Efficiency and Precision in Mass Production
Fully Automated Plasma Powder Cladding System at DURUM Verschleißschutz GmbH
Company Background
DURUM Verschleißschutz GmbH is a leading provider of high-quality filler wires, electrodes, and powders for wear-resistant applications. Specializing in the production of materials for industries with high demands on surface quality, DURUM offers tailored solutions for repair, maintenance, and wear protection through cladding. In collaboration with OTC DAIHEN EUROPE GmbH, DURUM developed a fully automated plasma powder cladding system to optimize the manufacturing of chisels for crushers used in the mining industry. The challenge was to automate the welding process for these complex, high-stress components while ensuring the highest quality standards.
Plasma Powder Cladding Solution from DURUM and OTC – Automated Production for Mining
The DURUM PTA welding system, DURWELD300T PTA, combines DURUM's advanced plasma powder cladding technology with OTC’s state-of-the-art robotics. This collaboration enables precise, reliable, and cost-efficient manufacturing of wear-resistant components for the mining industry, particularly for chisels used in excavator crushers. The PTA system guarantees uniform, reproducible cladding of components that meet the toughest requirements in the harsh mining environment. The welding program selection is managed through the integrated OTC recipe management system, which can be operated via the wireless OTC hand programming device (WiTP).
Technical Features of the Plasma Powder Cladding System:
- • Robotic Technology: OTC H5 robots (5 kg payload) for precise handling and positioning of parts
• Rotary Table: 300 kg rotary axis for efficient rotation of the chisels during the welding process
• Control System: Customized control solution from OTC for process monitoring and PTA welding parameter management
• 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 cladding system allows 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 rotary table and selecting the appropriate welding program. Due to the precise control and automation, the system ensures consistently high cladding quality, 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 Cladding System:
- • Capacity and Flexibility: The system can process different part sizes and geometries with varying batch sizes quickly and efficiently.
• Quality Standards: Precise and reproducible PTA weld seams guarantee consistently high cladding quality.
• Process Reliability: The intelligent control system continuously monitors production tolerances and adapts to material variations, ensuring process reliability.
Efficiency and User-Friendliness
Thanks to its sophisticated automation technology, the DURUM-OTC system requires only one operator. The combination of OTC H5 robotic 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, the use of the wireless OTC hand programming device provides the operator with maximum flexibility and makes it easier to work in confined spaces. The robust construction of the system ensures long-term operational stability and low maintenance needs.
Conclusion
The fully automated plasma powder cladding system developed by DURUM and OTC DAIHEN EUROPE provides an innovative solution for the mining industry and sets new standards in the manufacturing of wear-resistant components. By combining advanced welding technology with modern robotics, DURUM can now ensure efficient and high-quality production. This solution offers a cost-effective way to meet the increasing demands of the mining industry while optimizing the production process for long-term sustainability.