BR-102024017457-A2 - Robot for applying plaster to sugarcane mills using a system with two MIG welding torches with automatic angle compensation, maintaining the same distance to follow the profile of the grooves on the sugarcane mill shells.

BR102024017457A2BR 102024017457 A2BR102024017457 A2BR 102024017457A2BR-102024017457-A2

Abstract

This invention relates to an automated system for applying a weld mix to the shells of sugarcane mills, within the technical sector of welding devices and industrial automation. It comprises servomotors, adjustable rails on the X-axis, a carriage with displacement on the Z-axis, MIG welding devices, and an innovative automatic self-compensation mechanism that adjusts the distance between the torches and the grooves, even on surfaces with variable geometry. This allows for the parameterization of variables such as mill rotation speed, distance between grooves, and the number of weld tracks through a Human-Machine Interface (HMI). Advantages include uniform and precise weld mix application, reduced welding material waste, increased durability of the mill shells, greater operational efficiency, and improved operator safety by minimizing ergonomic risks and exposure to toxic gases. Developed for application in sugarcane mills, it is adaptable to other industries requiring precise welding on complex surfaces.

Inventors

CLAUDIO OSTI
MARCOS COIMBRA
MARCO ANTONIO DE SOUZA BITENCOURT

Assignees

OSTI & OSTI LTDA
CLAUDIO OSTI

Dates

Publication Date: 20260310
Application Date: 20240826

Claims (8)

[001] Sandblasting Robot for Sugar Cane Mills using a System with Two MIG Welding Torches with Automatic Degree Compensation Maintaining the Same Distance for Tracking the Profile of the Grooves on the Sugar Cane Mill Liners, characterized by using two MIG welding torches, implementing an Automatic Degree Compensation process that maintains a constant distance for the weld deposit and performs precise tracking of the profile of the grooves on the sugar cane mill liners, contributing to a more efficient and precise welding application.
[002] The system, according to claim 1, characterized by including a degree self-compensation assembly that automatically adjusts the distance of the torches in relation to the grooves of the mill shells, ensuring a uniform application of the coating.
[003] The system, according to claims 1 and 2, characterized by containing servo motors that control the X, Z and C axes, enabling lateral, approach and retraction movements, and angle compensation of the torches.
[004] The system, according to claims 1 to 3, characterized by including a Human-Machine Interface (HMI) case equipped with customized software, allowing manual programming of the start and end points of the plastering on each frieze.
[005] The system, according to claims 1 to 4, characterized by having a Control Case that integrates PLC, drives and circuit breakers, being responsible for controlling the servo motors and torches during automated operation.
[006] The system, according to claims 1 to 5, characterized by containing a set of MIG welding torches positioned horizontally and equipped with angular and linear adjustment mechanisms, allowing maximum efficiency in the application of welding.
[007] The system, according to claims 1 to 6, characterized by using adjustable rails on the X-axis with an aluminum structure, linear guides and quick-release fasteners, suitable for the variable length of the mill rolls.
[008] The system, according to claims 1 to 7, characterized by allowing the configuration of parameters such as mill roll rotation, distance between grooves and number of weld tracks per groove, automatically processing the operation up to the last groove's weld bead.

Description

Field of Invention [001] The invention in question falls within the area of welding devices, focusing on efficiency and speed of application, performed by the MIG welding process, without gas and torches fed by tubular wire spools. The process performs the spatter welding on the angled faces of the grooves of sugarcane mill shells. The spatter welding consists of spraying weld points in a specific region, leaving it with a rough appearance and high granulation. The invention aims to solve efficiency problems related to the use of welding material, the time required to perform the spatter welding, and the quality of the spatter welding on a set of mills in operation. [002] This is achieved through an innovative and intelligent technique of synchronous automatic distance and angular positioning compensation between two continuous wire MIG torches. This technique optimizes application time, the amount of material deposited, the ideal electrical charge for an effective arc and a strong weld, even with the component being welded in motion. [003] This report describes in detail the operation and essential components of this system, providing accurate information for the replication and understanding of the project. State of the Art [004] Currently, many of the plastering applications on sugarcane mill shells are predominantly carried out manually or semi-automatically. Manual plastering is done with a coated electrode and is sometimes the most dangerous and harmful to health, as the operator must work with the mill in motion and often covered in bagasse and juice, making a clear view of the area to be plastered impossible. Regarding safety and health, the following stand out: Toxic Gases - Hexavalent Chromium, particularly, which is extremely harmful to health, is generated in greater quantities during electrode plastering and in smaller quantities in wire plastering. Ergonomics - Due to the constant and often inadequate position, resulting from the layout of the facilities, the plasterer ends up suffering health damage, potentially losing hours and days of work. Risk of Accidents - In manual plastering, the plasterer runs the risk of serious accidents such as falls as well as electric shocks. High Temperatures and Humidity - In manual plastering, the operator is subjected to long periods of exposure to high temperatures, humidity, and vapors, thus increasing the degree of risk to their health. [005] While semi-automatic welding is less unsafe, it still requires direct operator intervention from time to time to correct the torch's position relative to the groove of the grinding roller sleeve that is receiving the bonding coat on its side faces. These traditional methods, in addition to the limitations and dangers mentioned, also facilitate the waste of welding material, excessive wear of equipment, and irregular and often ineffective application of the bonding coat on the side faces of the grinding roller sleeve grooves. Therefore, there is a clear need for an automated and precise system that can overcome these limitations and ensure efficient bonding coat application. [006] Plastering can be done using coated electrode welding, which, despite producing a weld with a larger particle size, is slower because it is necessary to stop the plastering process to change the electrode, which occurs on each face of the plastered groove. A mill roll to be plastered typically has 24 to 50 grooves, while with wire welding, the change only occurs at the end of the plastering of the roll; this, in turn, provides greater welding speed and avoids stopping the work to change welding "electrodes". Applying welding using a common electric welding machine can present challenges, both manually and semi-automatically. With manual application, the weld distribution is not uniform and the operation can require considerable time. [007] To solve these problems, the "Robot for Mills" was developed, with the Sirius Plastering Robot being the only robot that has a system with two MIG welding torches with automatic degree compensation. This system makes the torches follow the profile of the mill groove being plastered, thus maintaining the ideal distance between the welding nozzle and the face being plastered. This innovative system improves efficiency and reduces costs associated with welding application. [008] The invention reported in this patent uses two MIG type torches, each with a wire spool, in order to provide the welding element continuously and effectively, provided by the self-compensation adjusted automatically after the start of the plating operations on the faces of the sugarcane mill shell grooves. List of Figures [009] The following is a list of figures described in the drawings: • Figure 1: 3 distinct views representing the two "cars" and their movement on the X and Z axis tracks. • Figure 2: Detail of the torch assembly including the servo motor responsible for the C axis. • Figure 3: Complete presentation of the plastering