Robotic System for Automatic Weld Overlay Cladding Application

Background
Traditionally, the maintenance of deteriorated power plant parts depends on the skill of cladding welders; however, the highly-trained welders are critically scarce in the current labor force. Furthermore, the maintenance welding process is typically labor-intensive and time-consuming. The work quality based on human workers could be inconsistent, resulting in the process rework, increased cost, and business incompetency. Due to these imminent challenges, the Electricity Generating Authority of Thailand (EGAT) was seeking alternative solutions to alleviate them.

Goal
To develop in a large-scale robotic system for automatic weld overlay cladding. The system was designed with a more-dexterous elongated welding torch that is able to accurately maintain the tip-to-workpiece distance. The system worked seamlessly well with extremely large or hard-to-reach workpieces such as pipes, valves or shafts, without any accidental collisions.

What does the research team do?

• Users’ requirements acquisition
• Mechanical systems design
• Electrical and actuator systems design
• Robot control software development
• System testing
• Robot operators training

Outcomes

• Facilitate human welder to work more conveniently
• Reduce certain work procedures
• Achieve better work quality
• Shorten the maintenance lead time from a week to only two days
• Reduce the maintenance cost up to 40%
• Be more competitive in the business

Research Status

Development of the robotic welding system was financially supported by the research funding from EGAT. The system has been in service since September 2017 at the Workshop and Spare Parts Division.

Outlook

• Improve the performance of the first prototype
• Development of portable robotic welding system for field operations

Research team
MTEC: Dr.Nirut Naksuk and team

EGAT: Workshop and Spare Parts Division

Contact
Dr.Nirut Naksuk, Research Group Director, Engineering Design and Advanced Manufacturing Research Group

Tel: 02 564 6500 ext. 4149

Email: nirutn@mtec.or.th

Mrs.Rutchanee Mathong, Senior Analyst, Engineering Design and Advanced Manufacturing Research Group

Tel: 02 564 6500 ext. 4313

Email: rutchanc@mtec.or.th