High Technology Intelligent Workshop Solution
Lean fabrication intelligent workshop is mainly consisted of three core parts, which are lean fabrication management system, lean fabrication design system and lean fabrication production system.
• Lean Fabrication Management System
Solve all management problems during actual fabrication management process before reaching lean fabrication level.
• Lean Fabrication Design System
Solve the technology problems before production, realize the combination of production and design.
• Lean Fabrication Production System
It is the basic execution system to realize lean fabrication.
The whole intelligent workshop management system includes F-view System, Intelligent Pipe Spool Split System, Production Line MES System, Production Line Networking Monitoring System, Mobile Terminal Management System, Production Line Maintenance System, Welding Management System.
F-view System
** Workshop F-view: through the F-view, it is able to directly and live display each step of design, purchase, production, logistic, quality etc., find the stuck step in time, with high efficient communication, which can improve the whole workflow efficiency and accelerate the effective output of workshop.
** Production line F-view: directly display the workload of stations such as cutting, beveling, fitting up and welding etc., guarantee the whole productivity, improve the production efficiency.
** Station F-view: directly display the planned workload, actually completed workload, qualified workload of station, which improve the production transparency of station.
Intelligent Pipe Spool Split System
** Intelligently separate on-site welding end and fabricated welding end;
** Intelligently separate automatic welding and manual welding;
** Automatically calculate material list;
** Automatically calculate welding workload (inch);
** Automatically generate material drawing (pipeline, pipe spool drawings).
Production Line MES System
** Pipe spool information management: well manage the pipe spool information such as drawing, material, fitting, welding end etc.
** Material storage management: pipe material and fittings are separately stored by 'project'/'sort'; also through the 'heat treatment number', able to realize quality track of whole production.
** Mission package management: automatically check the material supply condition by 'project'; automatically balance the workload of each station by 'material'/'pipe diameter'/'pipe thickness' etc., realize automatic production scheduling, guarantee daily work completed within single day.
** Welding end quality inspection management: generate inspection records of each step such as fitting up, welding, dimension measuring, NDT etc. of every single welding seam.
** Handover report management: define the handover report template based on customers' requirement, able to automatically issue handover report.
Production Line Networking Monitoring System
** Transmission module: integrated PLC control system, able to collect the information of equipment running condition, process parameter and performance parameter, then update to networking monitoring system.
** Cutting and beveling equipment: monitor the information of cutting & beveling current and speed, raw material pipe, cutting & beveling parameters etc., monitor the cutting & beveling equipment condition such as running, stopping, failure etc., monitor the single work-piece production efficiency of cutting and beveling equipment.
** Welding equipment: monitor the welding current, welding voltage, wire feeding speed, welding speed and gas flow volume etc., monitor the welding equipment condition such as running, stopping, failure etc., monitor the single work-piece production efficiency of welding equipment.
** Integrated with MES system from the 3rd party, support import data from the 3rd party, the cutting mission can directly transmit to cutting & beveling equipment.
Mobile Terminal Management System
** Integrated production line MES system: receive mission package and welding end information.
** Feedback on mission package execution condition: feedback on the execution of tasks in cutting, beveling, fitting up, welding, painting and other processes.
** Feedback on quality inspection of welding end: feedback welding seam fitting up, welding, dimension measurement, hydrostatic test, NDT inspection and other test results.
** Track on material usage: use the heat treatment number to trace the usage of pipe material and fittings.
** Track on pipe spool fabrication: use the drawing number/serial number to trace the whole pipe spool fabrication process.
Production Line Maintenance System
** Transmission module: integrated PLC control system, collect equipment startup status and performance parameters, and transmits it to the IIOT.
** Equipment monitoring: monitor equipment status, key parameters, and overall performance.
** Prevention: forecast of replacement of key spare parts and periodic maintenance.
** Alarm push: push alarm information, trigger dispatch automatically.
** Monitoring report: abnormal cause statistics, equipment performance analysis, maintenance execution tracking, equipment energy consumption analysis, etc.
Welding Management System
** Digital welding process database: the basic data of the process are all managed and maintained in the system.
** Project management: it is managed and displayed in the form of project->command->welding seam->layer and realize production based on command and welding seam.
** Statistical analysis: through platform integration, statistical analysis such as attendence management, attendence statistical analysis, gas welding material consumption statistics, and equipment utilization rate can be realized.
** Welding seam management: support fully digital and structural parameter management of welding seam.
** Production management: dispatch workers with matching welding qualifications; choose welding layer and pass; welding seam live display.
** Quality management: after appearance and NDT test qualified, upload the inspection pictures.
Pipe Spool Fabrication Machines
| 1 |
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Pipe Cutting& Beveling All-in-one Machine
>Suitable for pipes not larger than 8",max.thickness:20mm
>Cutting efficiency:100times/8hrs
>PLC control with automatic measuring to guarantee the same processing cycle
>Widely used for small bore C.S/S.S production lines |
| 2 |
|
High Speed Band-saw Cutting Machine
>Three models available(16"type,24"type",48"type)
>PLC system control;self-measuring function with precision:±0.5mm
>Using hydraulic self-centering chuck
>It only takes 6 minutes to cut a 24" pipe of 25mm thickness
>Widely used for C.S/S.S production lines. |
| 3 |
|
High Speed CNC Pipe End Beveling Machine
>Automatic self-centering chuck
>Single V,double V,U type bevel
>Can be matched with pipe end turning devic
>High speed beveling:for example,it only takes 2.5minutes to get a 37.5 degree bevel for a S.S pipe end(diameter :610mm,thickness:25mm)
>Several models available:16",24",32",48" |
| 4 |
|
Two / Multi- Axis CNC Flame/Plasma Cutting Machine
>High efficient pipe cutting with automatic self-measuring function, pipe end beveling, intersection line profiling for both main and branch pipe.
>Five/multi-axis cutting machine can profile more complicated outlines with various bevel type
>Standard machine suitable for pipes nor larger than 24'' |
| 5 |
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Multi-function Pipe Fitting-up Station
>Suitable for flange,elbow,tee,reducer to pipe and special T-joint fitting-up.
>Light-duty type(manual) and heavy-duty type(motorized) are available.
>Different types available, 8" type, 24" type, 32" type, 48" type, 60" type |
| 6 |
|
Automatic Pipe Welding Station
>With two welding heads
>TIG/MIG/SAW are optional
>PLC system control & WPS programmed
>Max. efficiency fo reach welding head can be 400D.I/8hrs even use TIG/MIG technology.
>Different types available, 8" type, 24" type, 32" type, 48" type, 60" type |
| 7 |
|
Conveyor Handling System
>used for pipe convenient transporation during in pipe spool fabrication.
>Its speed is adjustable between 2M to 20M/min. |
Tank Construction Machines
| 1 |
|
Girth Seam Welding Machine
>Applicable to both bottom-to-top and top-to-bottom tank erection
>Adopting Sub Arc Welding technology
>Standard machine suitable for shell plate width: 1.3M-2.8M
>Max. Efficiency of AGW could be 30 times as manual welding |
| 2 |
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Vertical Seam Welding Machine
>Suitable for tank plate wall thickness is from 10mm to 50mm
>Motor frequency inverter drive system
>Weatherproof control box with digital display for welding speed
>Travel speed: 0~2200mm/min
>Beveled gear drive reducer, good locking ability in both directions |
| 3 |
|
Butt/Corner Seam Welding Machine
>Applicable to butt seam welding of bottom plates
>With magnetic idler system
>More than 99% Qualified first X-ray test.
>Suitable for both Top-to-Bottom and Bottom-to-Top Tank Construction Method |
For more information, please contact us, thank you!
Welcome to visit NAEC in Nanjing, China.
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