See how Sulzer supports Lisahally power station in Ireland with on-site automated weld overlay (cladding). https://www.sulzer.com/en/services/st... Sulzer’s core is flow control and applicators. We specialize in pumping solutions, services for rotating equipment, and separation, mixing and application technology. Our customers benefit from a network of over 180 production and service sites in about 50 countries around the world. https://www.sulzer.com

Green Control Systems

Household Waste Recycling Plant Process

Here’s a playful look into a new industry housing 2M Cladding Control Systems.

Tasked with protecting pipes exposed both internally and externally to extreme heat and noxious gasses, our cladding system diligently works to extend raw material life span and reduce the likelihood of any fracture lines or wear and tear.

This whole endeavour involves shape shifting between the very elements themselves throughout various process chambers, in an adventure of metamorphosis.

Green Control Systems

Plugs & Sockets

Most elements of 2M projects are bespoke and handmade for the project at hand.

Plugs and sockets are designed and assembled with fit, function, and durability in mind.

Green Control Systems

Site Trials

A look over a great expanse, a metal maze in Italy. High up on site, control system tests began within chambers of steam and gas.

Not safe for those with sensitivity to light ~ you’re about to see a myriad of sparks take flight as the automatic torch head begins seeing to the plight of pipes working in extreme circumstances.

Green Control Systems

Mind-blowing Metamorphosis

Back to nature for a more traditional definition of transition – prepare yourselves to be blown away by this lovable caterpillar peeling away through complex layers of growth as it becomes what it yearns to become – a Puss Moth!

My favourite part is the wriggles and jiggles and the stretches it takes to slip from one outfit into the next. This is a really jaw dropping process and it’s a privilege to see it unfold.

See what you think!

Green Control Systems

Where Does It All Go?

An interesting glimpse into a separation process required prior to the anaerobic process. Not for the fainthearted this one. It would be more becoming perhaps if we, like the caterpillar before us, produced little to no waste ~ and if what we did use and discard was easily returned to the earth with little to no mess?

Food for thought as we transfer the idea of digestion from the stomach to the mind in our very own internal process.

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Collaboration

Please join us on this conveyor belt for a quick zip through an exciting new enterprise – a cladding system upgrade resulting from collaboration between:

End Users QA Weld Tech

Machine Builders JTR Automation

System Designers & Integrators 2M Automation

Embedded tags will also whisk you away to relevant project and blog posts within our site. We hope you enjoy the ride. Buckle up!

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Bells & Whistles! i.e. New Features!

Below is a snapshot of the features 2M Automation developed on the B&R platform using B&R hardware:

Twin Arc System (Two Weld Torches) – Two Weld Power Sources and Two Hotwire Power Sources

Automatic Touch & Retract – Ability to automatically set up the torch height before the start of weld

Integrated Programmable Safety

Twin Closed-loop wire feed system with wire-speed verification and wire usage data

Twin Automatic Voltage Control (AVC) using closed-loop Stepper control

Servo-controlled carriage using an absolute-position encoder

Remembers Position of Carriage and Automatically returns to position on restart (optional)

Control and Monitoring of the cooling system using water

Control and Monitoring of the Gas flow

Automatic recording and collecting of weld data for use of IOT

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QA Weld Tech

End users QA Weld Tech strove for improved quality, reliability and efficiency when embarking on developing a machine, with the hope of meeting the exacting requirements of their customers.

As such, what we believe is the most technologically advanced cladding machine in the U.K was developed with collaboration.

QA Weldtech are responsible for the State-of-the-Art Torch Design that is an imperative part of this new innovation.

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JTR Automation

As the machine builders in this collaboration, JTR Automation were responsible for both:

design of the Integrated Welding Power Source Calibration, and

design of the Integrated Camera System for viewing the weld process.

Offering real-time and incredibly clear data, JTR Automation’s Advanced Weld Vision Systems reduce defects, improve safety, and maximise operational efficiency.

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Clicking the Cladding subject tag on any piece will take you to all posts associated with cladding in our site.

Exploring these write-ups and upgrade case studies will give you an idea about how our Cladding Control Systems have developed throughout the years.

By navigating to our Green Control Systems case study you will see further related developments and applications using 2M Cladding Control Systems.

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Wire Feeder

The wirefeeder with encoder feedback is a critical component in systems like TIG welding.

In these processes, a continuous wire is fed to the welding torch. It’s the wire feeder’s job to ensure a consistent supply of wire which is crucial for maintaining quality and efficiency.

Furthermore, encoder feedback to the wire feeder monitors and regulates the wire’s feeding speed and position – allowing for accurate control of the wire’s movement, speed, and length.

This type of information in real time allows for parameters to be adjusted on-the-go dynamically to ensure consistent feeding under various operational conditions, preventing wire jamming, excessive feeding, or insufficient wire supply.

#MechafinWirefeeders enable:

Accurate Speed Control.

Reduced Wear and Tear (by preventing unnecessary strain on the wire feeding components).

Enhanced Process Control.

Prevention of Wire Feeding Issues.

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Water Flow Sensors

To measure the flow rate of water in the system, water flow sensors are used. They monitor water usage, system efficiency, and also detect leaks.

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Junction Box

Here’s a junction box combining both motor and encoder wiring into an accessible location. It allows for efficient routing of power and signal cables to the motor and encoder while protecting components from things such as dust and moisture.

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Headstock Encoder

A headstock encoder is an optical or magnetic sensor which measures the position, rotation, or speed of a rotating shaft that is often attached to the headstock of a machine.

It provides feedback to the system, enabling precise control of movement in the machine. Position feedback may be provided for moving parts. Speed control may be provided for rotating components. Direction monitoring may feedback information regarding the direction of rotation of various parts.

Essentially, where set up and integrated correctly, accuracy and consistency are assured by headstock encoders.