controller• Major power savings• 3 phase connection• Cos phi of up to .99
Thyristor controller• 2 phase connection• Cos phi of .50 or less
Weld controller
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250 kVA single phase AC welding transformer
Power absorbed by welder(power taken from source)143 kVA
Power consumed by welder itself±53 kW
Efficiency is %37143
100 x 53
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250 kVA single phase AC welding transformer,equipped with 3 phase Arplas SyncronACWelding Control
Power absorbed by welder(power taken from source)63 kVA
Power consumed by welder itself47 kW
Efficiency is%74
63100 x 47
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Power calculation based on European power prices (€ 0,12 / kWh):
250 kVA single phase AC welding
600 drums per hour (0,8 mm)80% on time2 phase connectionCos φ measured 0,4143 kVA measured power consumption
142 kVA x 80% = 113 kVA / hour
250 kVA 3 phase SyncronAC welding
600 drums per hour (0,8 mm)80% on time3 phase connectionCos φ measured 0,9863 kVA measured power consumption
63 kVA x 80% = 50 kVA / hour
The power saving using the Arplas SyncronAC is 63 kVA per hour…This is a saving of € 7,56 per hour! (≈ $ 10,00)
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More advantages of the SyncronAC system:
•3 phase load of the power net. Some electrical companies charge a fine for loading only 2 phases of the net.
•Better weld quality due to the use of full sinus during welding (no phase shift).
SyncronACThyristor
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More advantages of the SyncronAC system:
•Higher weld speeds possible. If used with the new concept Arplas welder, speeds up to 23 meters per minute can be achieved. With old welders up to 18 meter per minute.
•Improved cos φ for the whole plant’s power consumption.•Thinner (cheaper) cables can be installed.•No special power transformer for welding machine
needed.•Normal AC welding transformer can be used if existing
machine is converted.
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More advantages of the SyncronAC system:
•Better weld quality by more determined start of weld, as no synchronizing time is needed.
•Less wear of electrodes as lower current peaks.•Smaller heat affected (blue) zone as more efficient heating
is used.
SyncronACThyristor
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More advantages of the SyncronAC system:
•Current adjustment without delay.•4 welding zones are included in the control system.•Simple setting of the controls.
on on
off
EOC: makes the weld longer
Weldsensor
Weldcontroller
Off Upsl Curr1 Upsl Curr2 Dwnsl Curr3 EOC Dwnsl Off
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Development of the system:
»Invented in 2003 – adapted for large drums.
»Arplas developed the first generation with a Swiss electronics company.
»Because of the high price and the reduced reliability, the complete system was redesigned in 2005.
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Development of the system:
…resulting in 4 versions:
SyncronAC 250SyncronAC 500SyncronAC 700
and SyncronAC 1000
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Development of the equipment in order to:
•Reduce cost of operation of the welder: • Less electricity, air and cooling water• Less maintenance• Less consumables• Less maintenance time.• Work operator free.
•Make the equipment more reliable: • Less down time.• More commercial and local purchased spare parts.• Less scrap production
•Improve the quality of the produced part. •Improve production speed of the equipment.
More than 140 Units operational all over the world.
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Further ongoing development:
•Weld quality insurance system: • Continuous monitoring of actual weld current.• Continuous monitoring of secondary voltage.• Continuous monitoring of weld thickness with teach in
system.
•This system will trace more than 90% of the weld defects during production.
•Production defects will be reduced to 0.01 % or less.
•System will be available in 4 to 6 months.
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Some references:We have build or rebuild 85 welders in the last 20 Years, from which 20 in the last 5 years. We also installed 120 SyncronAC on drum welders.
• Rafael Trejo Cuba• Balmer Lawry UAE• Balmer Lawry India • Insung Korea• Metadrum Syria• CPC Taiwan• Rheem South Africa• Sumbisa Spain• Hannels Norway
• Greif World Wide• Raft Brazil• Greif China• Elsa Mexico• That Drums South Africa• Rheem Chile• Schutz Holland• Hua I Taiwan (Greif)• Hemeyer Germany
And many many many others.
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Rebuild Newcor NB720 drum welder
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MSP 600 drum welder (2000) Brazil
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HSP 900 drum welder (2005) Taiwan
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HSP 800 drum welder (2006) China
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HSP 800 drum welder (2007) Mexico
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LSP 300 Drum welder (2008) Brazil
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HSP 800 m Drum Welder (2008) India
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HSP 900 H drum welder (2008) Singapore
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HSP 900 Drum Welder (2009) USA
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HSP 900 Drum Welder (2012) India
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May we thank you for you kind attention.
Any questions…?
www.arplaswelding.com
We have some handouts from this presentation and some technicaldocumentations available here.If you require these please meet me after the sessions ore anytime this week.
It is also possible to download this presentation trough our web site. Find the line as follows on our first page of our web site:Please click here to download a copy of our ICCR 2015 presentation.
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May we thank you for you kind attention.
Arplas Welding bvba
Anthonis De Jonghestraat 1 9100 Nieuwkerken Waas BelgiumTel.: +32 (0)3 7781464Fax.: +32 (0)3 7779450
Arplas Service office Asia - PacificIndustrial Power Engeneering
16 Jalan SS 4/1747301 Petaling JayaSelangor, Malaysia
Tel.: +60 (0)19 224 8063Fax.: +60 (0)3 78765105
www.arplaswelding.com