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Development of the mobile robotic device for renovating crane rails

The main goal of the project is to develop a unique welding robot for generating crane rails. An important part of the project is the research and development of optimum welding parameters.

Principal aim of the project is a development of the mobile robotic device that is capable of automatic welding of the crane rail guide. In order to apply durable ovelays on the wear out rail, it is neccessary to develope welding parameters very specific to the particular application. Automatic mobile device will apply new material alongside of the rail. In order to develope the welding parameters in most effective manner the statistical model of the welding process is going to be created. Simulation could be run on the model. It will minimize number of the welding experiments and help to find the best welding parameters. The new technology will revolutionize the repair of the crane rail guide. Instead of time consuming rail disassembly in dangerous condition under the roof the rail will be renovated without presence of human welder. Our equipment will dramatically improve not only the productivity of the rail repair but also contribute to the improvement of the safety. Principal features of the welding process: - The productivity of the work will be improved many times in comparision with the traditional rail replacement. - Very high quality of the overlay and remarkably high dimmensional accurracy of the applied metal. - Utilization of common material without special alloying components. - Limited waste of the added metal. - No need for the pre heating. Combination of the added metal and welding parameters insures sufficient heat imput which guaranties development of the microstructures without martenzit in the area of the weld and in the area of connection with a base metal. There is no need for a pre heating. This condition is valid for all rail types. - The hardness of the overlay is going to be same are slightly higher than the hardness of the base material. This is very important from the point of view of the wheels wear out. - All sorts of the welding parameters are going to be developed. It opens many possibility for achieving very different mechanical parameters of the overlay according the specific requests of the customer. - The renovation of the rail could be repeated many times without any limitation. - The welding procedures could be repeated with very high level of accurracy. Customer could be provided with the graphical output describing the welding process. After welding procedures are developed the mobile robotic welding device is going to be built. It will be capable to work in automatic mode without unneccessary interuption. The productivity of the welding in automatic mode is very high in comparision with the human welder. Recommended type of welding is advantagous because of very high deposition rate. It improve the evectivness dramaticaly. On the other hand if applied by human welder many interuptions must be considered because human being is not able to withstand very high level of heat generated by the process. Principal features of the mobile robotic device: - Capability to performed the general rail repair without replacement of the rail. - Automatic sub merge arc welding without application of pre heat. - Automatic rectification of the welding torch movement, regardless of rail wear out. - The device is capable to achieve very high accurracy of the weld and creation the correct profile. - Graphical output of the welding parameters alongside the timeline. - Considerable improvement of labor safety and general comfort of the work. - Very dramatic reduction of the amount of scrap metal produced in the process of crane guidance repair. The mobile unit will be able not only to weld in automatic mode but also performe a grinding. This operation bares high importance because the rail profile must correspond one hundred percent with the new one. Both operations will be preformed with minimum imput of the human operator. At the end of the project in 2011, at least one prototype is going to be built and all necessary welding procedures will be available. Our unique solution will be ready for commercial application. The commercial benefits are very promissing because of the uniqness of our device.
Acronym: 
DECRAROB
Project ID: 
3 656
Start date: 
01-01-2008
Project Duration: 
61months
Project costs: 
880 000.00€
Technological Area: 
Jointing (soldering, welding, sticking)
Market Area: 
Railways, Trains

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