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Sterling Group expands and modernizes welding fleet with esab fabricator em 401i Enhanced Arc Performance
Inverter technology also provides a faster response to changing arc conditions. “With the older equipment, we were getting inconsistent welds and spatter, not to mention it was hard to get or even find parts. Now we have consistency. The arc is stable, and we have less spatter,” says James.
Coupled with microprocess controls, inverter technology enables ESAB to incorporate additional functions into the Fabricator, such as adjustable inductance, which can reduce spatter, enhance bead- wetting action and create a flatter bead profile when MIG/MAG welding in the short circuit transfer mode. Users can also set crater fill voltage and amperage at the end of the weld to prevent crater cracking.
Energy Efficiency
Like on an aging human body, machine parts are often replaceable…until, they’re not. The Sterling Group, a leading UK manufacturer of high-quality plant bodies and step-frame (“beaver tail”) trailers for off-highway machinery transportation knows this firsthand. Older welding systems, a recent product line expansion and a new 25,000-ft. facility in North Yorkshire prompted Sterling to modernize and standardize on some of their equipment. “We’re patching up old units and replacing others, but the lead time to get new equipment was about six months,” says Jarl James, Sales Director, Sterling. “We knew we were at a point where we needed spare capacity to future proof our production. It was forward thinking.” Sterling’s growth and diversification with the recent purchase of Hymix concrete mixers prompted the company to upgrade its welding systems for widespread use in the facility. “We settled on welding equipment that includes a fleet of 15 ESAB Fabricator EM 401i heavy-duty
inverter-based welding power sources for MIG/MAG and flux cored welding,” says James. “We use the Fabricators across the company.”
Hiring and Training As Sterling has grown and diversified, so has its need for skilled workers. In so-called “normal” times, hiring is a challenge, but employers now need to rethink hiring. This requires considering candidates little or no welding experience, but with transferrable skills, a good attitude and strong work ethic. With these challenges in mind, Sterling’s choice to modernize and standardize on the Fabricator made a great deal of sense. First, a simple interface on the power source helps with training inexperienced welders. Predefined settings for selected wire (0.8, 1.0- and 1.2-mm wires) and gas combinations result in optimised arc performance.
“Select a welding process, then select the correct wire diameter and gas type, and the Fabricator is
set for optimised performance,” says James. “For an introductory machine, it’s a fantastic bit of kit for a new welder.”
While these machines make it possible for inexperienced operators to achieve a stable arc without a lot of fuss, they still allow operators to adjust voltage and amperage to refine arc characteristics. “Historically, training as it involves proper settings and guidelines has been difficult, particularly as a product range evolves and develops complicated controls,” says James. “A straightforward machine helps make the training process much easier.”
48 FEBRUARY 2022 | FACTORY&HANDLINGSOLUTIONS
In addition to a consistent arc, inverter technology has made a huge difference in energy efficiency. Fabricator units feature inverter-based power transformation technology. They operate at 86% electrical efficiency — a 30% improvement on step-regulated power sources — so they lower primary power consumption and are more environmentally friendly. An energy save mode reduces power consumption by 35 watts when the welder sits idle. “The cost savings on power from moving over to inverters is going to be big, especially with the way electricity prices are going up this year,” says James. These units also have a power factor of 0.91, which lowers primary amperage requirements. This
feature may allow for using more machines on the same circuit breaker or reduce worries about nuisance trips — important as Sterling grows.
Production
Sterling has historically used a solid wire for welding. Recently, the company was able to move to an all-position gas shielded flux cored wire in certain instances. By switching to ESAB’s OK Tubrod 15.17 flux cored wire (classified as an E81T1-Ni1M), operators could complete parts up to 70% faster. There was no need to reposition large or cumbersome weldments, which can be time consuming, and flux cored wire offers higher deposition rates. “We performed some time trials, where we had two machines side by side, one with solid wire and one with OK Tubrod 15.17,” says James. “For vertical up, it was just one pass with the flux cored, saving so much time.” With current and expected growth, production increases couldn’t come at a better time. What began as a search for ways to speed up their processes with a new wire, ended in additional longer-term welding solutions. By exploring new and different welding technology, Sterling uncovered training, performance, energy and production benefits to meet its growing needs.
ESAB
01992 768 515
esab.com
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