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Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 1
What is the difference between
Remote Handlingand
Handlingand
?
Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 2
What is the difference between
Office Engineerand
Workshop Engineerand
?
Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 3
In the toiletthethe
Workshop Engineer
first washes his hands
and then does the job
Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 4
When something goes wrong in
Remote Handlingyou cannot use your hands
Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 5
When something goes wrong in
Remote Handlingyou cannot use your hands
as you canin
Robotic HandlingRobotic Handling
Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 6
ITER Vacuum Vessel Welding
Development Package
Presentation based on the
Participating organisations:
VTT, Lappeenranta University of Technology, Hollming Works Oy, Tekes
Presented by: Pertti Pale
Date 2.6.2010
Place Annual Fusion Seminar VTT Tampere
7VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
Place Annual Fusion Seminar, VTT, Tampere
The ITER Vacuum Vessel Assembly
• 9 VV sectors• 27 upper port structures
9 port stub extensionsextensions18 port extensions
• 22 equatorial port structures
14 standard ports1 DHNB port t iextension
2 HNB port extensionsport stub extension4 NBI ducts
• 9 divertor port structuresp3 RH port extensions2 RH / diag port extensions4 pumping ports
8VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
The ITER Vacuum Vessel Assembly
• 9 VV sectors• 27 upper port structures
9 port stub extensionsextensions18 port extensions
• 22 equatorial port structures
14 standard ports1 DHNB port t iextension
2 HNB port extensionsport stub extension4 NBI ducts
• 9 divertor port structuresp3 RH port extensions2 RH / diag port extensions4 pumping ports
9VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
ITER CALL
ITER CALL
ITER CALL
ITER CALL
T i l S li Pl tTypical Splice Plate:• Length 2,40 m• Cross section 60 x 100 mm• Mass 130 kg
14VV Assembly Welding DevelopmentCherbourg 18.5.2010 Pertti Pale
Thermal Shield
Rib
Outer Shell Sector A
Rib
Outer Shell Sector B
Rib
Inner Shell Sector A
Rib
Inner Shell Sector BTool
Triangle Support Structure
Tool Arm
Tool Arm connection to the Robot
15VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
Thermal Shield
Rib
Outer Shell Sector A
Rib
Outer Shell Sector B
Robotic Functions:PREPARED in several positions and structures•Welding•NDTRib
Inner Shell Sector A
Rib
Inner Shell Sector BTool
•NDT•Machining•Measurement•Positioning•Thermal Shield Joining•Repair•Cleaning•Transport
Triangle Support Structure
Tool Arm
•Transport•ViewingADHOC in several positions and structures•Actions related to misalignment of sectors•Actions related to jams•Actions related to non‐satisfactory operations (eg. welds, NDT, measurement, positioning)
Tool Arm connection to the Robot
16VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
A combination of
• Magnitude
• Complexity
• Robotic tooling
• Methods
• Requirements
17VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
MagnitudeMagnitude• Total weld LxB = 2500 m x (40...60mm)
Welding• Thickness 40...60 mmc ess 0...60• All positions• Limited space• Operation distance• Robotic remote handling• Problem points• Problem points• Repair
NDT• Thickness 40...60 mm• Limited space• Operation distance• Robotic remote handling• Problem points
He Leak Testing• Limited space• Limited space• Operation distance• Robotic remote handling• Problem points
In‐Wall Shieldingg• Limited space• Operation distance• Robotic remote handling• Problem points
18VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
• HIGH dynamic machining force ‐ for cutting, weld repair and weld preparation ‐ 6 kN
• HIGH accuracy ‐ for positioning, measurement, welding and NDT – 0,1 mm
D i St ti D i
• LOW mass/size of robot ‐ for mobility, limited space and parallel operation of several robot systems – 1000 kg
PayloadDynamic
work force
Static repeata-
bility
Dynamic repeata-
bility
Robot mass Mounting
Motoman HP600 600 kg 0,5 mm 2400 kg
Kuka KR 240 240 kg 0,12 mm 1267 kg FloorKuka KRKuka KR
1000 1000 kg 0,2 mm 4690 kg Floor
Kuka KR 500 500 kg 0,15/0,3 mm 2350 kg Floor,
ceilingABB IRB
6650S 145 kg 0,14/0,28 mm 2175 kg Shelf
OTC AX-V500 500 kg 0,5 mm 3000 kg FloorF MFanuc M-
2000iA 900 kg 0,3 mm Floor
Fanuc M-900iA 350 kg 0,3 mm 1720 kg
Floor, ceiling,
angle, wall
Movable on
19VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
LUT ITER IWR 600 kg 600 kg <0,1 mm 0,1 mm 890 kg
Movable on rails, all angles
<‐‐‐‐‐‐‐‐ 1 m ‐‐‐‐‐‐‐‐‐‐>2350 kg
<‐‐‐‐‐‐‐‐1 m ‐‐‐‐‐‐‐‐‐>890 kg
KUKA 500‐2 LUT ITER IWR
Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 20/12
Annual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 21/12
Robust mass production ‐‐‐ abt 90%
Non‐robust individual production ‐‐‐ abt 10%
• Design to serve mass production
• Requirements to allow mass productionq p
• Robotic Tooling to serve mass production and individual production
• Methods to serve mass production
22VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
1. Installation of tooling2. Definition and fabrication of Splice Plates3. Preparation of weld area for longitudinal welding4. Positioning of Splice Plates5. Confirm ok for welding operation startg p6. 1st Pass Weld + UT + He Leak Test7. 2nd to Final Pass Weld + UT8. Preparation (incl. machining) of weld area for
transversal welding9. Confirm ok for welding operation start9. Confirm ok for welding operation start10. 1st Pass Weld + UT + He Leak Test11. 2nd to Final Pass Weld + UT12. Cleaning13. AcceptanceIn the case of defects:In the case of defects: 1. Machining 2. Rewelding 3. UT 4. For the root weld: also He leak test
23VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
Timing excercise
Case 1 – NG TIG• Weld length 2500 m• Plate thickness 40 ... 60 mmW ld h d NG TIG G 400 600 3
Timing excercise
• Weld method: NG TIG Groove area 400 ... 600 mm3• Weld volume abt 2500 m x 500 mm3 = 1,25 m3• Filler material 10 ton• Welding speed per station 0,5 kg/h• Arc time ratio assume 30%• Required time for 1 station = 10 ton/(0 5 kg/h)/30%=60000 h = 8 aRequired time for 1 station = 10 ton/(0,5 kg/h)/30%=60000 h = 8 a• Required time for 4 stations = 2 a
• Required time for 8 stations = 1 a
Case 2 – Laser Hybrid• Weld length 2500 m• Plate thickness 40 ... 60 mm• Weld method: Laser Hybrid Groove area in average 200 mm2• Weld volume abt 2500 m x 200 mm3 = 0,5 m3• Filler material 4 ton• Welding speed per station 2 kg/h• Arc time ratio assume 30%
• Required time for 1station = 4 ton/(2 kg/h)/30%=6000 h = 1 a
24VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
Development Programme Package
LAB• Experience• Infrastructure: space, technical environment, resources
ROBOTIC TOOL, HANDLINGROBOTIC TOOL, HANDLING• Existing system• Supporting team
WELDING, NDT• Industrial capabilities• Industrial capabilities• R&D capabilities
DESIGN, REQUIREMENTS• To be reconsidered during the Development Programme
25VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
/
Development Programme Package
LAB ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ROViR/VTT, TUT• Experience• Infrastructure: space, technical environment, resources
ROBOTIC TOOL, HANDLING ‐‐‐‐‐‐‐‐‐‐IWR/LUTROBOTIC TOOL, HANDLING IWR/LUT• Existing system• Supporting team
WELDING, NDT ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐VTT , industry• Industrial capabilities• Industrial capabilities• R&D capabilities
DESIGN, REQUIREMENTS• To be reconsidered during the Development Programme
26VV Assembly Welding DevelopmentAnnual Seminar 2.6.2010 Pertti Pale
ITER CALL
LUT ITER IWRAnnual Seminar 2.6.2010 Pertti Pale VV Assembly Welding Development 28
LUT ITER IWR