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Cost-Effective Automation of Tube Bending

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There is a general perception that investment in automation is financially viable only for large manufacturing firms due to the high investment in technology, quality control, training etc. However, smaller production units can also benefit by the implementation of partial or full automation which leads to savings of time and money. If, for example, a robot loads and unloads a shop’s CNC bending machines, human specialists can focus on more demanding tasks, such as quality control and machine programming. So, what are the factors and considerations for automation in tube bending operations to be cost-effective? We will explore this topic further in this blog.

Correct Feeder Selection

Various factors play a decisive role in metal bending processes. These must be precisely analyzed and accounted for beforehand. Simple bending geometries can be fed into the process via loading tables, step feeders, or conveyor belts. In this case, the length and tube dimensions determine appropriate choice of feeder. For instance, long tubes with a small diameter are not suitable for a chain feeder because of their unstable nature. Here, a loading table or a step feeder would be better choices. The cycle times in the bending process also must be taken into account. If the bending geometry is complicated or has multiple bends, there is no need for a feeder designed for speed. In this scenario, a system with a large loading volume may be the better choice.

In most cases, the workpieces must be separated before loading. Chain feeders are often the best choice here because tubes being fed into the bending process can be placed in the desired starting position—they do not have to be aligned for the bending process. Also, it is now possible to use sensors in a cost-effective way with simple loading systems. This also applies to scanning applied QR codes to call up bending programs during the production process. This makes it possible to change the bending geometry for tubes of the same diameter during the process. In this way, even small-series or individual pieces can be produced without interruptions.

Leveraging of Robotics

At times, a robot is simply the best choice for improving fabrication efficiency by automation. For instance, when tubes are loaded into a right/left bending machine, they often have to go through further processing stages before or after the actual bending process. CNC right/left bending machines with mandrels can rotate the bending head 180 degrees, thus offering the possibility of depositing bent tubes on a conveyor belt in a controlled manner. There are also options for bending machines that cannot rotate the bending head. Tubes can be discharged after the bending process via simple slides and baffle plates onto conveyor belts or directly into collection containers. In cases like these, in which many complex geometries are being processed, robots handle the jobs with the most ease. If a production cell is not an option, a robot that can perform loading and unloading in addition to the handling is usually the best choice. However, a robot always needs some space to make full use of its benefits. As space restrictions often play a decisive role and short distances achieve better cycle times, shops should consider a compact design to make efficient use of machine paths.

Final Synopsis

The above analysis provides a clear picture that a small, self-sufficient cell comprising a bending machine with simple overhead handling, in combination with a chain feeder and a conveyor belt for unloading, can be an extremely economical system, even in the smallest of spaces. It should be noted that automation always needs to be tailored to accommodate a steel fabrication shop’s specific environment, needs, and material flow to be truly successfully and efficient. In summary, automation can be a viable choice for every size shop to combat today’s challenges such as labour shortages, quality improvement, and production efficiency.

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Attracting Welding Gen-Z With Advanced Technologies

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The heavy steel fabrication industry has been plagued by a shortage of skilled welders for a number of years. Millennials and Generation Z (or even Generation Alpha) do not have a very positive view of working in this sector, and the rise of the service industry which offered high renumeration in a comfortable job environment meant that there was a feasible alternative towards working in production or manual jobs. Also, with experienced welders edging close to retirement or embarking on entirely new careers, there is likely to be a vacuum of welding experts in the near future. How can this problem be addressed? Technology is likely to be an enabler in this regard and this blog will delve deeper in this topic.

Older Welders’ Attitude Towards Technology

Experienced and weathered welders may be skeptical about advanced technologies, such as traditional robotic welding systems or new welding cobots. The sheer fear of losing control over their jobs is real, as is apprehension about being fired as a metal fabrication business relies more and more on robotic automation. In this regard, it may be worth expanding on the true benefits that technology can bring to the table. A conversation with welders can commence by telling then that welding robots will handle all the mundane and repetitive jobs. A follow-up conversation can be envisioned explaining that they can work on more complex, important, and strategic tasks. It may take them a bit of time at first to accept these details, however by involving traditional welders in Industry 4.0 project right from the start and investing in training, an earlier adoption of technology can be possible.

Enticing Tech-First Welding Employees

It is estimated that Generation Z – people born between mid-1990s and 2000s – will make up about 27% of the workforce by 2025. The priorities of Gen Z are less with regard to salary and more with alignment of their values to an organization which also fosters a healthy work/life balance. Technology is an inherent aspect of their lives and they focus on being up to date on the latest technology that makes their lives easier. Hence, to boost the curb appeal of open welder positions, pipe fabrication shops and manufacturers inevitably need to invest in technologies that can upskill welders and tap into their curiosity and creativity.

New solutions like welding cobots and dedicated apps democratize technology and lower the barrier of entry. These solutions can be adapted to the trade and to all business sizes. For instance, traditional welding robots are difficult to set up, require a lot of time to program, and are not suited for companies that deal with high-mix/low-volume production. However, welding cobots, especially those using dedicated apps, require no robotics knowledge. They not only leverage the expertise of current welders but also alleviate some of the gripes they have with their jobs. These new automated welding systems are designed for fast onboarding and minimal programming. The end result is that younger welders feel the companies they work for actually invest in their potential and contribute to advancing their careers.

Final Thoughts

In the current labor market where it is tough to find qualified and dedicated welders, businesses will have no choice but to adopt new work methods and equipment to transform welding from a manual and dangerous job into a cognitive career that is valued and highly coveted. On these lines, companies like BOC have opened Application Technology Centres in Australia to showcase state-of-the art welding processes. New technologies, such as welding robots and cobots, are providing highly compelling growth opportunities for welders of all generations. Hence, despite the staffing doom and gloom, strategies exist that can help welding or manufacturing teams looking to hire skilled welders or the few-and-far-between newcomers to the art of welding!

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Automation – Disruption in the Metal Fabrication Industry

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The manifold benefits of automation technologies on different industrial sectors have been well-documented. Robotics has helped to increase production and improve quality while working round the clock (robotics in oil and gas is an example) – thus providing an edge over work done by human personnel, especially for manual, repetitive and volume-based jobs. The same holds true for fabrication where automation is expected to increase its footprint in a big way over the next few years. So, what are the ways in which this disruptive technology enhances the metal and steel fabrication sector? This blog will look to explore this topic in more detail.

Enhanced Efficiency

Increasing productivity is one of the most important ways automated technologies improves structural steel fabrication results. This is due to the fact that fabricators have more time to work on other projects, resulting in faster project completion timeframes. In most cases, the amount of time required to accomplish work is reduced by up to two or three times. Also, automation allows fabricators to handle several projects at once, whether they’re for the same client or different ones. Beamline technology is an example, where rather than having fabrication specialists measure, cut and drill steel beams by hand, the technology automates this laborious and time-consuming procedure. In addition, beamlines also reduce the risk of injury to employees since the steel beam does not have to be moved as often.

Controlled Processes and Data Reporting

The metal fabrication industry is facing many challenges and, with the use of automated fabrication technologies and machines, it is possible to regulate the fabrication process and generate more predictable life cycles. Some heavy steel fabrication companies can deliver completed projects on time and correctly schedule fabrication personnel because of a more predictable life cycle. Some manufacturing processes that are regulated and automated include high-precision machining and fittings and cladding. Fabrication plant managers are able to better plan life cycles this way, which enhances the flow of projects, schedules, and precision.

To discover weldment errors and collect vital data for future reporting, automated fabrication equipment and software must be coupled with each other. As a result of the use of this data, metal fabrication businesses will be able to provide more accurate scheduling bids to their customers. To avoid costly rework and longer project completion times, this data may help detect quality control concerns ahead of time and reduce them before an inspection arrives.

Increased Safety

Automated manufacturing processes are not susceptible to human mistake, which may slow down output due to rework, since they are machine-run. The fabrication techniques and robotic technology have the potential to improve worker safety. Since big constructed modules don’t have to be moved by hand as often, there are less opportunities for human mistake to cause safety issues. With the aid of automated technology, the necessity for experienced fabricators is not decreasing. When it comes to specialized, repetitive activities such as heat inducted bending and cutting using robotic welding equipment, welders and fitters are still in demand. At a rate of roughly 6% each year, there is an increasing need for welding expertise in the industrial fabrication business.

Welding efficiency in the industrial fabrication sector is being improved by the use of automated welding technologies and skilled welders. After years of hand fabrication, the sector has now moved on to full-scale automation. Big labor savings and a massive boost in production have been achieved, and technology will keep the sector moving ahead.

The Final Word

While the applications of robotics and automation in fabrication are increasing, the importance of having people able to properly manage the technology and correctly interpret data is increasing. Quality is paramount when automation is involved and When fabrication projects are completed to the highest standards, the risk of having to conduct rework is reduced, which is both expensive and time-consuming. At the end of the day, streamlining is the way to go – and automation is there to lend a helping hand!

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How Robotics Can Transform Oil and Gas

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The usage of robotics has increased manifold over the last few years, due to technological advancements and an increased appetite to automate repetitive processes. Oil and gas companies have also started utilizing robots to eradicate inefficient processes, automate dangerous tasks and increase profit margins. It has been observed that the production phase of oil and gas operations is where robotics can add the maximum value. This blog will look to discuss the applications and benefits of robotics in energy and utilities and also look to highlight robotics’ potential to transform this sector.

Applications of Robotics in Offshore Oil and Gas

Offshore installations pose many challenges for human operators due to their inherent nature. Robotics play a key role in each operation type as discussed below: –

Upstream: On locating oil wells, operators start drilling to extract the underlying oil or gas reservoir. Robotics can enable players to undertake automated drilling without the need for human intervention. In addition, industrial robots can also be used for conducting seismic surveys using 3D modeling and visualization that would help reduce the chances of causing a permanent impact on the existing geological structure. An example is an ROV (remotely operated vehicle) that come with a video camera, lights, and artificial arms.

Midstream: Processing, transporting and storing of excavated oil or gas supplies are vulnerable to spillage which can adversely impact the marine ecosystem. Machines and Artificial Intelligence (AI) can assist with midstream inspection and maintenance. They can also help with designing, setting up and efficient remote monitoring of resources. Instances of blockages, corrosion or leakages in steel structural fabrication can be identified and resolved using UAVs (uncrewed aerial vehicles) and UUVs (crewless underwater vehicles).

Downstream: The refining and distribution processes of oil and gas refer to offshore areas that are almost too difficult for humans to reach and survive. In these cases, robotics can contribute to material handling and automated refueling without any procedure lapses. Leveraging of AUVs (Autonomous Underwater Vehicles), the torpedo-shaped machines that are self-operating and can cover a depth of up to 6000 meters helps in improving integrity management, repair and maintenance of machines engaged in downstream operations.

Benefits of Robotics in Oil and Gas

The 3 major ways in which robotics can positively transform oil and gas are detailed as follows:

Eliminating Safety Hazards: Hard manual labor, described as roughnecking, is one of the most dangerous jobs across all industries. Some robots eliminate the need for human roughnecks, which minimizes deaths, injuries, and losses associated with hazardous labor. Roughnecking robots can install drill pipes (developed using pipe fabrication) in complex environments, such as oil-bearing rocks and even out in the ocean. These efficient robots make life much easier for oil rig workers who no longer have to put their lives at risk to supply consumers with oil.

Reducing Costs: Robots lower operational costs because there is less need to install safety measures. Robotic platforms eliminate the need to provide housing, food, heating, cooling and other features. One can save money by not paying for expensive safety gear and robots require no work breaks or benefits.

Increase in Productivity: Advanced robots carry out tasks more efficiently as compared to humans. Robots also decrease the amount of downtime during and between work tasks. Downtime can be extremely costly on oil and gas platforms and one must take measures to minimize the same. Drilling sites and oil rigs benefit in several ways when robots perform essential tasks.

Conclusion

Robotics, Machine Learning (ML) and AI bring many automation benefits to the essentially manual process-driven world of oil and gas operations. In spite of advancements in manual excavation techniques, oil and gas is a safer and more productive industry with the integration of robotics. Companies need to invest in technology and tailor their requirements for their respective procedures. A downside is the possibility of shrinkage in size of the manual workforce, however in the long run, this is expected to benefit the energy and utilities industry as a whole. The world of robots is here and now – and we should enjoy the ride!

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Internet of Things – the new Oil and Gas trend

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What comes to your mind when you hear the term Internet of Things (IoT)? You may be reminded of fitness trackers, smart watches and other wearable devices or equipment which can be embedded with electronics or software. Applications of IoT have been increasing steadily and now, the oil and gas industry is set to experience its multiple benefits. The advantages of oil and gas IoT applications lie in creating value through an integrated deployment strategy. IoT will allow the industry to digitize, optimize and automate processes that were previously unconnected to save time, money and to increase safety.

Applications of IoT in Oil and Gas

Some of the ways IoT features in this industry are highlighted as follows: –

Acoustic Monitoring: IoT acoustic sensors in the oil field continuously analyze oil composition (oil, water, gas, etc.) within pipelines to determine types of crude oil, while laboratory tests from simulated field conditions and selected sensors exhibiting optimal oil flow performance enhance the readings. In addition, statistical models estimate the composition and flow rates to continuously improve planning for subsequent operations.

Seismic Exploration Sensors: Individual IoT sensors connected by fiber optic cables aid oil exploration by mapping subsurface drilling sites to determine new drilling locations and optimize output of operational sites. An Internet-connected seismic sensor network collects data and transfers it to servers to provide an image of the subsurface site. Comparative data analysis is conducted to select the best drilling site. A sensor-based system improves drilling rig productivity and reduces time required for site-selection data analysis.

Digital Twin for Projects: A fully loaded digital twin–a digital replica of an actual asset being constructed–gives oil & gas companies the ability to drill down virtually to obtain project progress updates (e.g., outstanding issues, bottleneck constraints) increasing knowledge-gathering efficiency. The digital twin also provides a 3D status report that allows management to “look around the platform” and understand the status of each component from design, build and assembly.

Benefits of IoT in Oil and Gas

IoT has led to many improvements in this industry. Some of these advantages are listed below:

Remote Services: Oil typically isn’t found in easily accessible areas. With safety and regulation issues rising, extraction sites in remote locations and the increasing price of equipment maintenance, IoT allows oil and gas companies to be available at all hours to manage issues ranging from spills to emergency shutdowns and remote field operations. For instance, massive amounts of reservoir data can be integrated with near-real-time field data to plan the placement of wells and water tanks and to determine flow rates.

Health and Safety: Oil and gas extraction is characterized by hazardous working environments. IoT allows companies better to predict when mining plant and equipment needs maintenance, to track spare parts on rigs, to know whether contract workers at a refinery are certified to be in certain areas and to determine the exact number of people to evacuate when an incident occurs.

Asset Tracking and Monitoring: Wireless sensor network oil and gas IoT applications are in great demand nowadays. Due to oil’s dramatic price volatility, companies are spending more time analyzing their investments and internal operations to see where reductions or changes can take place while still maintaining the business and maximizing asset utilization.

The Final Word

As a segmented industry with various streams, Oil and Gas would benefit from a seamless framework in which IoT applications and deployments are closely monitored across the ecosystem that comprises upstream, midstream and downstream players. The sector will benefit  from the adoption of asset tracking solutions and predictive maintenance and will enhance processes involved in crude oil refining. Those applications may even become a necessity for maintaining a lead over peers in the ultra-competitive global Oil and Gas marketplace!

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