ORBITAL

"Design, development and evaluation of an orbital laser welding head"

 Coordinatore ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE 

 Organization address address: CALLE RELVA TORNEIROS 27A
city: PORRINO
postcode: 36410

contact info
Titolo: Ms.
Nome: Gala
Cognome: Perez Perez
Email: send email
Telefono: +34 986344000
Fax: +34 986337302

 Nazionalità Coordinatore Spain [ES]
 Sito del progetto http://www.orbitalproject.eu
 Totale costo 1˙366˙043 €
 EC contributo 967˙276 €
 Programma FP7-SME
Specific Programme "Capacities": Research for the benefit of SMEs
 Code Call FP7-SME-2010-1
 Funding Scheme BSG-SME
 Anno di inizio 2011
 Periodo (anno-mese-giorno) 2011-01-01   -   2012-12-31

 Partecipanti

# participant  country  role  EC contrib. [€] 
1    ASOCIACION DE INVESTIGACION METALURGICA DEL NOROESTE

 Organization address address: CALLE RELVA TORNEIROS 27A
city: PORRINO
postcode: 36410

contact info
Titolo: Ms.
Nome: Gala
Cognome: Perez Perez
Email: send email
Telefono: +34 986344000
Fax: +34 986337302

ES (PORRINO) coordinator 33˙060.00
2    PRECITEC GMBH & CO KG

 Organization address address: Draisstrasse 1
city: GAGGENAU
postcode: 76571

contact info
Titolo: Dr.
Nome: Markus
Cognome: Kogel-Hollacher
Email: send email
Telefono: 49610682900
Fax: 496107000000

DE (GAGGENAU) participant 263˙927.96
3    Sill Optics GmbH & Co. KG

 Organization address city: Wendelstein
postcode: 90530

contact info
Titolo: Mr.
Nome: Berndt
Cognome: Zingrebe
Email: send email
Telefono: +49 9129 902314
Fax: +49 9129 902323

DE (Wendelstein) participant 178˙449.45
4    CONCEPTION MACHINE FAVEYRIAL SAS

 Organization address address: RUE RENE PANHARD - ZI LADOUX 4
city: CEBAZAT
postcode: 63118

contact info
Titolo: Mr.
Nome: Olivier
Cognome: Drouet
Email: send email
Telefono: +33 473258564
Fax: +33 473258565

FR (CEBAZAT) participant 162˙961.38
5    "Precisgal Utillaje, S.L."

 Organization address address: CALLE B 10 PARQUE TECNOLOGICO Y LOGISTICO VALLADARES
city: Vigo
postcode: 36312

contact info
Titolo: Mr.
Nome: Gerardo
Cognome: Argudin Rial
Email: send email
Telefono: +34 986475000
Fax: +34 986475001

ES (Vigo) participant 161˙097.90
6    INDUSTRIAS TECNICAS DE GALICIA SA

 Organization address address: CALLE MONTE FAQUINA 56
city: MOS
postcode: 36415

contact info
Titolo: Mr.
Nome: Alfredo Luis
Cognome: Roman Cajaraville
Email: send email
Telefono: +34 986 288132
Fax: +34 986 288485

ES (MOS) participant 158˙529.31
7    FRAUNHOFER-GESELLSCHAFT ZUR FOERDERUNG DER ANGEWANDTEN FORSCHUNG E.V

 Organization address address: Hansastrasse 27C
city: MUENCHEN
postcode: 80686

contact info
Titolo: Mr.
Nome: Walter
Cognome: Krause
Email: send email
Telefono: +49 89 12052713
Fax: +49 89 12057534

DE (MUENCHEN) participant 7˙330.00
8    LABOR S.R.L.

 Organization address address: via della Scrofa 117
city: ROMA
postcode: 186

contact info
Titolo: Ms.
Nome: Cristina
Cognome: Torrisi
Email: send email
Telefono: 390640000000
Fax: 390640000000

IT (ROMA) participant 1˙920.00
9    EQUIPOS NUCLEARES SA

 Organization address address: Jose Ortega y Gasset 20
city: MADRID
postcode: 28006

contact info
Titolo: Mr.
Nome: Pedro
Cognome: Ceballos Revuelta
Email: send email
Telefono: +34 942200169
Fax: +34 942200148

ES (MADRID) participant 0.00

Mappa


 Word cloud

Esplora la "nuvola delle parole (Word Cloud) per avere un'idea di massima del progetto.

laser    energy    path    beam    tailor    quality    orbital    consists    manufacturing    accuracy    intense    tubes    tube    market    operations    positioning    conventional    mechanical    sheet    workpiece    real    automation    competition    joints    heat    coupling    made    scientists    manufacturers    computer    vibrations    significant    exchanger    head    industrial    welding    speed    time    installation    joining    exchangers    robot   

 Obiettivo del progetto (Objective)

'The introduction of laser welding for the manufacturing of heat exchangers and steam generators can introduce some improvements in the manufacturing process such as the increase of the welding speed and of the quality level. Furthermore the automation of the process, involving the use of the laser welding technology, would permit to reduce the time between welding operations. Implementation of the laser welding process in industrial applications where orbital moving is needed involves the development of a special laser welding head. This is why a consortium of SMEs, consisting of companies with complementary expertises, have asked to LABOR, IWS-Fraunhofer and AIMEN to design and develop an orbital laser welding head for using in tube to sheet applications. The ORBITAL system consists in the design, development and construction of a new laser welding head adapted to the specific requirements of the orbital laser welding process and tailored for tube-to-sheet joints used in the production of heat exchangers. The system will be developed in order to enhance the characteristics of the laser welding process: high-speed welding, real-time control, easy automation, data exchange, accuracy. The ORBITAL laser welding system will be designed in order to satisfy the conditions of orbital welding applications, providing a good shielding gas atmosphere and a repeatable and robust positioning of the laser respect to the tubes to be welded thanks to a mechanical finger inserted in it. In order to achieve the objectives, it will be necessary to develop the three following technical aspects: an optical path in order to focus the laser on the workpiece, an electro-mechanical system in order to move and control the speed and path of laser beam around the tube circumference with a high positioning accuracy, and a control system that will be able to control the different parameters of the welding head and all the laser installation in order to perform the welding process.'

Introduzione (Teaser)

EU-funded scientists developed a tailor-made laser welding system to accommodate the challenging tube-to-sheet joints of large industrial heat exchangers. The technology has already received a warm welcome from manufacturers facing intense competition.

Descrizione progetto (Article)

The European industrial shell and tube heat exchanger market is currently subject to intense competition and facing challenges due to rising metal and energy costs. The welding process itself provides a large window of opportunity to regain lost ground. Replacing conventional welding procedures with automated laser welding could increase product quality and welding speed while decreasing energy consumption. It requires overcoming current challenges related to compatibility with the large tube-to-sheet joints and interference from vibrations on the factory floor.

With input from industrial partners, scientists developed the prototype for a novel laser welding head tailor-made for operations to produce large industrial heat exchangers with EU funding of the project http://www.orbitalproject.eu/ ('Design, development and evaluation of an orbital laser welding head') (ORBITAL). Orbital welding for joining tubes together has been around since the 1960s. In its current version, it employs computer-controlled rotation of a conventional welding gun around the tubes to be joined (i.e. in an orbital) with significant benefits over manual welding. Employing lasers in orbital welding under conditions of heavy external vibrations and, further, extending the process to cover joining of tubes to sheets are the important contributions of the ORBITAL project.

The ORBITAL system consists of the orbital laser head, the industrial robot on which it is mounted (the computer numerical control (CNC) system), and the coupling and positioning systems. The laser head contains the lenses that shape and guide the laser beam to the workpiece. The control system ensures high accuracy, high-speed processing and real-time control. The robot is coupled to the orbital head for auto-centring of the welding head when it enters the tube and for enhanced accuracy and repeatability. The positioning system is clamped to the workpiece during welding and innovative mechanical coupling blocks vibration transmission from the workshop to the welding head.

Scientists successfully delivered the required orbital laser welding system for tube-to-sheet welds required in the production of industrial heat exchangers. Given the continued growth of the European heat exchanger market and the stiff competition, ORBITAL technology is expected to have significant impact on EU manufacturers and the EU economy although the unit cost including installation is high.

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