The most advanced robotic welder in Africa has been installed at a
local conveyor-equipment manufacturer, surpassing even the
technology employed at local automotive manufacturers.
Melco marketing GM Derek Cohen believes it is also the first
robotic welder to be employed in this industry.
“The welder was installed in April, at a total package cost
of R2-million,” Cohen informs.
The package included the robot, a computerised welding machine,
advanced software, universal modular fixtures, a computerised
bending machine and tooling for components.
He reports that the upgrade was necessary fostone crusher sale in punjabr improved consistency
in the quality of the company’s manufactured conveyor idler
bases, as well as higher output rates and elimination of operator
fatigue.
Currently running at production levels of about 900 idler brackets
a day, production is hoped to be increased by a further 300 units
daily.
“The greater consistency methods of beneficiation of low grade iron oresafforded by automated welding means
that critical idler-bracket tolerances can be better
maintained,” Cohen says.
He explains that the accurate alignment of the bracket reduces the
likelihood of belt misalignment, thereby reducing wear on the tube
of the roller, so increasing roller life.
&ldquomtw series trapezoid mill;The deployment of this superior technology will create
opportunities for more advanced staff training,” Cohen
adds.
To ensure the consistent quality of its products, Melco has
developed an extensive in-house testing laboratory for conveyor
rollers and brackets, in which parts are subjected to the
conditions under which they have been designated to be applied, and
their performance monitored.
“We monitor the quality of our existing designs and test new
designs, specifically addressing such parameters as effective
sealing, running resistance, break-away mass, balance and noise on
rollers, and load tests and vibration on brackets.” Cohen
reports that substantial resources are dedicated to research and
development to maintain global competitiveness.
He states that conveyor users are more discerning than in the past,
demanding improved quality, higher tonnage capacities and longer
conveyors.
In turn, belt idlers have had to evolve to carry greater loads, run
at increased belt speeds and generate less noise.
Issues that have made global competitiveness more difficult to
uphold are the exchange rate and spiralling steel prices, he
feels.
Despite the challenges, over the last twelve months the company
managed to secure R30-million in local and export contracts for the
supply of conveyor idlers for new conveyors.
A project has also been secured for the supply of idlers to the US
for a 20-km lignite-carrying conveyor belt, a contract Cohen claims
to have been won partially on the basis of consistently-maintained
idler-bracket tolerances achieved with the newly-installed
machinery.
The project, already under way, is on target for completion in
August, and is worth $1- million.
In the future, the company hopes to integrate its robot-welder
software with its three-dimensional modelling package, Solid Edge,
to decrease current bracket-design programming times from eight
hours to less than two hours.
Now operating in 55 countries globally – up from a presence
in 20 markets ten years ago – Cohen states how important it
is to improve competitiveness continually, through better quality,
greater efficiency and reduced operating costs.