IoRW Meeting in Derby 11 th of May Schlatter Industries AG Rail Flash Butt Welding Machines. Speaker: Jürg Wahrenberger

Transcription

1 IoRW Meeting in Derby 11 th of May 2011 Rail Flash Butt Welding Machines Speaker: Jürg Wahrenberger Brandstrasse 24 CH-8952 Schlieren Phone: Fax:

2 Presentation Chapters 1. Introduction of with the main activities 2. Rail welding machines and systems - Stationary DC Welders GAAS80 and GAA100 - Mobile AC welders AMS60 and AMS New Development: mobile welder Schlatter AMS Schlatter Weld Analyzer, new features Jürg Wahrenberger 11 th May

3 Short history and facts of - Schlatter Company was founded already 1916 by Mr. H.A. Schlatter. - Schlatter Company is located in Schlieren which is very close to Zürich and to its intercontinental Airport. - Export > 95 % - Since 1995 Schlatter works according to quality standard ISO Schlatter offers now 95 years of experience and know-how in resistance welding. - Since 1998 listed company at the Swiss stock market. - Annual Turnover of Schlatter Group, depending on the economic situation, ranging between CHF 120 Mio and to CHF 240 Mio. Jürg Wahrenberger 11 th May

4 in Schlieren / Switzerland Jürg Wahrenberger 11 th May

5 Activities of - Wire Mesh Welding Systems: Reinforcing mesh welding machines for construction industry, fully automatic systems for massproduction of standard mesh sheets and dedicated systems for economical manufacturing of small series of special mesh sheets. Mesh welding machines for the production of mesh for shop equipment, display articles, shopping trolleys and baskets, protection fences, animal cages, cable trays - Radiator Production Lines Fully automatic lines for production of panel radiators for central heating Welding machines for production of element radiators. - Rail Flash Butt Welding Machines Stationary machines for Long Welded Rails (LWR) Stationary machines for turnouts, crossings, switch blades Mobile machines and systems for in-track welding of CWR Jürg Wahrenberger 11 th May

6 Reinforcing mesh products made on Schlatter machines Jürg Wahrenberger 11 th May

7 Production lines for reinforcing mesh sheets Jürg Wahrenberger 11 th May

8 Industrial mesh products made on Schlatter machines Jürg Wahrenberger 11 th May

9 Wire mesh welding machines for industrial mesh Jürg Wahrenberger 11 th May

10 Panel Radiators made of sheet metal Jürg Wahrenberger 11 th May

11 Panel radiator manufacturing lines Jürg Wahrenberger 11 th May

12 Small mobile element radiators, oil filled and electrically operated Jürg Wahrenberger 11 th May

13 Mobile element radiators, Boss stitch welder Jürg Wahrenberger 11 th May

14 Schlatter Rail Welding Systems for tracks for high speed lines as well as for for heavy haul tracks German ICE train Iron ore transportation in Brasil Jürg Wahrenberger 11 th May

15 First Schlatter Rail Welders developed 1949 One of Schlatter's first rail welders SSM250 in the Year 1949 Jürg Wahrenberger 11 th May

16 Schlatter Rail Flash Butt Welding Systems Stationary DC Machines Mobile AC Machines GAAS 80 AMS 60 GAA 100 AMS 100 Jürg Wahrenberger 11 th May

17 Control systems for all Types of Welding Machines For stationary machines For mobile machines Jürg Wahrenberger 11 th May

18 Stationary Welding System Type GAAS80 for Long Welded Rails Production Jürg Wahrenberger 11 th May

19 Aligning of the two rail ends Two positioning arms on both sides, totally 4 arms for aligning on approx. 2 meters length Adjustable crown stops integrated Sensors well protected against spatters Inner and outer aligning pins and crown stops (outer crown stops adjustable) Jürg Wahrenberger 11 th May

20 Clamping in the Web Clamping in the web at inlet side and outlet side of the machine. No slip as it clamps even more during upsetting due to special self-closing design. Clamping elements separate from the electrodes Jürg Wahrenberger 11 th May

21 Clamping in the Web with 1500kN 2400kN increasing Principles of the web clamping system: Basic clamping force F c 1500kN in the web on inlet and outlet side. Self-closing when welding force F w is applied i.e. increasing clamping force F c in addition to the hydraulic clamping force. Increasing force F w during welding results in increasing clamping force Fc. When full upsetting force is applied the web clamping force will result in a total of 2400kN! F w F c F c Symmetrical arrangement of hydraulic cylinders ensures firm clamping and prevents from slip. Jürg Wahrenberger 11 th May

22 Integrated deburring device Staggered deburring arms allow easy removing of the remaining loose burr Little material left for grinding Jürg Wahrenberger 11 th May

23 Stationary Machine Type GAA100 for Turnout Products Schlatter GAA100, welding grooved rails Schlatter GAA100 Jürg Wahrenberger 11 th May

24 Mechanical Design of the Schlatter GAA kN 1000kN 1000kN 1000kN Movable machine part (right side) is guided on standing levers, therefore no friction and play, no maintenance, very long life time. Total clamping force: 4 x 1000 kn makes sure that workpieces do not slip. Two synchronous upsetting cylinders, one below and one above the workpiece, ensure an absolutely parallel movement. Total max. welding force: 2 x 500kN = 1000kN No deformation of the machine frame. Upsetting force is evenly distributed over the whole cross section ==> best weld quality. Jürg Wahrenberger 11 th May

25 Various workpieces and profiles welded with GAA100 Jürg Wahrenberger 11 th May

26 Welding of combination Mn - CrNi - Rail Jürg Wahrenberger 11 th May

27 Control system GAAS80 and GAA100 2 Circuit breakers for protection of transformers and rectifiers, thermal and magnetic cut-out. 2 Circuit breakers for the control system and or the water cooling system. Control cabinet with function control PLC S7, SWEP06 and Schlatter Weld Analyzer Supervision and measuring of cooling water quality for rectifyer groups. Jürg Wahrenberger 11 th May

28 Easy Connection to electric mains Easy connection of incoming cables to copper bars. It allows connection of max. 4 x 185mm 2 incoming cables per phase. Two major mains cutouts for two Transformer/Rectifier groups with magnetic and thermal cutoout. Two smaller mains cutouts for the machine control and the water recooler Mains cutouts protect the machine from further damage in case of short circuit or overload. Inside of Connection Cabinet Outside of Connection Cabinet Jürg Wahrenberger 11 th May

29 Stationary DC Rail Weldiers in United Kingdom GAAS80 for Long Welded Rails Scunthorpe, Tata Steel (Corus) Eastleigh, Network Rail GAA100 for Turnout Manufacturing Sandiacre, Balfour Beatty Sheffield, Balfour Beatty Ruislip, Metronet Rail Jürg Wahrenberger 11 th May

30 Mobile Rail Welding Machines Main Features AMS60 AMS100 Vertical head stops (Crown position) Lifting device for defined crown Clamping in the web with steel elements, separate electrodes Alignment on running edge 60 tons upsetting force (600kN) For rails up to approx. 68kg/m Integrated deburring device Weight approx kg Vertical head stops (Crown position) Lifting device for defined crown Clamping in the web with electrodes Alignment in the center of the web 100 tons upsetting force (1 000 KN) For rails up to approx. 75kg/m Integrated deburring device Weight approx kg Jürg Wahrenberger 11 th May

31 Supra Multi Flex - Container Version Built into container Independant of rail gauge Easy transport from one construction site to another Two 20feet containers: - 1 container for energy supply (diesel engine / generator set) - 1 container with welding machine, control system, lift, hydraulic unit, cooling unit Alternatively, all incorporated into a 30feet container Jürg Wahrenberger 11 th May

32 Mobile Container System Container System with Schlatter AMS60 or AMS100, here with AMS100 Jürg Wahrenberger 11 th May

33 Supra Road Flex - Road/Rail Vehicle lorry based Built into a lorry Completely independant for transportation Easy and quick change from road to track Requires very little space for the change road to track Jürg Wahrenberger 11 th May

34 Mobile Truck based System Four axle truck with AMS60 Jürg Wahrenberger 11 th May

35 Mobile Truck based System Three axle truck with AMS100, at INNOTRANS 2008 Jürg Wahrenberger 11 th May

36 Schlatter New Development AMS200 Schlatter recently developped the new mobile rail flash butt welder Type AMS200, featuring: Distressing and Welding in one operation. Completely separate deburring Concept similar to the well known Schlatter AMS60, including the outstanding features: - Lateral alignment for perfect running edge, left- or right hand side - Clamping of rail ends in the web, with steel elements (not with electrodes!) - Separate Electrodes acting in the web - Perfect vertical alignment of running surfaces, crown angle adjustable - Overall dimensions and weights not exceeding those of the AMS60 Jürg Wahrenberger 11 th May

37 Schlatter AMS60 - Clamping and Aligning of rail ends AMS 60: Lifting to vertical crown stops Aligning system with selectable running edge : left or right hand side Clamping in the web with separate steel elements Electrodes with separate cylinders Jürg Wahrenberger 11 th May

38 Schlatter AMS60 / AMS200 - Clamping of rail ends Clamping of both rail ends in the web with excentric shafts No slip of rail ends due to Self Closing design when upsetting force applies. Clamping with steel elements, not with electrodes! Electrodes are protected against spatters during welding, long lifetime of electrodes. Jürg Wahrenberger 11 th May

39 New Schlatter AMS200 Main Features AMS200 AMS60 Welding- and destressing force is directly applied by hydraulic cylinders Deburring unit completely separate, rail ends remain firmly clamped and aligned during deburring operation. Welding force is applied via lever system. Deburring unit fixed to one machine side, clamps need to be slightly opened during deburring operation. Jürg Wahrenberger 11 th May

40 New Schlatter AMS200 Main Features AMS200 AMS60 Lateral alignment of running edge through control system, easy and quick. Free space around rail foot for fasteners, less ramping required. Lateral alignment of running edge with adjustable mechanical head- and foot stops, manual work. Little space around rail foot for fasteners, ramping is often required. Jürg Wahrenberger 11 th May

41 Complete mobile Systems with Schlatter AMS200 Supra MultiFlex with AMS60, AMS100 or AMS200, Container based Jürg Wahrenberger 11 th May

42 Supra Roadflex with AMS60, AMS100 or AMS200, Lorry based Jürg Wahrenberger 11 th May

43 Complete mobile Systems with Schlatter AMS200 Supra Varioflex, based on Colmar RRV Series 7700 Jürg Wahrenberger 11 th May

44 Schlatter Weld Analyzer - Latest Generation for Rail Flash Butt Welders, stationary as well as mobile Log Files Daily Reports 28 th February 2011

45 Schlatter Weld Analyzer System Standard Features The Schlatter Weld Analyzer shows the curves on the colour screen and stores: - weld current - weld force - travel of carriage as function of the time Tolerance fields can be defined; with indication in case that real values are out of tolerance. Tolerance fields are indicated with red lines on the screen. Saving digital weld data on internal Hard Disk and parallel on USB Stick or even directly on a LAN Drive. Long weld file names, up to 255 characters, for easy identification. Jürg Wahrenberger 11 th May

46 Weld Analyzer Display on Screen for three Curves: Force, Current, Travel This graph shows DC Welding (stationary) with preheating Impulses Please note: All preheating impulses can be supervised if required or desired. Jürg Wahrenberger 11 th May

47 Weld Analyzer Tolerance Fields with Indication if values are out This graph shows DC Welding (stationary) with preheating Impulses Jürg Wahrenberger 11 th May

48 Weld Analyzer Weld Analyzer, Tolerance Fields Tolerance fields can be set for all relevant sections of the weld process. The latest Version of Schlatter Weld Analyzer allows supervision of all preheating impulses. Also the velocity of the travel prior to upsetting is supervised. If values are out of the preselected tolerance field there is a red bar indication for the operator. The next weld can only be started after confirmation Weld processes are always finished, even with values out of the tolerance field. Jürg Wahrenberger 11 th May

49 Schlatter Weld Analyzer Log Files The Schlatter Weld Analyzer features an automatic creation of Log Files which can be used for constant statistic supervision of quality. The Export File can automatically be created when selecting one of the following options: - Every Day (starting at 00:00 o clock) - Every Week - Every Months - Every New Job Or, alternatively, can be deactivated when selecting: - No logging Or can be limited to Error Welds only. This is selected when clicking: Log Errors Only field. (see Weld Analyzer screen shot on next page) Jürg Wahrenberger 11 th May

50 Schlatter Weld Analyzer Log Files Weld Logs Selection Jürg Wahrenberger 11 th May

51 Schlatter Weld Analyzer Log Files In order to have all flexibility, the Export files are created as CSV files with the ending ( *.csv): (CSV: Comma Separated Values). CSV Files can be handled like and converted into standard Excel Files ( *.xls) Log Files from various different machines resp. Weld Analyzers can be combined into a centralized statistics. Very interesting for companies with several machines. Jürg Wahrenberger 11 th May

52 Schlatter Weld Analyzer Log Files Jürg Wahrenberger 11 th May

53 Schlatter Weld Analyzer Log Files Jürg Wahrenberger 11 th May

54 Schlatter Weld Analyzer Log Files Jürg Wahrenberger 11 th May

55 Schlatter Weld Analyzer Log Files Jürg Wahrenberger 11 th May

56 Schlatter Weld Analyzer Log Files Jürg Wahrenberger 11 th May

57 Schlatter Weld Analyzer Log Files Above Example shows only some few columns showing values of some variables The standard Log File comprises: - 54 columns resp. values - Weld File name - Job - Operator All relevant values are indicated: - in General: e.g. FF_EndVel : Ok / High / Low - actual Value: e.g. FF_EndVel[mm/s] : 2.40mm/s / 10.00mm/s / 0.50mm/s Jürg Wahrenberger 11 th May

58 Trouble Shooting via WA Log File - Example Example: Upset travel as a function of secundary current in 1 st preheating impulse: Jürg Wahrenberger 11 th May

59 Trouble Shooting via WA Log File - Example Example: Secundary Current and Flashing Even Time as a function of Date/Time Jürg Wahrenberger 11 th May

60 Schlatter Weld Quality All these features are developed for achieving constant high weld quality with narrow, parallel and uniform heat affected zone. Jürg Wahrenberger 11 th May