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MTPR/CCB-15-007

Interim Products (S2459)2015 NSRP All Panel

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Robotic Welding of VCS Interim ProductsManTech Project Number: S2459

NSRP Panel MeetingPlanning, Production Processes &

FacilitiesNovember 9-12, 2015

Steven PothierEngineering Assistant SeniorGeneral Dynamics, Electric Boat Corporation(401) [email protected]

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Robotic Welding Video

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Agenda

• Project Team• Project Goals• Phase I Tasks / Phase II Tasks• Qualification Process • Robotic Welding Technology• Accomplishments• Questions

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ManTech Project TeamDale Orren – NSAM Deputy DirectorWarren Southerland – Project Manager Barry Espeseth – Project Technical Representative

Ned Kaminski – Technical LeadMimi Reis – ManTech Program ManagerDerek McKee – Engineer Erin Foster – Welding Engineer QPSteven Pothier – Engineering Asst. Sr.

Nancy Porter – Senior Project ManagerAdam Uziel – Applications Welding EngineerJosh Chance – Principal Welding Technician

Joe Blackburn – TWH 05P24 Matt Sinfield – 05P24 TADavid Lammlein – 05P24 TA

Dave Hart – LCERepresenting PMS 450

Byron Rose – PMS 397Larry Becker – BAHCharlie McNamara – PMS 450

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Project Goals / Objectives

• Create a manufacturing cell at the Electric Boat Corporation Quonset Point Facility to robotically weld interim product assemblies that cannot be welded with a mechanized process Structural welding is a major contributor to VCS construction costs.

Opportunity to improve weld preparation accuracy, component assembly and fit-up, welding processes, equipment, and span time for interim products.

Increased use of fixturing, positioning, automation, and mechanization.

Electric Boat believes the best method to reduce welding costs is to increase the number of weld joints that are welded with automated equipment.

• Target cost reduction opportunity of more than 30% in labor cost per interim products assembly

• Share improvements with other Navy shipyards

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Task 1. Identify Assemblies to Weld in the Robotic Cell

Task 2. Develop Functional Specifications for Robotic Welding System

Task 3. Purchase or Lease Robotic Welding System

Task 4. Develop Offline Programming (OLP)

Task 5. Develop Welding Processes for Assemblies

Task 6. Phase I Reporting

Phase I Statement of WorkProcure Robotic Welding System for Part Family & Interim Product Assemblies

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Task 7. Deliver Purchased System to EWI

Task 8. Develop Welding Processes for Assemblies

Task 9. Deliver Robot Welding Cell to Electric Boat Quonset Point

Task 10. Transfer Welding Processes and OLP Knowledge to Electric Boat

Task 11. Robotic Welding Procedure and Personnel Qualifications

Task 12. Identify Process Enhancements for the Welding Robot

Task 13. Develop Roadmap to Implement Robotic Manufacturing at Electric Boat

Task 14. Phase II Final Reporting

Phase II - Statement of WorkPart Family & Interim Product Robotic Welding System Process Development and System Transfer to Electric Boat Quonset Point

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Qualification Process• For each test position, two different programming methodologies were

used; adaptive and non-adaptive. Adaptive methodology - uses a pre-programmed bead plan and through-

the-arc seam tracking to complete the entire weld with the operator ensuring proper bead placement, checking inter-pass temperatures, cleaning the bead surface between passes, and performing a workmanship inspection of each weld pass.

Non-adaptive methodology - the operator programed each pass with the teach pendant individually and through-the-arc seam tracking was not used to complete the weld. The non-adaptive methodology allows the operator to observe as the welding is

performed and adjust the welding parameters and oscillation during the process.

This variant was qualified so the robot could be used to make repair welds or touch up weld joints that could not be completed in adaptive mode.

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Qualification Process

• 4 qualification plates made to Tech Pub 248 - level I requirements 1 in the horizontal (2G) position for GMAW spray – Adaptive

1 in the horizontal (2G) position for GMAW spray – Non-adaptive

1 in the flat (1G) position for GMAW spray – Adaptive

1 in the flat (1G) position for GMAW spray – Non-Adaptive

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Qualification Process

• All 4 qualification plates were subjected to and passed the requisite Tech Pub 248 testing per Section 4.5Nondestructive testing

Visual Radiography Ultrasonic Magnetic Particle

Destructive testing All weld metal tensile Transverse tensile Weld metal charpy V-notch Transverse side bend

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Robotic Welding Technology

• Wolf Robotics completed system build on May 29, 2013, at which time members of the project team participated in a System Runoff

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Robotic Welding Technology (Cont.)

• 3D Part Search – Used to find the part in reference to the virtual cell.

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• 3D Part Search – Current is sent through the tip of the wire to sense where the part is. Finding the part in Z axis.

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• 3D Part Search – Finding the part in X axis

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• 3D Part Search – Finding the part in Y axis

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• Dry Run – Dry running the programmed weld path to insure accuracy.

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• Dry Run – Checking layer / bead placement, weave design, weld speed.

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• Dry Run

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• Dry Run

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• Return to Home Position – Returning to Home will get robot up and out of the way of the part. Home is also a safe position so the Robot can move along the track safely.

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Initial Design

Accomplishments

• Robot cell was installed in Bay 4 at the Electric Boat Quonset Point Facility

Cell at Wolf Robotics prior to Shipping to EWI

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Accomplishments

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Accomplishments

• Welded Practice Plates Sample Flat and Horizontal plates

were welded and sent for Radiographic (RT) inspection for verification – Passed

Data Collection software was used to monitor all welding parameters

• Welded Qualification Plates Flat 65 kJ – Passed Flat Non-Adaptive – Passed Flat Adaptive – Passed Horizontal Non-Adaptive – Passed Horizontal Adaptive – Passed

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Accomplishments

• Robotic arc welding is currently considered a “special weld” per section 4.4.8 of Tech Pub 248 (The Requirements for Welding and Brazing Procedure and Performance Qualification).

Electric Boat qualified the robotic arc welding procedure as “Mechanized-R” in accordance with Tech Pub 248 “special weld” requirements.

• The welding procedure qualification records were submitted August 2015 for approval Working with SOSG to finalize qualification approval

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Accomplishments

• The Electric Boat submittal package included the following documents: Welding Procedure Qualification Records (WPQRs)Welding Technique Sheet (WTS)Welding Procedure Qualification PlanWelding Operator Qualification and Verification PlanFirst Article Assemblies, Validation of Similitude

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Accomplishments

• Developing qualification plate OLP, bead plans, and process parameters Gas Metal Arc Welding (GMAW) spray - flat position

Adaptive / Non-Adaptive / 65kJ

GMAW spray - horizontal position

Adaptive / Non-Adaptive

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Questions?

Steven PothierEngineering Assistant Senior General Dynamics, Electric Boat Corporation(401) [email protected]

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