African Fusion March 2015

Welding and cutting

The torch: the focus for automation A utomotive supplier Johnson Con- trols in Lahnwerk (JCI), Germany,

Tomove along the seam, thewelding robot needs a reference point to start from and any positional deviation must be identified and compensated for. Con- ventional techniques for determining this point involved errors and additional costs after each change of a gas nozzle. Torches also become distorted by heat and require continuous realignment. The solution from SKS Welding Systems eliminates these shortcomings by dealing with the cause: an annular circumferential ridge on the retaining headof the torchnowdefines a reference position that is independent of the gas nozzle. The ‘workpiece search’ function uses this ridge. A test voltage is applied to the retaining head. Upon contact with the ridge, the robot controller receives a correspondingmessage and calculates a robot path that is adapted to the specific position of the workpiece. The high TCP (tool centre point) accuracy of the torch is, therefore,

has managed to eliminate a bottleneck in welding processes for joints in car seat structures. The welding experts at the production site in Dautphetal are now using SKS’ Power Clutch torch sys- tem for components such as SGR tubes and brackets. Viktor Werz of manu- facturing engineering at JCI confirms: “After switching to welding systems with SKS torches, the seams now meet our quality standards at higher welding speeds and with shorter cycle times.” At the facility, JCI manufactures high-quality car seat structures using S420 MC tubes and have found a smart way to combine high-tech electronics and mechanical creativity. SGR tubes and bracket parts are joined by feeding the diagonally cut end of a 38 mm tube through a round extended and beaded hole in a 3.0 mm -thick metal pressing, and thenwelded around a circular seam.

maintained between each changover. “We now achieve extended tool life and higher welding speeds. Cycle time has been reduced by twelve seconds per part,” says Werz. www.yaskawa.za.com Developing young welding talent A ir Products South Africa’s Josua Le Roux, GM central support says: “Welding skills are critical in many industries and it is no secret that there is a dire shortage of engi- neering skills worldwide, specifically when it comes to expert welding. It is, therefore, our great pleasure to have provided welding gases to facilitate the Young Welder of the Year competition at the SAIW.” Air Products provided various specialist gases including argon for TIG welding and its special blends: Coogar 82 for MIG welding and Fluxblend for flux-cored welding. In addition, the company contributed towards accommodation and other costs related to the competition. “We are passionate about train- ing, skills development and the empowerment of young people in South Africa,” says Le Roux. “It is our hope that the use of Air Products’ range of specialist welding gases and the experience in taking part in this event will have an extremely positive impact on the future careers of these young welders,” he adds. www.airproducts.co.za The flanged seam that leaves a small section free for a ‘nose’ in the notch of the metal pressing.

Unique Welding Alloys relocates U nique Welding Alloys’ Boksburg branch has outgrown its Cason Road premises, and has relocated to bigger premises at the company’s distribution centre on 19 Van Dyk road. “We saw this as an ideal opportunity to rationalise operational costs in order to continue tooffer competitively priced, quality products to our customers,” says managing director, John Smithyman. “Our customers will also experience improved turnaround time due to a new gas ramp and ample, secure parking,” he recently merged all its divisions: Wel- damax, Unique, Selrod and Maxweld andBraze intoone tradingentity, namely Unique Welding Alloys, and the reloca- tionand rebranding of the newBoksburg branch is in line with phase one of this merger. www.weldamax.co.za Wire feeders with all-round protection F ronius has expanded its Case wirefeeder range for mobile use in the TransSteel power sources for quite some time, the company has now intro- duced suitable wirefeeders for the TPS/i (WF 25i Case) and TPS (VR 4000 Case) adds. The new premises also have an onsite service centre, ensuring awin-win for both Unique Welding Alloys and its customers. The holding company, Weldamax, harsh environments. In addition to the VR 5000 Case that has been available for

series. Users can choose between versions with a standard spool (D300) or a small spool (D200). The completely closed and shock-resistant devices are pro- tected against dust, humidity and water spray, making them particularly suitable for use on oilrigs, in shipbuilding, for rolling stock manufacture and anywhere where harsh environmental condi- tions prevail. www.fronius.com

Fronius’ VR 5000 Case wirefeeder for D300 spools is protected against dust, humidity and water spray.

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March 2015

AFRICAN FUSION