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Continuity crucial for Wärtsilä Nederland Kruiningen BV

Since the commissioning of the first Panasonic VR welding robot 25 years ago, Wärtsilä Nederland Kruiningen BV and Valk Welding have been working closely together to manage and optimise the process of welding overlays on large pistons. Now that possibilities are being explored to apply more overlays in the same amount of time while simultaneously needing to machine away less material, the collaboration has entered a new phase. “Always looking for where additional gains can be achieved for the customer. In that, Valk Welding still proves to offer high added value even after 25 years,” says team leader Jaap Weber.

Wärtsilä Nederland Kruiningen BV

In the large maritime sector, pistons in ship engines can sometimes be the size of a coffee table. Such pistons show considerable wear over time due to the often high temperatures. In Kruiningen, they are restored by machining, overlay welding, and machining again, so that their service life is extended. That process was developed 25 years ago in close cooperation with Valk Welding and with support from the supplier of the shielding gas. “Then you are talking about the correct combinations of rotation speed of the piston, amount of shielding gas and welding machine settings, recorded in the DTPS offline programming system.”

Always looking for where additional gains can be achieved for the customer. In that, Valk Welding still proves to offer high added value even after 25 years.

Team leader Jaap Weber

Nowadays less wear on pistons

Whereas pistons in ship engines were previously heavily loaded and many millimetres had to be machined off, the current generation of ship engines is subject to lower loads and therefore shows less wear on the pistons. “For us, that means we must machine less and apply less overlay. However, the amount of work has not decreased. As soon as the grooves are worn out, the pistons come to us anyway. The difference compared to the past is that we now only apply the overlay that is necessary, and by doing so we have reduced CO₂ emissions. We recondition while maintaining the components,” Jaap Weber explains.

Grown along from G1 to G4 controller

Recently, an older welding robot was replaced again by the latest generation with G4 controller. “While it was a challenge for us to keep the older generation welding robots operational with the spare parts we had in stock, we have said farewell in time to the older VR types. For our operators, this means that they have experienced all updates from G1 to G4 controller. It is certainly a big step, but because the icons on the teach pendant have remained the same, the implementation went quite smoothly. We now still have 2 robots with G1 controller, 1 with G3 and the new one with G4 controller, which has replaced the G2. The plan is to replace the other two old ones in the coming years.”

20–30 welding hours per piston

Whereas two manipulators were used initially for the sake of continuity, Wärtsilä soon concluded that the efficiency gains were limited. “With 20–30 welding hours per piston, the second manipulator remains idle all that time. With 3 welding robots dedicated solely to pistons we now recondition over 250 pistons per year. (The fourth welding robot is used for welding ship valves.) If you want to increase that capacity, you will need to add an additional welding robot. Another possibility would be to shorten the welding time, but then you reach the limit of the deposition rate. Together with Valk Welding, we are now therefore investigating the possibilities of reducing heat input, so that the speed could be increased. For continuity and process improvement, the involvement of the supplier is of great importance to us. With their customer-friendly approach, their support, service, training and special welding wire, the cooperation with Valk Welding is crucial for continuity and quality,” Jaap Weber summarises.

www.wartsila.com

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