Thermal loop solutions: a path to improved performance, sustainability and compliance in heat treatment NEWS
Thermal loop solutions: a path to improved performance, sustainability and compliance in heat treatment A
thermal loop solution is a closed loop system with several essential components, including an electrical power supply, power controller, heating element, temperature sensor and process controller. The electrical power supply provides the energy needed for heating, the power controller regulates the power output to the heating element, the heating element heats the material, and the temperature sensor measures the temperature. Finally, the process controller adjusts the power output to maintain the desired temperature for the specified duration, providing better temperature control and consistent outcomes.
PERFORMANCE BENEFITS
Heat treatment thermal loop solutions offer several advantages over traditional heat treatment methods, including improved temperature control and increased efficiency. The thermal loop system provides precise temperature control, enabling faster heating and cooling and optimized soak times. In addition, the complete design of modern thermal loop solutions includes energy-efficient heating and overall ease of use. Thermal loop solutions can also be integrated with Industry 4.0 frameworks and data management systems to provide real-time information on performance. Combining AI and machine learning algorithms can also provide additional performance benefits, such as the ability to analyze data and identify patterns for further optimization. The effectiveness of heat treatment thermal loop solutions can be measured using metrics such as overall equipment effectiveness (OEE). OEE combines metrics for availability, performance, and quality to provide a comprehensive view of the efficiency of a manufacturing process. By tracking OEE and contextual data, organizations can evaluate the effectiveness of their heat treatment thermal loop solutions and make informed decisions about optimizing their operations.
SUPPORTING SUSTAINABILITY
Heat treatment thermal loop solutions provide several sustainability benefits, including reduced energy consumption and waste. The power controller regulates the power output to minimize energy waste, and the possible integration with renewable energy sources provides a complete power solution that spans from element design to recycling. The thermal loop solutions, in combination with insulation design and materials, provide energy-efficient solutions that contribute to sustainability and reduce the environmental impact of heat treatment processes. Adaptive thermal system (ATS) solutions are the next frontier of thermal loop solutions. Watlow has decades of experience with thermal systems to help engineers and designers to incorporate ATS technology into a variety of industrial processes and products. ATS, which combines sensing, heating and control technologies, represents a different and more innovative approach to controlling thermal performance for complex systems, and provides a merged design between heater and control systems.
REGULATORY COMPLIANCE
NADCAP, the National Aerospace and Defense Contractors Accreditation Program, is an industry-driven program that provides accreditation for special processes in the aerospace and defense industries. Heat treatment is considered a “special process” under NADCAP because it has specific characteristics crucial to aerospace and defense components. These characteristics include process sensitivity, limited traceability, critical performance requirements and potential risk.
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The aerospace industry’s AMS2750™G pyrometry specification and the automotive industry’s CQI-9 Issue 4 regulations are crucial for ensuring consistent and high- quality heat-treated components. Adherence to these regulations is essential for meeting the stringent quality requirements of the aerospace and automotive industries and other industries with demanding specifications.
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nents. Adherence to these eeting the stringent quality ace and automotive industries
Continuous improvement is also emphasized by both AMS2750™G and CQI-9 Issue 4, requiring manufacturers to establish a system for monitoring, measuring and analyzing the performance of their heat treatment systems. By integrating these regulations into a precision control loop, heat treatment thermal loop solutions can provide the necessary level of control and ensure compliance with AMS2750™G and CQI-9 Issue 4, leading to the production of high-quality, heat-treated components that meet the performance required and safety standards. Heat treatment thermal loop solutions provide several benefits over traditional heat treatment methods, including improved temperature control, increased efficiency, and improved sustainability outcomes. The integration with Industry 4.0 and data management systems, as well as the use of OEE metrics, further help enhance the performance of heat treatment processes. As Industry 4.0 digital transformation continues to evolve, heat treatment thermal loop solutions will play an increasingly important role in the future of heat treatment.
Watlow
www.watlow.com
Ficep UK launches new robotic welding technology to tackle skills shortages F
icep UK has launched a new automatic and robotic processing solution, the request from the market is for a quality welding system to help address skilled labour shortages and increase productivity.
In an exciting new partnership with AGT Robotics, Ficep has launched the SABRE welding robot to seamlessly tackle the most challenging and labour-intensive processes that fabricators are facing in today’s structural steel fabrication market.
The SABRE complements Ficep’s existing machine range by performing the robotic welding of all secondary components on the
main member. The SABRE automatically senses all the relative surfaces so the robotic welding process can be generated without any manual manipulation. The operator simply needs to load the section after the detail has been tack welded at the proper locations into the automated welding positioners.
Combining the Ficep SABRE welding robot with Ficep E Lexington system, which makes laser marks on the steel to indicate locations and welding codes, can match the productivity of up to eight employees who would traditionally use manual layouts and welding. Further simplifying the process, its unique
software automatically downloads the CAD data, or auto-generates welds as per customer specifications. This eliminates the need for manual programming or adjustments. As the robot welds the first section, the operator can load and tack weld the next section into a second set of rotators and using the E Lexington will see the position of the secondary part with high quality laser lines. Once the SABRE has finished welding the first section, the robot moves to the next section for welding while the first section is being unloaded by the operator.
Ficep UK
www.ficep.co.uk FACTORY&HANDLINGSOLUTIONS | JUNE 2023 5
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