EMEX - Engineering, Machinery & Electronics Exhibition
KONECRANES INTRODUCES COMPLIANCE GAP ANALYSIS
Regulatory compliance and best maintenance practices are crucial in optimising the safety, performance, reliability and efficiency of overhead cranes vital to major manufacturing, materials handling, mining, food and beverage and other material handling applications, but when there are several different programmes across multiple sites, it can be difficult to see if anything is missing.
To search for and fill any compliance gaps in maintenance programmes, Konecranes is introducing to Australasia its Compliance Gap Analysis service, where a qualified trained Inspector will thoroughly evaluate all aspects of a programme, including inspection methods and documentation, preventative maintenance, repair processes and operator safety.
“Konecranes’ Compliance Gap Analysis is designed to identify if any gaps exist in your current maintenance program using information from all applicable OEM documents and overhead material handling standards,” says Joseph Cefai, consultation services manager, Konecranes Australia and New Zealand.
Konecranes draws on its experience as the world’s largest crane service organisation – with over 450,000 pieces of equipment across all makes and models under service worldwide – to provide an expert opinion on whether a company’s current crane operations and maintenance practices are aligned with applicable OEM, regulatory requirements and best practices.
“Our aim is to provide a holistic view of the current situation and find key gaps that may have otherwise been overlooked, despite best intentions,” says Mr Cefai.
A typical process involves three key steps:
An on-site meeting with safety, maintenance and operations representatives, plus any other associated departments or personnel, where information-gathering methods are explained and questions about the analysis method are answered.
A comprehensive review of the facility, where the Konecranes Inspector studies key processes that typically include inspection practices, pre-shift checklists, and corrective maintenance procedures.
A findings review, conducted in person with key stakeholders, where safety-critical items are prioritised and other professional recommendations are made. Information is treated in commercial confidence.
“Compliance Gap Analysis can be a useful tool for safety and maintenance managers seeking to employ best practice and standards compliance, because it gives an external expert opinion and covers all aspects of inspection, service and maintenance simultaneously,” says Mr Cefai.
Compliance Gap Analysis is part of a broader suite of Konecranes services, including RailQ runway analysis, RopeQ wire rope inspection and CraneQ crane geometry survey.
ENERPAC RAIL BRIDGE GANTRY TACKLES DEADLINE
Timing is critical for road and rail construction and land and maritime infrastructure projects, to avoid unscheduled disruption to passenger and freight services.
However, even the best project planning can be undermined by adverse weather conditions, such as those encountered in Australia’s remote northern regions and in coastal regions throughout both Australia and New Zealand. Even winds greater than 20kph may prevent bridge deck lifting using a crane, leading to project delays.
A safe and precise bridge deck lifting alternative is Enerpac’s Hydraulic Gantry lifting systems, which are being deployed throughout Australasia for use in heavy lifts involving construction, infrastructure, transport and mining, maritime and energy applications. Enerpac gantry systems are proven in Australasia and globally, with one of the technology’s recent successes being demonstrated by a leading road and rail heavy lift company, Osprey Heavy Lift Ltd, which used an Enerpac SBL900 gantry to prepare a replacement bridge section on the Chester line in the UK.
GANTRY LIFT TECHNOLOGY
The SBL 900 deployed on this project was one of two types Enerpac provides rail construction: Super Lift (SL) series: for lifts up to 400 metric tonnes (mT), and Super Boom Lift (SBL) series up to 1100 mT.
Both types comprise four or more telescopic legs and an overhead beam or girder, allowing vertical lifting of heavy loads. If movement of the load is required, the complete gantry system and load can be traversed along a track.
The Enerpac hydraulic gantries feature self-contained hydraulics and electrics, self-propelled wheels or tank rollers, mechanical locking permitting load holding for extended periods of time and Intellilift wireless control system.
Intellilift provides the operator with information about the stroke, lift and load per unit and automatically corrects any unsynchronised motion of the individual units, as well as unobstructed views of the load for a safer lift.
Moreover, the gantry lift is less affected by wind speeds than using cranes, allowing the gantry to be used at up to four times the wind speed permissible with a crane. A gantry can be used in areas where crane access is impractical, and it allows a continuous lift onto SPMT’s (self-propelled modular transporters) that is more efficient and safer than traditional jack and pack used on smaller bridge decks, says Enerpac Australasia mining and heavy lifting technology manager Warren Baltineshter.
Several of these advantages demonstrated in practice in the Chester Line lift, where “the Enerpac gantry was the ideal lifting system for this bridge deck replacement project,” says Nigel Fletcher, managing director, Osprey Heavy Lift Ltd.
“Working at ground level and the ease of lifting the deck onto an SPMT made for a smooth installation of the new bridge desk,” he says.
An Enerpac hydraulic gantry is cost effective to mobilise. The gantry’s telescopic leg can be folded down for ease of transportation, either on a flatbed trailer or in a container.
Once on site, the gantry allows the new deck to be completely constructed on-site at ground level, avoiding the need for working at height requirements.
Gantry lift systems are part of the Enerpac range of heavy lift, shift, balance and place solutions, which includes the world’s largest portfolio of heavy lift and load control applications. Enerpac systems – such as hydraulic gantries, strand jacks, skidding systems, self-erecting towers, SPMTs and synchronous lift systems – can handle some of the world’s most challenging lifts, including awkwardly shaped and sometimes massive structures weighing tens of thousands of tons in maritime, mining, energy and heavy industrial applications.
NEW BONFIGLIOLI 300M PLANETARY GEARBOX RANGE SETS INDUSTRY-LEADING TORQUE BENCHMARKS
Torque increases in the new Bonfiglioli 300M series. Average Nominal torque [Nm] of 4 stage reduction and in-line gearbox configuration. For right angle and combined gearbox 3/A 3/V performance increases.
Bonfiglioli is introducing to Australasia its new 300M range of planetary gearboxes, which achieve greater torque without increasing the size of the gearbox, to produce greater performance, efficiency, and cost saving for many industries such as bulk materials handling, mining process equipment, food and beverage, materials handling, water treatment and waste handling.
The 300M series has eight new sizes from 310M to 318M, all of which have a significant improvement in torque over their preceding models and set new industry benchmarks for torque ratings at one million cycles.
Depending on the size, torque has been improved by up to 45%, as shown in the graphic below.
One of the innovative improvements in the series is the addition of a new bearing design. The 300M series uses a customised roller design with an inner race on the pin and an outer race on the planet gear. This creates a bigger roller diameter, with a higher load capacity and greater torque.
“The new 300M series has been engineered to the highest standards of quality. The gearboxes are built for reliability, durability and improved performance,” says Malcolm Lewis, managing director, Bonfiglioli Australia and New Zealand.
“A significant advantage of the higher torque capacities is that a smaller size gearbox can do the same task that a larger one would have had to do previously. This can mean savings in power, space and costs, both up-front and ongoing,” he said.
The 300M series is completely interchangeable with the existing 300 series gearboxes, and no machine modification is required when upgrading to the new units.
Major applications for the 300M series include:
• Mining – car dumpers and stacker reclaimers
• Materials handling – screw conveyors and apron feeders
• Cranes and winches – jib cranes and ship loaders
• Food and beverage – spiral freezers and flaking machines
• Water and wastewater – mixer agitators and band screeners
“These are competitive industries where companies are always striving to improve efficiency, minimise downtime and reduce costs. The 300M series has been designed with these goals in mind, and the industry-leading torque benchmarks will greatly optimise their performance,” says Mr Lewis.
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ON-SITE SAFETY TRAINING WITH BITE
Global high-pressure hydraulics leader Enerpac is introducing to Australasia new on-site safety training designed to optimise the uptime and performance of widely used tools while spotlighting workplace hazards and preventable accidents.
Enerpac’s Goal Zero safety programmes draw on the organisation’s practical workplace experience in more than 30 countries and its commitment to promote the goal of zero harm to employees, customers and end users of Enerpac and other-brand heavy lift, shift, position, fabrication and bolting machinery used across Australia, New Zealand and PNG.
“As a hydraulic technology and safety leader in Australasia for more than 50 years, Enerpac is now taking a further lead in the industry by taking its unique expertise out on site where it will do the most good for busy people and companies,” says Enerpac Western Australia territory manager David Capper. “These are practical, down-to-earth safety training development courses designed to deliver immediate benefits from course leaders who combine local expertise with global knowledge and standards. The key outcomes on which they focus are reduced accidents and downtime.”
Mr Capper is working in partnership with his East Coast colleague and SE Queensland/ Northern NSW territory manager Sandy Whyman, along with Enerpac’s network of territory managers, to bring the safety message on-site to audiences who might not otherwise have the time or opportunity to bring themselves up to date with technology advances and the latest safety and maintenance best practice global standards.
Elements of the on-site courses are tailored to the needs of individual sites and workshops, including mine, oil and gas, energy generation, primary processing (including paper, sugar, food and beverage and agribusiness) bulk handling, construction, infrastructure (including ports and defence establishments) transport (including rail, road and aviation) and energy generation and public water and local authority service utility organisations.
They include: tool inspections and correct workplace usage guidance; maintenance and storage practices that optimise safety and uptime; spotlighting potentially dangerous practices, with case studies; extending tool life and productivity; safety guidelines for general situations and for particular industries; attendance certificates
The courses are open to groups including tool users; supervisors; inspectors; safety managers; project and site engineers; maintenance shutdown engineers; administration and management staff concerned with risk assessment and management; training and development managers.
Visit www.enerpac.com/au-safety for inquiries about scheduling and composition of courses.
THE GREAT KIWI ENGINEERING CHALLENGE IS ON
XPO ANNOUNCES PRINCIPLE SPONSORSHIP; FINALISTS FOR EMEX 2018
It’s great to see that when you toss out an idea, even from the root of you being angry at the world – or in this case, someone bagging Kiwi ingenuity and highlighting skewed statistical analysation of it – that others can grab hold of a limb and help grow it, because they see merit.
Page 10 of this issue has the official announcement by XPO Exhibitions in its endorsement of The Great Kiwi Engineering Challenge.
They spotted a good concept, shoved all-in along with NZ Engineering News, and logistically the Challenge will be in part propped by its avenues to market to promote the event. Finalists in two categories will be exhibited on Engineering News‘ stand with announcements of the winner on the seceond day of EMEX 2018 at the Greenlane Event Centre on May 2 (exhibition runs May 1-3).
The competition launch itself will be featured in our October edition and open for entries from October 1. We will make a song and dance about it at that time, and give you all the information needed to showcase your engineering talent through your manufacture of a Kiwi – any Kiwi – in Professional and Student sections. Quality of make will be important, but much judging emphasis will be placed on Kiwi innovation. Moving CNC-machined parts or perhaps you’ll go down the road of a mechanical robot Kiwi, or even something out-of-this world 3D printed; whatever you choose it needs to make people’s jaw drops that you and the engineering industry have been able to turn such a simple and proud Kiwi symbol into a re-engineered masterpiece. A work of mechanical art.
Go for it. We are looking for one more principle sponsor as well as next-tier-down sponsorship from within the industry. If you are a supplier to the engineering industry and would like your company to get involved flick me an email to firstname.lastname@example.org.
Kiwi’s are indeed an innovative lot, and I don’t care what anyone says. We are, as we’ve had to be. In my role as NZ Engineering News editor I’ve already seen plenty of what the professionals have to offer (that’s you lot). And, of course, then there’s the SHEDers.
But even the professional engineers down this way have to think well out-of-box on occasion (and that doesn’t mean they neglect quality either, sheesh).It usually means you have to make something you don’t have or can’t get hold of, from what you have at hand. So you adapt with what you have and quite often, and I know this for fact, your adaption surpasses the original.
I’ve even talked to people who have turned out complex, heavy-duty machinery from a picture in a book. Now that’s creative. One of the funniest moments though, and I think that it was at an NZ Steel awards evening, was when MC for the evening comedian and engineering SHEDer enthusiast Te Radar talked about the great, historic Kiwi No 8’ers in engineering. I remember, in particular but one of many funny yarns, his portrayal of the first ever submarine – built in Dunedin, believe it or not. It was called the Platypus, which in itself boggles the mind.
Finding gold at NZ’s most southern port was a priority, and in 1873 on December 14 the banks were loaded with onlookers at the world‘s first sub, the Platypus, as it froze its toes in the icy waters.Designed to work in Otago goldfield rivers, the Platypus was an iron cylinder constructed of 3/8-inch plates (total length 35 ft/10.6m, diameter 7ft 2ins/2.2m.) A paddle or wheel box was fitted on each side and between an iron hatch covering allowing entrance into the hull.
Dredging was the aim. Getting stuck turned out to be the game. For over four hours the ingenious craft stayed submerged until help came. It was truly cutting edge in terms of design, mechanics and engineering… if only for that rock.
Te Radar‘s delivery brought it all to life as he described manual flag messages and crew running along the bottom of the seabed through an open hatch, in true flickered-frame, black-and-white, Laurel and Hardie-fashion.
So, it’s in our DNA to try, and try again through innovation. Prove the engineering industry still has that mettle. No sinking subs please, but Kiwis that fly, cry, turn into a meat pie… they’re all good. A word to the wise, with the talent this industry has behind it we are expecting it to be a showcase to the whole country of just what you guys are capable of – best not to over simplify.
Accurately spray coatings and lubricants using spray technology
Increasing production rates, minimising set times and maximising savings on expensive coatings and lubricants are a few objectives processors strive to achieve when choosing an automated lubrication or coating spray system. The skilled engineers at Spraying Systems Co have developed highly efficient electrostatic systems with these objectives in mind.
Being in the engineering industry for over 79 years, Spraying Systems has become the world’s leading supplier of spray products and automated spray systems. The company has developed a range of electrostatic spray systems which can be used in numerous different manufacturing applications.
Electrostatic spray systems work by using the simple principle of spraying a negatively charged liquid or coating to a neutral, grounded target. The AccuJet Electrostatic Spray Systems from Spraying Systems utilise electrostatic spray nozzles to coat chains, conveyors and trays with minimal waste.
Another major concern for processors is that of overspray. Eliminating overspray is not only beneficial to your operations, but also to the health and safety of your workers. The overspray that drips off from conveyors and surrounding equipment can spill onto the floors which poses a dangerous risk for workers.
One of the many benefits of using AccuJet Electrostatic Spray Systems is that they are able to apply coatings and lubricants with high accuracy which leads to reducing or eliminating overspray altogether and decreased waste of costly coatings and lubricants which ultimately leads to increased savings for the operator. Also, clean up time is dramatically reduced due to the cleaner state of the equipment and floors.
As each of the electrostatic systems operate using the electrostatic spraying principle, they are all able to deliver a high transfer efficiency rate, typically over 90%. This is due to the physical attraction of the liquid to the intended target. This results in virtually eliminating overspray, reducing waste of expensive coatings and improving the quality of the overall process.
For processors looking to improve chain lubrication, the AccuJet Electrostatic Chain Oiler System is the ideal choice. The system uses electrostatic spray nozzles to precisely apply lube to key lubrication points along the length of the chain. The system’s low-flow injector pumps can deliver lubricant to as many as four electrostatic spray nozzles simultaneously. As the chain is adequately lubricated, the risk of chain breaks is reduced.
For those in the food industry interested in an electrostatic system, the AccuJet Electrostatic Conveyor System is ideal for pan coating and other bakery and snack coating applications. The AccuJet Conveyor Nozzles are designed to coat pans uniformly, resulting in improved product quality. The nozzles use electrostatic technology ranging from 0.01 – 5 cc per minute. The spray nozzles minimises the possibility of clogging which can sometimes occur when using other conventional spray nozzles for conveyor coating applications. Food safety is increased due to the accuracy of the AccuJet Conveyor Nozzles which reduce product contamination resulting from overspray. This system can also be used for rolled metal lubrication applications.
Beverage can lubrication, stamping and general industrial applications all require a system that is able to coat with a heated lubricant. The AccuJet Electrostatic Heated System consists of a Heated Nozzle Manifold and heated tank controlled by an AccuJet PLC Controller to heat and accurately apply lubricant. The lubricant remains heated at a consistent temperature with even heat distribution as a result of the recirculation system. The Heated Nozzle Manifold can be fitted with up to eight nozzles, depending on the requirements of your application and each nozzle can be individually actuated if need be.
In addition to the electrostatic systems, Spraying Systems has designed range of lubrication systems that are ideal for applying lubricants and corrosion protection fluids to blanks, coils, pipe sections, stamping and forming tools, wires, bars and more. Furthermore to selecting a spray system that improves efficiency, many manufacturing plants are looking to use systems which are able to reduce their company’s environmental impact. Using a spray system that is able to control and precisely apply lubricant can reduce liquid consumption by up to 90%.
The expert engineers at Spraying Systems had this mind when developing the AutoJet Lubrication Systems. The systems are designed to decrease lubricant waste and improve the consistency of the application whilst producing little to no mist.
The L210 and P400 AutoJet Lubrication Systems both consist of a base unit and a coil lubricator. The systems are controlled using PLC technology which allows for precise control of the pump that delivers lubricant to the spray nozzles. PLC technology allows for lubricant amounts to be set with a high degree of accuracy which in turn, minimises waste and environmental impact.
For lubricating with light types of media such as emulsions or vanishing oils, the L210 system is ideal. The system uses hydraulic spray nozzles and due to their flat spray pattern, they are able to coat over considerable widths, making them an economical choice.
The P400 system is ideal for high viscosity media, high speed applications and for applications that require an even film. The air atomising spray nozzles used each feature a needle that is able to precisely open and close with each pulse. This action efficiently cleans the nozzle orifice of any debris or residue. The system also features an oil mist separator which ensures that no mist is able to escape on the floor and surrounding equipment.
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TUFF STUFF UTE LININGS PROTECTS UNDER THE LONG WHITE CLOUD
Tradespeople, service engineers and transport workers need a form of protection for vehicles that will minimise damage and corrosion from their everyday activities.
By using surface protection, the service life of a vehicle can be extended, in addition to reducing servicing and repair costs.
In addition to the work environment, variable climates—from maritime coasts through freezing alpine highlands to sulphurous steam in active tectonic sites—can also be damaging to any truck, ute or car.
Rhino Linings Australasia’s (RLA) Tuff Stuff is a premium spray-applied lining product that has a thick, textured surface that provides enhanced slip resistance for cargo and maximum protection against corrosion, scratches and dents. The lining forms a permanent air and water-tight bond that prohibits rust, corrosion and surface abrasion. The non-porous lining is easy to clean and the non-abrasive surface texture helps keep cargo in place.
John Papas, regional sales director at RLA, says that selecting the correct product is important which is why all RLA dealers and applicators receive the same comprehensive and intensive training. After initial training they then have access to a network of experienced and knowledgeable staff.
“We have technically experienced staff in Australia, but we can also call on the expertise of our overseas counterparts, particularly in the US, for specialist advice,” he says. This depth of knowledge and experience for which products can be used and in what situations is just a phone call or email away for applicators. “The beauty of the digital age is that we can provide customers anywhere in the region with videos and photographs of best practices done by people anywhere in the world.”
Most other companies just provide the material and a datasheet and that is all. “RLA can give that human factor,” Mr Papas adds.
According to Peter Morgan, general manager of RLA, the structure of the polymer used for ute linings has to be resistant to abrasion and chemical attack. The material’s strength comes from the bonding and cross-linking of the resin and hardener. “When considering a coating you have to think about the physical characteristics of what might be stored in a ute; tools and equipment are often heavy, with sharp edges,” Mr Morgan says. “You also have to consider the physical environment where a vehicle might be used.”
RLA’s Tuff Stuff is warranted not to crack, warp or peel even under extreme temperatures. It is used extensively to protect vehicles such as utes, trucks, 4WDs, prime movers, trailers, boats and horse floats, in addition to military vehicles, flooring, buildings and industrial equipment. RLA’s polymer coatings are also flexible which allows them to stretch and shrink as substrates expand and contract due to temperature and surface fluctuations.
All the company’s dealers and applicators—including those in New Zealand—have access to the same product range. “We manufacture all products on the Gold Coast and ship to dealers and applicators throughout the region,” says Mr Papas.
“While there are some areas with potentially slightly more corrosive environments,” says Mr Papas, “we only occasionally have to include any special additives.” Even if tradespeople are carrying acids, fuels or solvents, RLA has a suitable surface coating. “In extreme cases, Rhino Chem 21-70 can be used in vehicles, tanks and bunds where concentrated sulphuric acid is stored,” says Mr Papas. “Once fully cured it is virtually impenetrable to most chemicals.”
The rapid setting of the company’s polymers means they can be applied up to two or three times thicker than other liners providing more protection, more sound deadening, more slip resistance and more vibration absorption than any other ute liner on the market.
However, Mr Morgan explains that his company’s products were not just used for ute trays or even horse trailers. “Adding Rhino Linings to the options available to a panel beater or repair shop can extend the range of services that they can offer.”
Automotive paint and repair shops already use similar techniques and procedures that would result in a good application of the spray-applied polymer. Similar to the work carried out by a spray painter, the area to be covered has to be masked off. The tape used has an embedded fibre tear strip that is used to create a clean edge to the sprayed material.
The non-porous lining is easy to clean and the non-abrasive surface texture helps keep cargo in place whilst providing insulation against road vibration and noise, unlike the drop-in plastic liners of its competitors.
A major consideration in applying any surface treatment to a structure is the requirement to minimise downtime. “The beauty of our coatings is that they are rapid setting,” says Mr Papas. “We can spray them on and they gel in less than a minute depending on the actual polymer used.”
RLA assists its dealers in developing best method procedures and practices for chemical handling and machinery used to apply the company’s products. The company is committed to the development of new technologies, products, and services that offer the best solutions to the needs of customers, applicators and distributors.
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BEFORE YOU REPLACE: MODERNISE, MAINTAIN OR RETROFIT
An example of a Konecranes modernisation on an old 1965 hoist (top) that was modernised in 2016 (bottom)
There are a number of valid reasons to consider replacing an overhead crane. Your application or production demands may have changed, statutory requirements may have changed or critical components are reaching the end of their economic service life.
Replacing a crane with something new may seem like the obvious option, but there are actually three viable alternatives that will cost-effectively upgrade an existing crane and extend its service life: modernisation, tailored maintenance and retrofits. Before committing to one of these options, it is advisable to consult with professionals who can assess the current situation and make appropriate recommendations.
Modernisations preserve aspects of the existing asset that are in good condition (saving capital funds) and complement those aspects with the addition of selected new replacement components that enhance reliability and safety, adding current technologies. Common modernisations include the replacement of hoists, trolleys, operator cabs and controls to achieve increased capacity, speed, duty and load control.
Before determining what modernisations are needed on a crane, it is highly recommended that the crane undergo a thorough evaluation such as Konecranes’ Crane Reliability Study (CRS). In some cases, a major assessment will need to be undertaken, such as cases where it is a very old crane and there is no record of one being done recently. The major assessment is one way of ensuring the crane is standards compliant.
The CRS is an engineering assessment that evaluates the current condition of a crane and provides a theoretical estimate of its remaining design life and provides recommendations for the next steps. Any of the structure or components excluded from the modernisation scope will still be assessed in compliance with standards, which provides a complete and compliant solution upon completion.
Konecranes modernisations achieve outstanding results through a combination of consultancy, careful inspection, observation, and world class experience and solutions. Konecranes’ capability to provide a life extension on existing assets is fiscally responsible and delivers a high return on investment.
Proper crane maintenance can add years to its service life, and helps optimise its efficiency, reliability, productivity and safety. Maintenance can be divided into two main types, corrective and preventative maintenance.
Corrective maintenance occurs when a fault has been identified, either during a regular inspection, or through real-time crane monitoring (such as Konecranes TruConnect technology).
Timely repair of faults improves safety and makes good economic sense. It also reduces the risk of emergency breakdowns, and is often mandated by industry regulations.
Planned repairs are scheduled according to inspection and maintenance regulations. Optimally, the repair is coordinated and scheduled around production schedules, to minimise the impact of any downtime.
Preventative maintenance is part of a well-planned schedule and aims to eliminate potential problems before they occur. Konecranes creates proactive, customised maintenance plans based on individual equipment, application and duty cycles, with the overall aim of reducing risk and downtime, improving safety and reliability and identifying valuable improvement opportunities.
Konecranes’ advanced TruConnect real-time monitoring technology takes preventative maintenance one step further, by constantly monitoring crane usage and providing real-time updates. Potential faults or problems can be identified at the earliest possible opportunity, and corrected before they cause major downtime.
Retrofits are an easy and economical way to add additional features and technologies to your existing overhead crane. They typically require much less pre-planning and downtime than full modernisations, which means a useful new feature can swiftly be added and begin improving the performance of a crane.
Common retrofits include hoist and component replacements, variable speed control, radio remote control and LED lighting.
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A LASER SOLUTION FOR JOINING DISSIMILAR METALS
The long-standing challenge faced by welding and design engineers of joining dissimilar metals has finally been met. The challenge lies in the differing physical properties and metallurgical incompatibility amongst dissimilar metals that has been found to prove difficult for a welding task. However, it is now possible to use a nanosecond welding process where most combinations of widely used metals can be joined, and achieve acceptable joint strength.
Lasers from the SPI RedEnergy pulsed range have been designed to offer greater power and control during the welding process, and can work with all of the key metals including aluminium, brass, copper, and various types of steel. A continuous wave range of lasers offering strengths of 200W to 1kW, can weld everything from thin steel to thick carbon steel and stainless steel. Regardless of the thickness, or how different the chemical and mechanical properties of two dissimilar metals are, successful welding can be achieved using fibre lasers.
The complication with dissimilar metal welding occurs when two very distinct and very different metals are welded together. It is not always as easy as simply melting the two parts together to form a bond. The problem arises in the transition zone between the two metals, where the intermetallic compounds are formed. Copper and steel are two other metals which are often welded together, but both possess very different properties and are not mutually soluble. A successful weld occurs where the new joint is as strong as the metal with the weaker tensile strength. In this way, the joint will be able to withstand any stresses that it faces.
Like traditional laser welding, dissimilar metal welding requires an understanding of the metals being used as key factors need to be considered by the metallurgist before beginning, regarding solubility of each metal, researching the intermetallic compounds that will form the transition zone, and the weldability of these compounds to ensure no negative outcomes. Additionally, consideration must be given to the coefficient of thermal expansion of the two metals, their melting rates, the possibility of corrosion and finally it is essential to consider the conditions where the weld will be in operation.
The considerations of joining dissimilar metals prior to laser welding is of great importance as joining of dissimilar metals is commonly used in high-volume industries such as the automotive and aircraft industries. Here joins need to handle incredible pressures to provide a high level of safety and security, for example, where two separate parts of an airplane fuselage are welded together, high levels of strength are required to withstand the pressures from high altitudes. The need for dissimilar metal welding is also found in power plants, chemical plants and food processing applications, joining ferritic low alloy steel with austenitic stainless steel, a metal that is commonly used in these industry. In the electronics industry the manufacturing of batteries, fine wires, fuel cells, and even medical devices use welds of dissimilar metals. Industrial applications for fittings, forgings, and tubes, commonly found in heat exchangers, liquid metal reactors, and boilers require welding of dissimilar metals.
The demands of differing industries bring with it the need to create effective manufacturing technologies such as the inclusion of nanosecond infrared fiber lasers in production as they offer high reproducibility, accuracy and productivity along with the all-important low cost in terms of capital and maintenance.
Until now the use of nanosecond (ns) pulsed lasers has been limited but recent pioneering development by SPI Lasers saw the introduction of the master oscillator power amplifier (MOPA) in ns fibre lasers. Viewed as extremely versatile tools due to their ability to control and tailor the pulse characteristics to the requirements of applications, this is achieved through the ability to change the pulse duration and frequency. Regardless of the thickness, or how different the chemical and mechanical properties of two dissimilar metals, successful welding can be achieved using ns fiber lasers.
The nanosecond welding process offers multiple options in join design that includes weld geometry flexibility, for example, joining copper on 718 super alloy, aluminium on brass, aluminium on copper, stainless steel on aluminium, stainless steel on copper, titanium on aluminium, and titanium on copper. SPI RedEnergy pulsed lasers provide an economic and effective solution to the welding of dissimilar metals. SPI products are available in Australia and New Zealand from Raymax Applications.
SYNC GRIP PULLERS FOR SIMPLE, SAFE AND PRECISE BEARING REMOVAL
The new SG-Series Sync Grip Pullers – in mechanical and hydraulic configurations up to 45 tonnes capacity – optimise safety, simplicity and speed of removal of bearings, bushings, gears, sleeves, wheels, fly-wheels, sprockets and other shaft-mounted items.
Being introduced to Australia, New Zealand and Papua New Guinea, the new tools enable one man to do jobs that often previously took two men, says Darryl Lange, Enerpac national sales manager. Applications include maintenance of fixed and mobile machinery and plant as well as heavy vehicles and rolling stock in industries such as the automotive, construction, civil, mechanical, production and process engineering, manufacturing and metal working, mining and energy, oil and gas, materials handling, primary production, road, rail and tracked vehicle transport, water and waste water industries.
For loads up to 20 tonnes, the SGM-Series mechanical pullers provide an economical and efficient option, with all the same rugged high-strength features as the hydraulic option. For more complex tasks, up to 45 tonnes, the MPS-Series hydraulic pullers offer hydraulically applied pulling force through a detachable hydraulic cylinder, to increase pulling capacity and reduce operator fatigue.
“Both the mechanical and the hydraulic Sync Grip Pullers offer efficiency as well as safety, because one worker can do a job that often requires two with other tools. A safety and workplace benefit is that the pullers will even grip on surfaces where normal pullers would slip off – for example, on tapered bearings,” says Mr Lange.
“Their, smooth, simple and safe operation means that, instead of impact hazards created by removal methods using hammers and levers – with risks to both the workpiece and maintenance personnel – Sync Grip Pullers draw parts smoothly and precisely without the need for heating or prying,” says Mr Lange.
“Sync Grip Pullers are the latest evolution of Enerpac’s advanced puller technology. Being able to facilitate simultaneous engagement of each jaw adds an additional level of safety and reliability to a very common industrial process,” he says.
THE NEW RANGES:
• Maximum reach, mechanical pullers, 105-600mm spread range 110-680mm).
• Maximum reach, hydraulic pullers, 320-700mm, spread range 350-980mm
• Threaded spindle and jaw indexes provide adjustable reach
• Three jaw configuration for even load distribution, with two-jaw configuration available in mechanical pullers for confined access situations
• High-strength forged jaws for superior reliability
• Optional accessories that expand application range and increase utility.
• Hydraulic models are available in standard kits which include detachable hydraulics cylinders and a choice of pump options, along with a gauge assembly and hose for safe monitoring of applied pulling forces.
• Cross-bearing puller sets available to complement Sync Grip technology, featuring quick set up to tackle a variety of jobs and precise hydraulic control for fast, efficient and safe pulling. Available in 6-22 tonne capacities with maximum reach 357-831mm and 260-580mm in spread range.
• Backed nationally and on-site by the sales, service and technical expertise of the Enerpac distributor network, which has been a market leader in Australasia for more than 50 years
The post SYNC GRIP PULLERS FOR SIMPLE, SAFE AND PRECISE BEARING REMOVAL appeared first on NZ Engineering News.
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