Welding and Hydraulic

(Diskusi PLT Mikrohidro) Oleh-oleh dari Cihanjuang - Cimahi - Bandung

2008-04-14T16:41:00.000-07:00

(catatan khusus : bagi yang nggak hobi membaca, dianjurkan ndak usah membaca tulisan ini. Kepanjangen. Mending dengerin cerita temen yang sudah membaca saja. Ocree?)

Assalamu alaikum wr wb.

Semoga kesejahteraan dan keselamatan selalu tercurah bagi kita semua.

Sobat, ane mau sedikit tapi banyak (nah, bingung kan) berbagi cerita tentang "jalan-jalan" ane sehari di Cihanjuang kemarin tanggal 8 Nop.
Ceritanya tuh ane ditugasi "jalan-jalan" ke Cihanjuang oleh Kompeni ane (pinjem istilahnya Om Monang-Saipem), pasnya di CV. Cihanjuang Inti Teknik di Jl. Cihanjuang no 204, Kelurahan Cibabat - Cimahi Utara - Cimahi. ( Cimahi itu ikut Kab. Bandung apa bukan se? )
Ini terkait rencana Kompeni ane mau mengembangkan PLTMH di salah satu kebun yang ada di kaki Gunung Kelud. Naaaa, katanya lagi, di antara sekian banyak kompeni yang bergerak dalam pengembangan atau tepatnya manufakturing PLTMH di Indonesia, ya di CIT atau Cintek inilah yang tingkat inovasinya paling effisien dan membumi. ( Ah, masa iya? ) Makanya ane pun hinggap di situ. Sayangnya Mas Tho'fan - Medion (yang mestinya jadi tuan rumah di Cimahi) malah pas dines ke Lampung, jadi ane ga dapet guide gratisan deh. Btw, mas Ari darmariyadi di mana ya? Ane ga punya kontak personnya se

Pertama kali ane sampe di sana sempat bingung juga, karena bayangan semula ane itu berupa lokasi industri yang ujudnya begitu lah (dibayangin sendiri aja, ya). Kenyataannya, tampak depannya malah seperti deretan rumah-rumah di kota gitu. Lha, tulisan CV-nya saja juga nggak ada. Hanya nomer 204-nya lah yang bikin yakin kalo disitulah lokasinya. Bahkan ruangan pertamanya bukanlah kantor, melainkan suatu showroom sekaligus toko penjualan oleh-oleh berupa minuman Bandrek, Sakoteng, dan lain2. Lho? (Hubungan bandrek sama PLTMH akan dijelaskan berikutnya).

Yang menjadikan yakin bahwa ini kompeni yang kami tuju adalah di ruang tunggu showroom Bandrek itu (yang nyaman karena sejuknya udara dan secangkir bandrek hangat gratis, bahkan boleh nambah) adalah terpampangnya segala macam piagam, sertifikat maupun tanda penghargaan dari banyak instansi, kampus maupun kompeni2, atas keberhasilan Cintek dalam "pengembangan energi yang terbarukan dan bermanfaat sosial ekonomi". bahkan salah satunya berskala ASEAN lho. Boleh juga ya?

Nah, setelah menunggu kurang dari sepeminuman secangkir bandrek (niru gayanya Khoo Ping Hoo, waktu sepeminuman teh) ane dan rekan2 diterima manajer di sana. Sayangnya ndak ketemu sama pak Eddy Permadi si Boss besarnya.
( asal tahu saja, Beliau ini bareng sama DR Ir Eddy Prianto (Undip) mendapatkan anugrah penghargaan di bidang Pengembangan Energi Terbarukan dari Menteri Energi Sumber Daya Mineral yang juga Ketua Dewan Penasehat PII, bersama tujuh insinyur lainnya (termasuk bu tri mumpuni jadi 9 orang) dalam Rapimnas Persatuan Insinyur Indonesia (PII) dan HUT ke-55 PII di Gedung Merdeka, Bandung tanggal 24 mei kemarin.)

Dhess, setelah mendapat presentasi powerpoint ala seminar-seminar gitu, yang mirip nonton Discovery Channel model Bandung TV, kami pun langsung diajak berkeliling ke dalam bengkel kerja mereka.

nah, bisa jadi inilah yang "menyebabkan" Cintek banyak dikunjungi oleh kompeni2 dan instansi2 lain bahkan diburu oleh lulusan2 ITB. Mereka sangat "open manajemen". Di sana kita bisa dengan bebas bertanya, memotret, utak-utik bahkan mencoba segala macam alat yang sedang diproduksi di bengkelnya. Mulai dari proses perancangannya, proses machining spare part (cor, bubut maupun welding) , assembly elektrik-mekanik, sampai dengan pengujiannya yang mesti lolos "Quality Control" staff ahlinya. Tidak ada`yang ditutupi atau dirahasiakan. Di sana juga ada laboratorium alamnya, meski agak terpisah jauh dari bengkelnya, dimana kita secara langsung dapat melihat alat terapannya yang di dasar lembah sungai irigasi Leuwi Layung (di kampung babu girang eh... maaf, maksude Babut Girang, Cimahi Utara), jadi bisa tau persis cara operasionalnya PLTMH mulai dari mengatur dam air, memutar turbin sampai proses penyaluran daya listriknya ke beban, bahkan hal-hal proteksi dan
struktur pekerjaan sipilnya.
Ndak takut dapet saingan ni? Betul, ternyata mereka tidak khawatir bila ada pesaing di pasar yang sama. Bahkan memang untuk indonesia ditunggu untuk segera bermunculan kompeni yang bergerak di sektor ini. Ada yang sudah siap? kali aja ada alumni Undip yang segera mengorbit di sektor ini.

Itu aja daya tariknya? Ndak lah. Selain sebagai kompeni yang "open manajemen" bahkan "open pabrikasinya", Cintek juga memberikan contoh inovasi PLTMH yang segalanya dimulai dari skala kecil (bahkan bisa juga disebut tenaga piko hidro). Inilah nilai plusnya. Cintek saat ini sudah berhasil mengembangkan PLTMH model turbin propeler celup berkapasitas mulai dari 100 watt, hanya dengan sumber air rata-rata 5 liter/detik dan beda head minimal 2 meter, dengan biaya hanya 3 juta rupiah per alat. Paket tersebut sudah lengkap berupa propeler dan generator dalam satu paket (kira-kira ukurannya sedikit lebih kecil dari wadah es krim Walls yang 20rb itu atau panci rantang di rumah), operasionalnya submersible atau dicelup, bahkan dengan garansi daya tahan 5 tahun. Jadi bagi konsumennya, tinggal nyambung dari kabel output yg sudah ada untuk menyalakan misalnya 5 biji lampu SL 18 W. Praktis sekali buat masyarakat yang memang tinggal di pucuk gunung sana. Diitung2 sama
biaya pasangnya PLN, puih, kalah murah deh. (Yang kerja di PLN ga boleh komentar lho, nanti jadi berbales pantun deh)

Cintek juga sudah dipercaya Departemen ESDM, terbukti 2 proyek PLTMH model turbin Crossflow yang dikelola Cintek telah diresmikan langsung oleh Pak Purnomo Yusgiantoro. Bisa dicek ke Mbak Rina Irawati jika perlu.
Selain itu juga dipercaya membuat dan menerapkan 2 buah turbin khusus sistem propeller tubullar yang bisa memproduksi masing2 70 kW, hanya dg debit air 600 liter/detik dan beda head 14 meter, di Gassau - Swiss. Subhanallah!

Di tingkat ASEAN pun sudah punya nama, karena diakui sebagai kompeni "pengembangan energi yang terbarukan dan bermanfaat sosial ekonomi". kenapa demikian? Karena selain usahanya dalam membangkitkan listrik dengan tenaga mikrohidro, Cintek juga berperan aktif menggerakkan warga di lokasi proyek PLTMH-nya untuk terlibat dalam perawatan PLTMH tersebut maupun di dalam pemanfaatan listrik tersebut untuk kegiatan ekonomi. Alhasil, mereka punya banyak binaan home industri yang tersebar di Tasikmalaya, Bandung, Cimahi dan sekitarnya, yaitu berupa kerajinan bordir, mebel, penggilingan padi dan kopi, proyek2 industri pasca panen lainnya, bahkan sampai jadi home industri Bandrek dan Sakoteng yang mereka beri merk Hanjuang.
kebetulan home industri minuman Bandrek dan Sakoteng itu sendiri berlokasi di sebelah bengkel Cintek sehingga ane pun sempat mampir melihat proses produksinya. Wah, wah, mojangnya cantik-cantik euy! Ooops, bukan itu maksudnya. Ternyata dalam home industri Bandrek saja, mereka sudah bisa menyerap sekitar 50 orang warga lokal sekitarnya hanya untuk proses produksi dan pengemasannya. Belum lagi percetakan, transport dan lain2nya. Yang jelas, listrik untuk proses produksinya mulai dari pengering, "nggongso" (bahasa Indonesiane apa ya?), mixing, mencacah dan menghancurkan rempah-rempah bahkan pengemasannya, semuanya produksi sendiri alias GRATIS.

Naaa, terus hubungannya sama Elektro Undip apa dong? Mbulet aja ya dari tadi. Hehehe... Tentu ada lah hubungannya. Ini dia diantaranya.
yang pertama, seinget ane di sebelah utaranya Widya Puraya tuh ada air terjun kecil yang tembusnya nyambung ke lapangan perangnya Arhanud. Atau paling tidak sungai Tembalang di bawahnya Fakultas peternakan atau utaranya LPPU. Kira-kira itu punya nilai potensi nggak ya untuk dikembangkan jadi laboratorium terapan mikrohidro di Undip? Coba deh dosen Lab Konversi Energi-nya diajak diskusi. Pasti jawabannya IYA. Kalo soal dananya, au ah gelap.
yang kedua, melihat kinerja Cintek yang open manajemen seperti itu, apa ndak eman-eman kalo rekan2 yang masih aktif di kampus, atau khususnya yang juga warga Priangan, sampai melewatkan untuk menoleh dan hinggap sejenak menggali ilmu di sana. Insya Allah itu jadi modal kuat dalam memahami konversi energi. Apalagi Cintek juga memberi kesempatan kursus kepada umum untuk proses metalurgi maupun elektrikal-mekanikalnya. (Pas kebetulan bareng kunjungan ane itu ada 2 orang alumni ITB Teknik Penrbangan yang mau kursus pengecoran disitu). wah, pasti deh adik2 akan lebih siap memasuki dunia kerja nanti. minimal, dapet secangkir bandrek gratis. Hehe...
Yang ketiga, kabarnya kita-kita ini kan "agen of change", bener nggak sih? Lha, kalo mengingat TDL PLN yang hampir saja diancam dinaikkan terkait naiknya harga minyak dunia, apa bukannya sudah terlambat kita saat ini jika tidak segera melirik tenaga Mikrohidro sebgai "renewable" energi yang buuuuanyak tersedia di bumi Indonesia ini? masak harus nunggu Malaysia nge-klaim Mikrohidro sebagai budaya energinya?
Coba deh direnungkan, barangkali lumayan buat ngisi waktu kosong daripada bengong gak ada bacaan yang lain.
Wassalamualaikum wr wb.

Btw, buat yang di kampus, ane minta tolong dong diceritain tentang DR Ir Eddy Prianto yang barusan dapat penghargaan untuk desain rumah hemat energi. Siapa beliau dan bagaimana konsep rumah hemat energi yang beliau desain tersebut. Terima kasih sebelumnya.

---

Mas Mustaqim

Biodegradable Hydraulic Fluids Prove Beneficial - Fire Resistance a Plus

2008-04-12T00:37:00.000-07:00

Tony Noblit, Houghton International

In 2000, Houghton International formulated a fire-resistant vegetable oil hydraulic fluid – Cosmolubric B-230. This technology made it affordable for manufacturers to switch to a biodegradable, oil-based, fire-resistant fluid without compromising performance.

After putting Cosmolubric B-230 to the ultimate test – continuous, daily use in heavy-duty applications – customers are pleased with its performance. Following are the experiences of Cleveland-based AK-ISG Steel and Dallas-based Chaparral Steel.

AK-ISG Steel: Safety is a Top Concern
Cleveland-based AK-ISG Steel is capable of producing 450 tons of flat-rolled electrogalvanized steel per year. The mill uses three hydraulic systems in its production process. Two of the three hydraulic systems use water-dilutable hydraulic fluid, but its 1,000-gallon Nireco Edge mask hydraulic system requires a straight mineral oil. The pumps and pistons on this system need to be continually lubricated, and water-based fluids are incapable of doing the job. After a devastating fire in 2001 (caused by a spark that ignited hydraulic fluid), AK-ISG decided to evaluate its products, determined to find a fluid that met its performance requirements and was fire-resistant.

AK-ISG took no chance of another fire erupting. After consulting with its fluid supplier of 15 years, Houghton International, AK-ISG decided to switch to the Cosmolubric B-230.

Cosmolubric B-230 is a blend of natural esters rather than a synthetic oil. Because it is made from a canola oil base along with a unique blend of additives, Cosmolubric B-230 is fire-resistant. Management was convinced of the product’s effectiveness after seeing an operator spray B-230 directly into a flame – with no flare-up.

While the product costs more than conventional hydraulic oil, it provides excellent lubricity and equal pump life. Most importantly for AK-ISG, B-230 yields the same performance characteristics as the previous fluid, making it an easy swap. “Although it is not an extreme temperature application, the Nireco system is touchy,” said Chris Pace, engineer for Hydraulic Systems at AK-ISG. “Changes in viscosity can change the performance of the valves, so we wanted to use a similar product.”

Because the hydraulic fluid is extremely stable, operators at AK-ISG have not had to change out the system since the fluid was introduced in 2001. The mill uses approximately 1,000 gallons per year, which it keeps in a tote to top-off the system as needed.

“We’re pleased with Cosmolubric. It hasn’t oxidized and our acid numbers, which we monitor constantly, are fine. I haven’t found a product that does what it does. Houghton samples our fluids monthly. Because we have 40 cylinders, mineral oil gets mixed with the fluid. Houghton conducts flash point tests periodically to make sure that the fluid maintains a high flash point. They do whatever is necessary to keep us operating efficiently.”

Chaparral Steel: Canola Tackles Oxidation
As the nation’s 10th largest steel mill, Chaparral Steel is a technologically advanced facility that recycles steel into bar and structural products. Chaparral’s products include specialty bar grades for use in the construction, automotive, railroad, defense, mobile home and energy industries.

Chaparral’s melt shop uses four different hydraulic systems to move red-hot steel out of the furnace and onto the cooling bed, then into the rolling mill for processing. Each system has a 600-gallon fluid tank that is topped-off on an as-needed basis.

Because Chapparal hydraulic systems operate under high pressures, between 1,800 and 2,000 psi, acid started to accumulate.

“These systems run hot, so condensation seeps in,” said Bob Davis, manager of crane and hydraulic steel production at Chaparral Steel. “In the past, we’ve had problems with the condensation turning the fluid to acid. We tried different hydraulic fluids, and they always had problems.”

Performance improved when Houghton recommended Cosmolubric B-230 as a cost-effective, stable, biodegradable oil-based hydraulic fluid to combat acid problems while maintaining its fire-resistance properties. After switching to the fluid in 2001, Chaparral performed ongoing testing and analysis. Houghton sampled the fluid on a quarterly basis as well, testing for acid and other physical characteristics. The fluid has never oxidized, and the acid numbers have remained low.

“Cosmolubric B-230 has been in the system now for four years, and we haven’t had any acid issues. It costs less than other synthetic fluids, and performs as well or better than the fluid originally recommended by the manufacturer for use with the system. I like the product, and recommend it to our other mills,” Davis said.

The Quest for the Perfect Hydraulic Fluid

The pressure is on. Today’s products and materials need to be biodegradable and environmentally friendly, pushing manufacturers to find alternatives to traditional products. This pressure includes hydraulic fluids – hauling gallons of mineral oil-based fluids because hazardous waste is no longer acceptable or cost-efficient.

Until recently, manufacturers haven’t had much choice. Synthetic alternatives to mineral oil, such as polyglycols and polyol esters, have been priced out of reach for most manufacturers. Those with high-pressure and other extreme applications requiring a fire-resistant hydraulic fluid have had to “bite the bullet” - paying up to six times more for synthetic hydraulic oils than they used to pay for petroleum-based products.

To answer this need, Houghton began to formulate an effective hydraulic fluid based on vegetable oil. Because vegetable oil is a naturally occurring ester, it is biodegradable. It also exhibits good lubricity, on par with synthetic polyol ester fluids. In addition, vegetable oil is a relatively inexpensive base stock. So what’s the problem?

These vegetable oils have traditionally exhibited low oxidative stability – a critical shortcoming which prevented their widespread use. However, Houghton continued its research and testing, working with additive packages and using selected base stocks, and at last created the fire-resistant fluid.

Cosmolubric B-230 is canola oil-based, and uses additive technology to successfully perform like polyol esters. It contains viscosity index modifiers, rust and oxidation inhibitors, extreme pressure (EP) additives, copper passivators and defoamers. These additives have improved the oxidation stability of vegetable oils so that they can equal the desired characteristics of synthetic polyol esters.

In benchmark tests comparing Cosmolubric B-230 to premium synthetic polyol ester fluids, Cosmolubric was found to provide overall comparable performance in lubrication, pump life and oxidative stability (Table 1).

	Canola Oil	Synthetic polyol	Mineral polyol
Appearance	Clear amber	Clear amber	Clear amber
ISO viscosity grade	68	68	68
Viscosity at 210°F	75 SUS	68 SUS	53 SUS
Viscosity at 100°F	335 SUS	305 SUS	330 SUS
Viscosity index	214	214	90 to 100
Acid number	0.9	3.0	0.8
Flash point, °F	495	595	385
Fire point, °F	610	615	425
Pour point, °F	0	-10	5
Specific gravity	0.92	0.92	0.88
Table 1. Cost Comparison of Hydraulic Fluid Base Stocks

Houghton released Cosmolubric B-230 in 2001. The fluid is Factory Mutual approved as a “less hazardous fluid.” It also passed the ASTM D665A corrosion test. Among its physical properties are viscosity index of 214, ASTM flash point of 495°F (257°C), and ASTM fire point of 610°F (321°C) – all of these properties are par with the leading synthetic polyol esters. But the good news is that Cosmolubric B-230 costs less, making it a practical replacement for synthetic polyol esters, especially in applications where fire resistance is a paramount concern (Table 2).

Hydraulic oil type	Cost per unit
Mineral oil	1.0
Invert emulsion	0.9
Water glycol	2.0
Canola oil	4.0
Synthetic polyol ester	4.5
Phosphate ester	7.0
Table 2. Cost Comparison of Hydraulic Fluids Base Stocks

Please reference this article as:
Tony Noblit, Houghton International, "Biodegradable Hydraulic Fluids Prove Beneficial - Fire Resistance a Plus". Machinery Lubrication Magazine. March 2005

Issue Number: 200503
Machinery Lubrication
Industry Focus

Hydraulic Pressure Cone Crusher

2008-04-12T00:35:00.000-07:00

HP Series high efficiency Hydraulic Pressure Cone Crusher is a world-level cone crusher developed from the up-to-the-minute technology of Germany. The cone crusher not only improves the production capacity and crushing efficiency, but also widen the applying area, the hardness of materials range from limestone to basalt. It has a second-to-none crushing performance in the work of medium-size crushing, fine crushing and super fine crushing. The crusher is the improved type of spring cone crusher and can be used to replace ordinary hydraulic pressure cone crusher in the line of mining and construction. It is the most ideal equipment for large stone crushing factory and mining industry.

Character and technical advantages of Hydraulic pressure Cone Crusher:

HP Series high efficiency Hydraulic pressure Cone Crusher has a better performance compared with spring cone crusher and ordinary Hydraulic pressure Cone Crusher:

1. A high crushing ratio and production efficiency
——the connection of higher turning speed and stroke makes the rated power and passing capacity improved greatly and the crushing ratio and capacity increased.

2. Less spare part consuming and low operation cost
——advanced crushing principal and technical data, reliable operation and low operation cost. All parts of the crusher have anti-wearing protection, which can make the life time of spare parts increased by 30% and the maintenance costs decreased to the lowest. The crusher avoids the disadvantages of impact crusher like low average crushing ratio, large energy consumption, fast abrasion of hammer, impact plate and lining board.

3. between-layer pressuring crushing and better finished product shape.
——The crusher adopts between-layer pressuring crushing principal and the suited turning speed, not the traditional single particle crushing principal. The special crushing cavity can makes the crusher crush materials selectively, thus the proportion of fine product and products of cubic shape be increased distinctly and products of lump size decreased by a large extent.

4. Hydraulic pressure protection and hydraulic pressure cavity clearing, high automatization and less stop production and repairing time.
——the discharge opening adjusted by hydraulic pressure and overload protection makes performance of the crusher increased by a large extent, the maintenance and operation easier, the repairing time shorter; the bidirectional metal releasing hydraulic pressure vat makes slab pass through crushing cavity; the crusher can discharges materials automatically when the hydraulic pressure works under the conditions of iron passing and instantaneous overloading, thus there is no trouble of stopping the crusher to discharge materials by hand.

5. Thin oil lubrication makes the life time increased.
——Unique design of thin oil lubrication system prolongs life time of the crusher, high performance and not touchable labyrinth airproof part blocks off the dust and remove the common disorders like the mixture of oil and water in spring cone crusher.

6. Manifold crushing cavity
——It is only need to change fixed cone lining board and movable cone lining board; the type of crushing cavity can be changed from standard coarse cavity to short head fine cavity, which can meet various kinds of need.

7. Easy maintenance and operation.
——all parts of HP cone crusher can be assembled, disassembled and repaired from the top and side part, including the fixed cone and movable cone. For the changing no need to disassemble the crusher body and fasten the bolts. Hydraulic motor makes the performance of crusher better.

8. The crusher can provide customers a higher capacity, better product shape, and easy be operated.

Common problems for Hydraulic pressure cone crusher:

The performance of ordinary hydraulic pressure cone crusher can acts as the reference for the performance of HP series cone crusher. As a composing unit of the production line, its performance can be influenced by other units like feeder, belt conveyor, vibrating screen, motor, transmission part and hopper, etc.

Take care of the following factors which can influence the performance of hydraulic pressure cone crusher:
1. choose the right crushing cavity according to the materials be crushed;
2. the feeding size should be right;
3. materials distributed equally around the round of crushing cavity;
4. automatically control system;
5. discharge opening of cone crusher works normally;
6. the model of belt conveyor be seasoned with the max. processing ability of the crusher;
7. choose the right screen model for advance screening and closed screening.

The following character can decrease the capacity of Hydraulic Pressure:
1. the fine particle with size less than that of feeding hole surpass the max. capacity of the crusher by the extent of 10%;
2. Sticky materials mixed in the feeding;
3. no feeding control;
4. materials allocated improperly around the crushing cavity;
5. the recommended power not used;
6. screening capacity not enough;
7. discharge opening now works normally;
8. Materials too hard or too elastic.

Technical Data:

Model	Feed opening (mm)	Output adjustment range (mm)	Max feed size (mm)	power (KW)	capacity (t/h)	weight (t)
HPC-220C	215	15-38	200	220	150-300	20

Note: capacity will be related with some operating condition as physicals of the materials, way of feeding, feed size etc.

Hyflo - Hydraulic Power Units and Hydraulic and Pneumatic Engineering

2008-04-12T00:28:00.000-07:00

Hyflo, a South African organisation, is well known in engineering circles and has become synonymous countrywide with both hydraulic power units, and hydraulic and pneumatic engineering.

In 1954, when the organisation was founded, it was predicted that hydraulics and pneumatics would play a vital role in the advancement of the South African industrial sector. Hyflo has been in the forefront of these developments ever since, by producing high-quality hydraulic power units.

Hyflo's main areas of business include:

Supply of hydraulic power unit equipment and components
Engineered systems for hydraulic power units
Hydraulic power unit installation and commissioning
Repairs and service for hydraulic power units

Hyflo have continued to move forwards into the demanding military market, providing specialised hydraulic power units for naval vessels around the world. Hyflo's custom-designed hydraulic power units are built specifically to operate in the rigorous conditions the naval industry demands.

Hyflo has provided custom hydraulic power units of different sizes and configurations for South African Navy corvettes and IPVs and Indian Navy OPVs. They are currently supplying hydraulic power units for Pakistani Navy frigates and providing a re-order for the Indian Navy OPVs.

SAN CORVETTE HYDRAULIC PROPULSION SYSTEM

Hyflo was contracted by Wärtsilä Lips Defence (France), to design and manufacture the South African Navy (SAN) corvettes' hydraulic propulsion system, and in this department the SAN corvettes are unmatched.

The hydraulic propulsion system is called CODAG-WARP (Combined Diesel And Gas Turbine – Waterjet And Refined Propellers). The hydraulic propulsion system consists of two diesel engines, each generating 5,920kW, coupled via a three-stage gearbox to two 3,400mm diameter Controllable Pitch Propellers (CPPs).

In addition, the hydraulic propulsion system has one 20MW gas turbine, which drives a waterjet which has a six-bladed impeller with a diameter of 2,800mm and an intake diameter of 2,100mm. With these, the vessel has a maximum speed of more than 27kt and a cruising speed of 20kt.

The two controllable pitch propellers are each controlled by independent 18.5kW hydraulic power units. Each hydraulic power unit comprises of a shaft-driven internal gear pump mounted on a reduction gearbox, which is used in normal operation, and an electrically driven stand-by pump.

The waterjet, which is the largest produced in the world to date, is primarily used for additional propulsion of the vessel. The hydraulic propulsion system is used for activation of two hydraulic cylinders situated on the waterjet.

CUSTOM HYDRAULIC AND PNEUMATIC NAVAL SYSTEMS

Hyflo uses advanced technology to design, manufacture, install and commission complete custom naval hydraulic and pneumatic systems at Hyflo's two major facilities in Johannesburg and Cape Town, both of which are equipped with the latest computer hardware and CAD software.

Using Hyflo's ISO 9001 structures, all designs and calculations of Hyflo's custom naval hydraulic and pneumatic systems are reviewed internally to ensure that the customer's specifications and requirements are fully met. Custom naval hydraulic and pneumatic systems are manufactured and assembled by experienced artisans in Hyflo's well-equipped workshops.

Manifold block assemblies are designed in 3D and manufactured in-house using HydraForce and ISO 7368 high-performance cartridge valves. This provides customers with a naval hydraulic system where all the control functions are integrated into a single manifold.

NAVAL HYDRAULIC AND PNEUMATIC ENGINEERING EQUIPMENT

Hyflo is the appointed South African representative of internationally renowned manufacturers such as Bosch Rexroth, Char-Lynn, Cross, Eaton, EPE, Hydraforce, David Brown Hydraulics, Moog, Parker ITR, Rahmer & Jansen, Stauff, and Voss, Weatherhead, Serto, Safeway, Hunger and Wepuko in hydraulics, and SMC and Zaytran in pneumatics.

A vast range of naval hydraulic and pneumatic engineering equipment and components, such as pumps, motors, valves, cylinders, hoses, hydraulic pipes and fittings, are stocked.

Hyflo Southern Africa (Pty) Ltd
50 Neptune Street
Paardeneiland
Cape Town
7420
South Africa
Tel: +27 21 514 3000
Fax: +27 21 511 7877
Email: sales-ct@hyflo.co.za
URL: www.hyflo.co.za

http://www.naval-technology.com/contractors/hydraulics/hyflo/

A one-dimensional spot welding model

2008-04-12T00:24:00.000-07:00

A one-dimensional spot welding model

K. T. Andrews, L. Guessous, S. Nassar, S. V. Putta and M. Shillor

Source: J. Appl. Math. Volume 2006 (2006), 24 pages.

Abstract

A one-dimensional model is proposed for the simulations of resistance spot welding, which is a common industrial method used to join metallic plates by electrical heating. The model consists of the Stefan problem, in enthalpy form, coupled with the equation of charge conservation for the electrical potential. The temperature dependence of the density, thermal conductivity, specific heat, and electrical conductivity are taken into account, since the process generally involves a large temperature range, on the order of 1000 K. The model is general enough to allow for the welding of plates of different thicknesses or dissimilar materials and to account for variations in the Joule heating through the material thickness due to the dependence of electrical resistivity on the temperature. A novel feature in the model is the inclusion of the effects of interface resistance between the plates which is also assumed to be temperature dependent. In addition to constructing the model, a finite difference scheme for its numerical approximations is described, and representative computer simulations are depicted. These describe welding processes involving different interface resistances, different thicknesses, different materials, and different voltage forms. The differences in the process due to AC or DC currents are depicted as well.

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Links and Identifiers

Permanent link to this document: http://projecteuclid.org/euclid.jam/1174321248
Digital Object Identifier: doi:10.1155/JAM/2006/17936

http://projecteuclid.org/DPubS?verb=Display&version=1.0&service=UI&handle=euclid.jam/1174321248&page=record

BOC Gasses Ireland: Solution by process: Welding

2008-04-12T00:19:00.000-07:00

From craftsmen with a small workshop to automotive manufacturers with automated assembly lines, we provide our customers with versatile and high quality products, consumables and equipment to deliver cost-effective and flexible welding solutions

Services

Our technical experts work with you to develop individualised solutions to optimise your operations. Our welding specialists will help you select the most appropriate gases and equipment and consumables for cost-effective and high quality solutions.

Our total welding solutions offer versatility, high quality product, reliable performance, higher productivity, lower cost and safe environmentally friendly operation for welding processes such as the following:

Electric or Arc welding

Welding processes that use a welding power supply to create an electric arc between an electrode and the base material to melt the metal at the welding point. These can use direct or alternating current and consumable or non-consumable electrodes. The welding region is often protected by inert or semi-inert shielding gas and/or a filler material.

Arc welding is widely used because of its low capital and running costs and includes:

MIG or Metal Inert Gas Welding – suitable for welding all common materials and many of the less common ones too. This flexible and adaptive process is used to obtain high productivity and high quality results.
TIG or Tungsten Inert Gas Welding – less productive but mainly suited to welding of sheet materials and for putting in the root run of pipe butt welds.
MMA or Manual Metal Arc Welding – low productivity fusion welding process but versatile as it welds all sorts of components, does not require a shielding gas and therefore can be used outdoors.
FCAW or Flux Cored Arc Welding – a more productive and higher quality variant of MIG but which produces more particulate fume.
MCAW or Metal Cored Arc Welding – a more productive alternative of MIG but which produces significant fumes.
Submerged Arc Welding – mechanised arc welding process specifically used to weld carbon, carbon-manganese, alloys and stainless steel, capable of very high weld deposition rates and welding speeds.
Plasma Welding – widely used in automatic installations for the construction of vessels or containers in stainless steel, and for high pressure pipe welding. It uses 2 gas flows: a constriction and a shielding gas.

Gas welding or oxy-fuel welding

The heat needed to melt the metal comes from a fuel gas burning with oxygen in a torch. It is also called oxyacetylene welding since acetylene is the predominant choice for fuel gas.

Spot welding

This process uses two shaped copper alloy electrodes to concentrate welding current and force between the materials to be welded. Spot welding is typically used to weld steel sheet metal in automotive body applications or aluminium alloys and can easily be fully automated.

Laser welding

Laser welding offers the advantages of deep penetration and high speed. It is used where other welding processes can’t deliver either the required distortion control or productivity. Depending on material and application, the process can use a variety of shield gases based on helium, argon or mixtures.

Industries

We are the world’s largest supplier of welding products and consumables and our products are used across industries for maintenance operations on production premises.

[See our full list of industries]

Welding is just one aspect of our offer for metallurgy and advanced materials for industrial production:

Automotive – expertise, gases and equipment for automotive OEMs and component manufacturers.
Defence and shipbuilding – the highest quality welding performance products for engineering equipment.
Consumer goods manufacture and general fabrication – complete solutions including laser, resistance and spot welding.

Products

Welding and cutting gases – shielding gases such as argon, helium, carbon dioxide and fuel gases such as acetylene.
Laser gases – such as carbon dioxide, nitrogen and helium.
Welding equipment and consumables:
- Torches, guns, welding machines, wire feeders.
- Such as wires, electrodes, fillers, tips

Source:
http://www.bocgases.ie/product_catalog/Welding,299,0.html

Industrial Robot

2008-04-12T00:16:00.000-07:00

Robot Manufacturers
Company	Robot Types & Applications
ABB - (Asea Brown Boveri)	Provides industrial robots for Cleaning/Spraying, Cutting/Deburring, Grinding/Polishing, Material Handling, Machine Tending and Palletizing/Packaging.
Adept Technology, Inc.	Offers a complete line of high-speed SCARA robot and linear modules designed for assembly, handling, and food packaging tasks. Also provides Automation Software, Machine Vision and Motion Control Products and Simulation Software.
American Robot Corp.	American Robot offers two industrial robot product lines: Merlin six-axis articulated robots, and the modular Gantry 3000 gantry style robots.
Angelus Research	Manufacturers of several lines of intelligent robots including - Educational line of Whiskers Robots teach the world's children about the next technology wave beyond the Internet: Intelligent Robots and Machines. Their Military Robots like Intruder and ART are used to make the most dangerous job in the world: Military Operations, safer. Their military line of robots are dual use, also providing Law Enforcement activities support in life threatening situations.
Arrick Robotics	Provide mobile robots and PC-based automation products including stepper motor control systems, linear and rotary positioning tables, robotic workcells, and automation accessories such as pulley reducers and grippers.
Barrett Technology	Barrett Technology manufactures a complete line of robotic arm and hand manipulators.
BRIC Engineered Systems	Provides a line of Gantry and Cartesian Robots.
Cloos Robotic Welding, Inc.	Robotic welding solution.
Columbia/Okura LLC	Columbia/Okura LLC is your single source for robotic palletizers and turnkey material-handling needs. We provide four-axis, multi-articulated robots and proven end-of-arm tooling.
Cybermotion	Leading manufacturer of mobile robotic systems for security purposes.
Denso Robotics	Provide 4 & 6 axis industrial robots.
EPSON Robots	EPSON E2 Robots are the next generation of SCARA robots designed for maximum speed, maximum throughput, maximum controls capability, and maximum ease of use. Also have a line of high-speed 6 axis robots.
FANUC Robotics	FANUC Robotics offers total automation solutions for assembly, painting, palletizing, packing, welding, dispensing, cutting, laser processing and material handling applications.
IAI America	They offer a full line up of SCARA robots and linear actuators.
Kawasaki	Kawasaki is among the leaders in robot installations worldwide. Our product line of F Series, Z Series, M Series, MD/ZD and K Series robots offers payload capacities from 2kg to 500kg for light, medium, and heavy payloads and high speed, high accuracy applications.
KUKA Robotics	KUKA Robotics is one of the world´s largest robot manufacturers. KUKA offers a complete range of advanced design robots, covering all common payload categories and robot types: SCARAs, Palletizers, 6-axis Robots, Welding Robots, Gantry Robots. KUKA robots are utilized in a diverse range of industries including the appliance, automotive, metal, logistics, food, pharmaceutical, medical, foundry or plastics industries. KUKA robots are found in a multitude of applications including: material handling, machine loading, assembly, packaging, palletizing, welding, bending, joining, and surface finishing.
Mitsubishi	Provides high speed 5, 6 and 7 axis articulated arm industrial robots and a full line of SCARA robots
Mobile Robots (ActivRobots)	Produce a line of mobile robots for manufacturing and material handling, research, security, safety and education purposes.
Motoman Robotics	Wide range of 4, 5 and 6-axis industrial robots, controllers, and robot administration and control software. Applications include Material handling, machine tending, grinding/polishing, gluing/sealing, palletising, painting, spot welding, arc welding, and assembling.
Nachi Robotics Systems, Inc.	Nachi Robots handle load capacities from 4 to 300 kg. They can be used for many applications including spot and arc welding, material handling, cutting, sealing, painting and palletizing.
PARI Robotics	PARI manufactures a complete line of Gantry and Portal Robots.
Panasonic Factory Automation (PFA)	Panasonic Factory Automation (PFA) markets a full line of factory automation equipment and services, including: Panasert automatic insertion and SMT placement machines, CIM software, KME/Create advanced electronic assembly equipment and Panarobo assembly and arc welding robots.
Robotics Design inc.	Manufactures mobile robots and manipulators.
Samsung	Samsung opened the era of robots for assembly in Korea in 1984 and provides various factory automation systems.
Sankyo Robotics	Sankyo Robotics is a worldwide provider of precision, industrial robot systems for the assembly, handling, fabrication and positioning of small parts, typically weighing in the 1 to 10 Kg range.
SchillingSub-Atlantic Alliance	Specialize in the production of multiple-axis manipulators and related support equipment.
Seiko Instruments	Seiko offers a wide selection of high precision robots including SCARA (BN Series and BL Series), Cartesian (XM3000 Series), and Cylindrical (RT Series) configurations.
SONY	High speed and desktop assembly robots.
Staubli	Staubli recently purchased the robotics division of Bosch Rexroth. The new range of SCARA SR robots complements perfectly the existing RX and TX six axis robot range known for their reliability, robustness and performance in terms of precision and speed.
Thermo Electron Corp.	Thermo offers a range of highly reliable robot systems designed specifically for the laboratory. They include articulated robots, such as the CRS CataLyst Express, and high speed distributed motion robots, such as the CRS Vertical Array Loader.
Toshiba Industrial Products	Cartesian Robots
Unimate	The UNIMATE Series 2000 and 4000 industrial robots are among the most widely used industrial robots in the world. With over 20 years of continued improvement, they have been used successfully for spot welding, die casting and investment casting, material handling and many other applications.
Yamaha	Provides single axis, Cartesian, Pick-and-Place, and Loading robots with supporting controllers.

Source:
http://www.engineershandbook.com/Components/robots4.htm

Capabilities of spot welding equipment

2008-04-12T00:13:00.000-07:00

Welder questions answered
20 March 2008
From March, subscribers to Thatcham’s crash repair method database escribe will receive vital information on the capabilities of spot welding equipment.

Welder specification sheets will give an overview of spot welding equipment available to the repairer including for each model phases/volts, details of the required air supply, cooling systems and, in the near future, validated vehicle manufacturer approvals. The specification sheet will be updated regularly and supplied as a newsletter within Thatcham’s times and methods product escribe.

Following the formation of the Repair Industry Welding Action Group (RiWAG) and working closely with The Welding Institute (TWI) Thatcham has also introduced an accreditation programme for resistance spot welding equipment.

There will be two levels for welding manufacturers to choose from Verification and Accreditation. Verification will independently confirm the manufacturer’s claims concerning the machines power and tip force. Accreditation will go further, with the machine put through its paces performing a series of spot welds on different metals and thicknesses using coated steel, boron and dual phase and therefore representative of a difficult joint found in today’s vehicles.

Dean Lander, Accreditation Manager at Thatcham, explained further, “Amongst the range of challenges facing the modern vehicle repairer, welding to the safety and quality standards demanded by the Kitemark is perhaps one of the most difficult. With Thatcham now providing an independent assessment of a welding machine’s capabilities and a summary of uses, technicians can now concentrate solely on the repair and weld with confidence.”

Repair Technologies Manager, Andy Walker, agrees, “The welder specification sheet that will now be included within escribe is an example of just the sort of information that RiWAG was set up to provide. Alongside the new accreditation process for welding equipment, this is clear evidence of how RiWAG’s joined up approach is beginning to address the industry’s key welding issues.”

Source:
http://www.easier.com/view/News/Motoring/article-169270.html