Mining Industry
Fully Automated Plasma Powder Overlay Welding System at DURUM Verschleissschutz GmbH
DURUM Verschleissschutz GmbH is a leading supplier of high-quality flux-cored wires, electrodes, and powders for wear-resistant applications. The company specializes in producing materials for industries with demanding surface quality requirements and offers tailored solutions for repair, maintenance, and wear protection through overlay welding. In collaboration with OTC DAIHEN EUROPE GmbH, DURUM developed a fully automated plasma powder overlay welding system to optimize the manufacturing of bits for crushers used in the mining industry. The challenge was to automate the welding process for these complex, heavily stressed components while ensuring the highest quality standards.
The DURUM PTA welding system, DURWELD300T PTA, combines DURUM's advanced plasma powder overlay welding technology with OTC's modern robotics. This collaboration enables the precise, reliable, and cost-effective production of wear-resistant components for the mining industry, in particular bits used in excavator crushers. The PTA system guarantees consistent, reproducible overlay welding of components that meet the toughest demands in harsh mining environments. The welding program is selected via the integrated OTC recipe management system, which can be operated using the wireless OTC handheld programming device (WiTP).
Technical Features of the Plasma Powder Overlay Welding System:
- Robot Technology: OTC H5 robot (5 kg payload) for precise handling and positioning of parts
- Turntable: 300 kg rotary axis for efficient rotation of the bits during the welding process
- Control System: Custom OTC control solution for process monitoring and management of PTA welding parameters
- Integrated Sensors: Intelligent sensors for continuous monitoring and compensation of production tolerances in raw materials
Flexible Use and Benefits for Large-Scale Industrial Production
The fully automated plasma powder overlay welding system enables DURUM to produce wear-resistant components with high precision and efficiency. The entire production process runs automatically, with the operator simply placing the parts on the turntable and selecting the appropriate welding program. Through precise control and automation, the system ensures consistently high coating quality that is reproducible without manual intervention. The system is designed for three-shift operation, making it ideal for large production volumes.
Benefits and Services of the Fully Automated Plasma Powder Overlay Welding System:
- Capacity and Flexibility: The system can quickly and efficiently process different part sizes and geometries with varying batch sizes.
- Quality Standards: Precise and reproducible PTA weld seams guarantee consistently high coating quality.
- Process Reliability: The intelligent control system continuously monitors production tolerances and adapts to material variations, ensuring process reliability.
Efficiency and Ease of Use
Thanks to its sophisticated automation technology, the DURUM-OTC system requires only one operator. The combination of OTC H5 robot technology and the advanced PTA welding system ensures the precise and reliable execution of the welding process, which was previously manual and labor-intensive. Particularly noteworthy is the use of the wireless OTC handheld programming device, which gives the operator maximum flexibility and makes working in tight spaces easier. The system's robust design ensures long-term operational stability and low maintenance requirements.
Conclusion
The fully automated plasma powder overlay welding system developed by DURUM and OTC DAIHEN EUROPE offers an innovative solution for the mining industry and sets new standards in the production of wear-resistant components. By combining advanced welding technology with modern robotics, DURUM can now ensure efficient, high-quality production. This solution provides a cost-effective way to meet the growing demands of the mining industry while optimizing the production process for long-term sustainability.