Although advances in flexible automation (robotics) are rapidly moving forward, many times development of a single purpose welding system to address welding of a specific part is the most effective approach to automate the welding process. Our design staff can determine if automation can reduce your welding costs. EWA will completely manage the project including the designing, building, training and installation of the system. If you prefer, EWA can supplement your design capabilities to develop a welding systems solution.

Design and implementation of special, staging fixturing, as well as weld fixturing is our specialty. Effective fixture development along with application can increase safety, through put, fatigue, and bottlenecks in your welding or cutting departments. Alignment with EWA’s years of proven design and system manufacturing capabilities can be the resolution to your welding problems.

As a result of their Partnership, and a successful history of working with shipyards throughout the United States; representatives of both Pandjiris, Lincoln Electric and Eastern Welding Automation were given the task of developing and building a propulsion shaft overlay system utilizing Pandjiris state-of-theart fixed automation equipment and Lincoln’s new Power Wave submerged arc welding technology.

At the heart of the system requirements were the abilities to handle a variety of shaft sizes (including tapers) and a minimized heat input. The combination and expertise of both Pandjiris’ fixed automation equipment and PLC precision torch positioning system, teaming with the latest in Lincoln’s submerged arc welding technology, produced yet another success story. The system will replace manual welding of the ID and OD surfaces on propulsion shafts.

The system requirements included both step-over and spiral overlay and tapered surfaces at up to 2" per foot. Internal overlay requirements were for diameters as small as 15" and up to 12" in depth. The turning rolls utilized for the system are the exclusive Pandjiris Missouri Mule series with vertical adjustment to provide precision alignment of the propulsion shaft for the overlay process.

The operator interface for the system is a touch screen which allows manual operation of all axes of motion along with programming surface speed, pitch and taper. The system PLC automatically initiates motion with arc start and automatically adjusts part rotation speed on tapered parts to maintain a constant surface speed during the welding operation.

As a result of this very successful collaboration, multiple packages have either been placed, or are projected to be placed at shipyards throughout the U.S. for the overlay process. The system has exceeded the customer applications and generated great excitement amongst the operators who will no longer have to perform the overlays as a manual operation.

Pandjiris Eastern Welding Automation and Lincoln Electric continue to team together to offer fully integrated Turnkey Systems and Fixed Automation Solutions for customers here in the United States and throughout the world.