Product Applications – Cladding Systems
Gullco KAT Travel Carriages: Case Study of Automated Splice Welding System for Ohio Steel Fabricator
Product Application File – Cladding Systems
Gullco International of Ontario, Canada have for many years manufactured vertical overlay bridges / gantries mainly for the application of cladding Boiler Tube sheets both in factory during manufacture and later for on site refurbishment.
These machines, whist being special are made largely from standard products from the world famous Kat travel carriage system. These cladding machines have been developed to provide the many users with their unique requirements which include: The ability to swing the vertical track to align it to the boiler tubes The vertical Kat must support and control two oscillator heads sometimes one metre away from the Kat Remote control of all 3 Kats Vertical Kat to sustain much more than it’s normal 45kgs capacity travelling vertical Be easily assembled on site, inside boilers Two welding heads working simultaneously In broken down parts the machine must be able to pass through a man way hole High speed vertical up return after vertical down weld
These machines are sold all over the world with early machines being developed in the very important German market where most of these machines have currently been sold (well over 100) as well as in Denmark, France, UK, Turkey and North America.
These boiler sheets are made from carbon steel, which if left without being clad would last only weeks in service. The filler material used for this application is Inconel which is difficult to feed over distance, for this reason push-pull torches are normally used. Once the vertical track is aligned to the boiler tubes the Kat will be started along with the welding machines and oscillators, the Kats will travel vertical down welding at 60cm/min until and end limit is reached. The welding torches will be repositioned and the Kat will return at full speed to the top of the track to repeat the above.
These machines must be able to operate right from the boiler roof to the boiler floor. As shown above welding can be carried out to the boiler floor. The track configuration can also be reversed so that welding can be carried out to the roof.