In April 2024, we carried out the measurement and adjustment of an automatic welding machine for Air Products. The customer decided to use laser measurement technology due to the relatively large diameter (180mm) and distance (6000mm) of the rolls. As a result of the measurements taken, it was possible to reduce the coaxial deviation from 53mm to 1.6mm!
Project description
Customer: Air Products
Challenge: The customer identified a problem with a flange pipe welding machine used to produce DN100 and DN150 pipes. There was a problem with the quality of the welds due to incorrect concentricity of the rollers turning the flange to be welded. The customer was having difficulty determining the correct concentricity tolerances, which posed a risk of sub-optimal welding results. Due to adjustment constraints and a demanding design – the rollers were 180 mm in diameter and spaced 6,000 mm apart – the client needed expert support in accurately aligning the rollers and selecting an appropriate measurement methodology.
PROram’s solution
PROram developed a detailed plan for measuring and correcting the roll alignment of the AP212 automatic machine. The process started with the selection of a measurement methodology adapted to the large dimensions of the machine and the limited adjustment range of the rollers. As part of the solution, PROram carried out:
- Accurate initial measurement of the roll concentricity to determine the current deviations from the base.
- Basing and setting reference points to stabilise the measuring axes, which facilitated accurate positioning of the rollers on both sides of the machine.
- Subsequent adjustments to thepositioning of the rollers, allowing the axis deviation to be reduced to an acceptable level. The corrections were necessary to adapt the system to produce tubes according to the required concentricity.
- The final control measurement, which confirmed the reduction of the concentricity deviation to an acceptable level for the production of DN100 and DN150 pipes.
For the measurements, PROram’s specialists used, among others, a Leica Absolute Tracker AT500 from Hexagon.
Benefits for Air Products
As a result of the activities carried out, the customer gained:
- Improved concentricity of welded flanges – final alignment corrections enabled high precision to be achieved, significantly improving the quality and consistency of the flanged pipe manufacturing process.
- Optimisation of the production process – precise measurements and corrections allowed Air Products to optimise the setting of the AP212 automatic machine, and this directly contributed to increased productivity and reduced potential costs associated with production deviations.
- Expert support in determining tolerances – PROram measured and helped Air Products select the right welding automation settings for repeatable, high-quality products.
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