TPT May 2012

T echnology N ews

Cameras that help to monitor fusion welding processes

MELTTOOLS LLC has developed a range of cameras for cost-effective visual monitoring of fusion welding processes. MeltView cameras automatically adjust to immense changes in light to provide a clear image before, during and after welding. The cameras are ruggedized against the welding environment and customised to fit automated and mechanized welding applications such as internal pipe cladding and tube/pipe welding. Rework and scrap rates have a significant impact on profit margins, and a clear image of the melt pool enables the operator to detect product flaws in real- time and correct processing errors. Other benefits of real-time visualisation include faster and more accurate set up of welds, reduced operator stress/fatigue and shared process monitoring among operators, managers, and quality assurance team. EXACT Tools Oy has developed a new method to cut pipes and has launched a brand new range of steel and plastic pipe cutting systems along with cutting accessories onto the UK market. These new innovative solution providers are available exclusively through Wilkinson Star Limited (Exact Tools UK Division), the Manchester, UK-based industrial equipment supplier. The award winning innovative PipeCut range of pipe cutting systems are one of the fastest, easiest, safest and most precise ways to cut and bevel pipes and tubes on site producing a straight ready to install finished surface in a multitude of diameters and materials eliminating many of the problems associated with pipe cutting. There are more than seven different models available ranging from the PipeCut 170 and 170E systems for cutting 15mm – 170mm diameter steel and plastic pipe to the PipeCut P400 for cutting and bevelling in one process, plastic pipe from 100mm to 400mm

Quality assurance may become integrated into production during in-process inspections, and visual records may be combined with process signal data as part of a product traceability program that enhances the manufacturer’s reputation. With today’s sophisticated tube and pipe welding machines, a clear view of the melt pool is often difficult to obtain. It may be obscured by clamps, joint geometry, multiple torches, wire-feeders, sensors (including seam trackers and bead profilers) and shielding devices. To meet this challenge, MeltView cameras are designed to fit into various work envelopes. In addition, many welding processes are hazardous due to high temperatures, trapping hazards and awkward positions (eg great or small heights), and a visual monitoring solution is essential for safe and accurate in diameter with a wall thickness up to 25mm. Each model can be supplied with a choice of three different blades – TCT (tungsten carbide tip) blades for general use in cutting steels, copper, aluminium, plastic and multi- layer materials; Cermet with ceramic tips for heavy duty applications such as cutting stainless steel and acid proof steel; and diamond discs for cutting cast iron pipes. Exact pipe cutting systems are suitable for cutting a wide range of tubes and pipes including spiral duct tube ranging from 75mm to 1,000mm in diameter with wall thicknesses ranging from 1.5 to 6mm. Thesesystemsare ideal for theprofessional industrial pipe installer employed in power generation, refinery and chemical plant, hospital and other construction sites, house building and renovation, shipbuilding, wood pulp, fresh and waste water systems, heating and cooling systems, gas installations, maintenance and repair work. They are very easy to use on steel, cast iron, stainless steel,

operation. MeltTools is committed to reducing the barriers to integrating visual- monitoring systems into today’s welding equipment. MeltView cameras feature integrated gas- or water-cooling for long-life and reliable function as well as an optional integrated gas-knife and replaceable spatter-guard to maintain a clear optical pathway under conditions of high spatter/ vapour. MeltView cameras are also available with integrated LED lighting. The video output is in convenient analogue format, which may be fed directly into a monitor for a simple and easy-to-maintain visualization system or may be converted to a digital record for process analysis and/or record keeping. MeltTools LLC – USA Website: www.melttools.com aluminium, copper and most types of plastic. The cutter firmly grips the pipe to be cut with the blade being automatically positioned to cut correctly. In addition the entire weight of the cutter rests on the pipe. When started the blade chips the pipe surface rather than grinding it, producing a burr-free cut surface that is ready for installation. The operation is dust free and does not produce any sparks. Each system comes supplied with its own pipe holders (except model V1000 which are an optional extra), pipe saw, allen keys, CD user manual and carry case. Other features of these products include the ability to cut pipe at floor level, improved working environment and user safety including fire safety, increased productivity through extremely fast cutting speeds, light to use and pipes can be cut everywhere where

High-speed steel and plastic pipe cutting machine

electric power is available. Exact Tools Oy – Finland Website: www.exacttools.com

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M ay 2012