Retrofits

Compass bg Customize For
Your Needs

General

Retrofits typically consist of a complete overhaul of the controls and motion axes of systems produced by other manufacturers. We retrofit manipulator, linear seam welder, weld lathe, and bore cladding systems as long as the fixturing is functioning adequately.

A Retrofit consists of replacing all of the control components including servo motors, amplifiers, and encoders. This ensures compatibility with the AMET XM Weld Control architecture when integrating with other manufacturer’s fixturing. A common retrofit integrates multiple weld processes such as Plasma and TIG or MIG and Subarc to increase versatility and capacity.

Retrofits are performed at the AMET facility in Rexburg, ID to integrate and test all components. Often, we require the existing weld fixtures on-site at our facility for integration, but in some cases, we create temporary fixtures for testing and assembly. The new controls and motion axes are then integrated and installed at the client’s facility.

Capacities

AMET offers the following capacities when retrofitting automated welding systems:


  • Weld Head Motion (Vertical and Horizontal):

    • Motorized Motion: Servo motor driven precision slides with programmable motion in increments of 0.001 in (0.025 mm). The slides are available in a wide variety with a range of motion from 2 to 60 in (51 to 1524 mm).
    • Manual Motion: Hand crank slide with 6 in (152 mm) of motion. Additional sizes available upon request.
    • Pneumatic Motion: Air-driven slide with 6 in (152 mm) of motion. Activation can be controlled by weld program. Additional sizes available upon request.

  • Rotary Motion: Programmable in increments of 0.1 degree and by speed (RPMs). Speed is dependent upon drive assembly components of rotary device.
  • Linear Motion: Upgrades to linear motion axes such as carriages on seam welders or booms on manipulators. These upgrades include servo motors with encoder feedback to provide programmable motion by distance or speed. Speed and distance capacities are dependent upon existing equipment setup and capabilities.
  • Power Supplies: AMET is capable of integrating multiple arcs into one system. We offer TIG & Plasma, MIG and Subarc, and Multiple Wire Subarc. We also integrate other combinations of these processes. Contact us with your specifications.

Advantages

AMET Retrofits are a cost-effective way to renew existing equipment such as lathes, manipulators, or seam welders. Our extensive experience performing retrofits and our advanced control packages provide an excellent upgrade option with the following advantages:


  • Retrofits are possible with most welding fixture manufacturer equipment. AMET integrates with manipulators, seam welders, lathes, positioners, and cladders. Additional fixtures are also possible. Please contact us regarding custom or specialized equipment.
  • Older equipment is refreshed and updated with advanced weld process controllers. Precision and accuracy can be renewed to the original state or possibly upgraded to a higher level of precision, extending the service life of the equipment.
  • Retrofits cost less than a completely new system, yet still offer the same level of advanced controls and integration that AMET provides on new systems, providing a high return on investment.
  • Our advanced and versatile controls allow multiple arcs or processes to be integrated into a single system. Our engineers design and create the necessary brackets and motion components for integrating multiple arcs or processes into a single weld head. This level of flexibility offers efficiency and a capacity for welding a wider range of products without the need of multiple systems.

Controls

The XM Controller is a very powerful weld controller, and is the center of each retrofit. It is capable of integrating with and controlling the following equipment:


  • Welding Power Supply: The XM is capable of controlling all weld parameters of several brands and types of welding power supplies.

  • Arc Voltage Control (AVC): The AVC provides constant arc standoff and also allows for touch starts and touch retract.

  • Cold Wire Feed Control: Wire feed speeds and wire retract are programmable.

  • Hotwire Feed Control: Wire feed speeds and voltage to the wire before it enters the weld puddle are programmable.

  • Linear Travel Control (horizontal and vertical): Motion is programmable by distance, speed, or time.

  • Oscillation Control:

    • Mechanical Oscillation: Dwell time and oscillation distance are programmable.

    • Magnetic Oscillation: Programmable control of slew time, dwell time, amplitude, and arc position. The arc can be deflected and maintained in a set position to aid in certain types of welding such as fillet welding.

  • Rotation control: Motion can be programmed by RPM, degrees of rotation, or time. Continuous and manual (jogging) rotation are also available on the XM Controller.

  • Gas Control: Manual flow meters and a gas solenoid provide a constant gas flow rate. A soft button activates gas at the default flow rate until the button is deactivated or until the end of the weld program.

Technical Data

Call AMET: (208) 356-7274
Standard Features
Optional Features
End Use Applications

Standard Features on Retrofits


1

AMET Advanced Controls. The architecture used in AMET’s controls allow us to accommodate a wide range of power supplies, fixturing, safety, and automation equipment. The controls are designed and built in house to seamlessly integrate with existing equipment.

2

Precision and Manual Motion Axes. AMET produces and integrates motion axes and the necessary bracketry for vertical and horizontal weld head movement. The precision axes consist of servo motor driven components with encoder feedback for programmable motion and position. Manual axes are hand crank driven slides with manual brakes to prevent movement during welding operations.

3

Testing. AMET control components are produced in house, which allows us control over the quality and the ability to test each component as it is produced. This includes individual components such as control boards and complete assemblies like control modules and the XM Controller. Each component and assembly is rigorously tested, as is the whole system to ensure proper functionality, compatibility and longevity.

4

Fixturing. AMET performs retrofits on manipulator, seam welder, lathe, positioner, and cladding fixturing made by virtually any manufacturer. The fixturing can be new or used as long as it is functioning adequately at the beginning of the retrofit process.

5

Integration. The controls and motion components are integrated with the fixturing for performing hard automation welds. The advantage to an AMET retrofit is that we design the software and hardware of our controls to seamlessly integrate with each fixture. This holistic approach ensures compatibility with virtually any weld fixture.

6

Complete System. AMET provides complete systems with a warranty on all AMET produced components. Upon completion of testing and integration at the AMET facility in Idaho, we setup and install the retrofit system onsite at the client’s facility.

Retrofits numbered

Optional Features on Retrofits


Borecladintersecting sized
Intersecting Bore Cladding Capability

Intersecting bore location and size can be programmed through the XM Controller. During cladding, the arc will automatically be extinguished when the torch reaches the edge of the intersecting bore and then reignite once it reaches the other side. This will be repeated until the system has clad around the entire intersecting bore and then continuous cladding will resume. Bores must intersect the main part at an angle perpendicular to the center.

Offline programming
Offline Programming Software

Weld programs can be created, modified, or stored on a PC. These programs can be moved back and forth between the controller and the PC using a USB storage device or through an Ethernet connection. This software can increase productivity by allowing programs to be created/edited while the XM is executing a weld program.

Automation software
Automation

A critical part of the allure of XM Controls is the ability to automate functions in the welding process. The system may be set up to enable laser tracking, start part rotation when the weld commences, and even load and unload a part. Up to10 pre-weld and 10 post-weld operations can be programmed into each weld program.

Amet camera light attached smaller
Arc Viewing Camera

Arc Viewing Cameras can be added to a GTAW/PAW system giving the operator a view of the weld arc from a remote location. This keeps the operator in a safe location and reduces operator stress and fatigue. Additionally the image that is shown on the monitor is magnified and shows greater detail than what could be observed without the camera. Multiple cameras may be integrated for projects where a view of the lead and trail side of the weld zone is required. Please see the Arc Viewing Camera page for additional information.

Data acquistion
Data Acquisition and Tolerance Checking Software

Data is collected and analyzed in real-time to ensure all modules are within the set tolerances. The data points are displayed graphically on the XM display and can also be exported as a .csv file and viewed on a program such as Microsoft Excel. These files can be exported through one of the USB or Ethernet ports on the XM Controller.

Laser tracking unit
Laser Seam Tracking

The XM integrates with a Meta laser sensor to scan and automatically track the joint during welding. The laser continuously scans the joint profile and makes the necessary adjustments to ensure the torch maintains the programmed location. The scanned profile is also displayed in real-time on the operator console monitor. Seam tracking can be configured for single or multi-pass welds.

Avc module
AVC for GTAW/PAW System

An AVC (Arc Voltage Control) Module is added to provide the weld head with automatic arc standoff. The module provides automatic height adjustments to maintain a consistent arc voltage throughout the entire weld, including automatic adjustments on multi-pass welds.

Camera   monitor saw
Camera System (SAW)

A video camera and cross-hair laser generator are mounted to the weld head to aid in monitoring during welding operations. The video feed is displayed in real-time on the operator console monitor. The camera is also used to aid in positioning the torch(es) during setup.

Plc controls opt
PLC Controls

We integrate components into our controls for automating additional functions other than the welding process. These components include safety equipment such as automatic weld screens or curtains that are programmable to automatically open and close at the end or beginning of each weld. We can also integrate additional tooling such as automated part loading equipment.

Tig   plasma head
Multiple Process Weld Head

Our advanced controls allow us to integrate multiple weld processes into one weld head. Each process can be operated independently or simultaneously. For example, a TIG & Plasma weld head would feature two AVC axes (one for each torch) and either torch could operate or they can both operate simultaneously for Keyhole Plasma with a TIG trail. We offer TIG & Plasma, TIG & MIG, TIG MIG & Plasma, and SAW & MIG. Any of these combinations are available and would be completely programmable from ONE central controller. Other combinations are also available. Please contact us with any requests.

6 wire cladding head 1
Multiple Wire Weld Head

AMET specializes in offering custom weld heads. We offer GTAW and PAW weld heads with two wires. The wire feeders can be synced to operate simultaneously or they can be separated to operate independently. We also offer multiple wire SAW head welds. Up to 10 wire weld heads can be integrated with our control packages for applications such as cladding. Heads with 3 wires are available for thick wall welding applications.

Sppd opt
Single Point Power Distribution

AMET provides fuse-protected power to all system components from a single primary power circuit (provided by customer).

Coordinated motion opt
Coordinated Motion Module

Up to four motion axes can be integrated together. This allows each axis to function and coordinate together, much like the axes of a CNC milling machine, to perform welds on unique part geometries.

Virtual alignment
Virtual Alignment (Teaching Mode)

The operator can “teach” a weld path by manually moving the weld torch along the seam and selecting points. Up to 20 points can be selected to create a circumferential, longitudinal, or combination weld path. After all of the desired points are selected, the system will retrace each one to create a custom weld path. This can be helpful if parts or materials vary or have unique joint configurations. The path can be repeated for multiple pass welds, or offsets can be applied to repeat the motions of the original path in a new location.

Flux system
Flux Delivery and Recovery System

The entire system is air-pressurized and heated to provide continuous flux delivery and recovers unused flux to help reduce costs. The system consists of a feed tank, delivery and recovery unit with 5 HP vacuum, and hopper for delivery at the weld head. The hopper is equipped with a valve to allow the operator to control the ratio of new and recovered flux delivered at the weld head.

Turntable
Turn Table

AMET manufactures a full line of high precision turn tables with weight capacities from 550 to 22,100 lb (250 to 10000 kg). We also offer standard version turn tables with weight capacities from 2,200 to 132,200 lb (1000 to 60,000 kg). Each turn table faceplate includes a thru-hole for a gas purge device.

Pzt1000
Positioners

AMET manufactures a wide range of positioners with weight capacities from 550 to 22,000 lb (250 to 10000 kg). They feature 135 degrees of motorized tilting and continuous motorized rotation. The rotation axis can be integrated with the XM to provide programmable control for welding operations. High-precision models are also available with harmonic drive rotation for the most stringent needs. The standard configurations include a fixed base, but an elevating base is also available. Each positioner includes a thru-hole for a gas purge device.

Programmable Gas Control

Adds programmable gas flow control for GTAW and PAW applications.

60 ton fit up station
Fit-up Station

AMET manufactures fit-up stations for aligning two sections prior to welding. The fit-up stations feature four (4) wheels that are controlled hydraulically. The wheels are divided into pairs A & B and C & D, and there are several options for moving them to accommodate a wide range of applications. The following motions are possible: each wheel can be moved independently (in/out from the centerline), each pair can be moved simultaneously (in/out or side-to-side), or all four wheels can be moved simultaneously. The fit-up station can also be mounted on a rail system and have motorized motion in a growing line system.

Servo motor electric brushless
Precision Boom

The precision boom option upgrades the horizontal motion of the manipulator boom with a servo motor and encoder, which is integrated with the XM Controller. This provides the boom with welding axis quality motion for longitudinal welds.

Touch start opt
Touch Start

Arc initiated by touching the torch tip to the part for GTAW and PAW applications.

Mechanical oscillation opt
Mechanical Oscillation

A precision servo motor driven ball screw slide with encoder feedback provides mechanical oscillation. The oscillation motion is completely programmable including dwell time, oscillation frequency and width, and travel speed.

Mag oscillator clean sized 1
Magnetic Oscillation

Magnetic probe is used to deflect the arc back and forth in a stirring motion for excellent sidewall tie in. The arc can also be deflected and maintained in a set position. This can be beneficial for fillet or otherwise hard-to-reach joints. Dwell time, oscillation frequency, and width are all programmable from AMET controls. Compatible with both magnetic and non-magnetic materials.

Bore torch
Spiral Path and Step-Index Cladding

The vertical or horizontal axis is integrated with the rotary axis to provide precise cladding motion. We offer both Spiral Path, and Step-Index cladding options. Spiral welds begin at the bottom of the part and spiral upward until the defined height is reached. Step-Index clads in a straight line for each revolution of the part. After each revolution is completed, the torch steps upward and begins the next pass. The pitch of the spiral and the step height are programmable.

Complex Intersecting Bore Cladding

Includes all of the features from the Intersecting Bore Cladding option with the addition of automatically cladding bores at off-center and off-angle intersections.

Monitoring Sensors

AMET offers several sensors to monitor several functions and aspects of the weld. Each one of these sensors can automatically terminate the weld program if levels exceed the set parameters. The following sensors are available:
• Humidity Sensors – measures humidity levels at the weld puddle
• Oxygen Sensors – measures oxygen levels at the weld puddle
• Water Sensors – monitors water flow for components such as torches
• Gas Sensors – monitors gas flow for shielding/backing/purging gas

Purge solenoid
Integrated Purge/Backing Gas

This package includes a gas union, digital solenoid, manual flow meter, and a gas line from the solenoid to the gas union for purging or backing gas capability. The digital solenoid is integrated with the XM for programmable and manual on/off control of the gas. Programmable flow control is also available.

Wireless symbol
Wireless Communication

Weld programs and data can be transferred between a PC or sever and the XM Controller wirelessly.

Barcode scanner
Bar Code Program Selection

Weld programs can be automatically selected by scanning a bar code associated with a specific part. This can help eliminate the incorrect program being loaded and run. Beneficial if many different parts are to be welded and operator needs to frequently switch between weld programs. Includes the bar code scanner and the necessary software to integrate with the XM Controller.

End Uses For Retrofits