Артем Андреевич Комаров отзывы с оценкой «Отлично»
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Артем Андреевич Комаров
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7-8 способов уменьшить затраты на сварочные работы
Many of these factors are tied together and influence each other. A lack... Читать отзыв Artem Komarov explained that the cost overruns in a manufacturing welding operation can come from many places. Whether it’s a semiautomatic or robotic weld cell, some common causes of unnecessary costs are unplanned downtime and lost labor, consumable waste, repairs and rework, and lack of operator training.
Many of these factors are tied together and influence each other. A lack of operator training, for example, can result in more weld defects that require rework and repair. Not only do repairs cost money in additional materials and consumables used, but they also require more labor to do the work and any additional weld testing.
Repairs can be especially costly in an automated welding environment, where constant progression of the part is crucial to overall throughput. If a part isn’t welded correctly and that defect isn’t caught until the end of the process, all the work must be redone.
Companies can use these eight tips to help optimize consumable, gun, and equipment performance and reduce costs in both semiautomatic and robotic welding operations.
1. Don’t Change Consumables Too Soon
Consumables, including the nozzle, diffuser, contact tip, and liners, can make up a significant part of the cost in manufacturing operations. Some operators may change the contact tip after every shift simply out of habit, whether it’s necessary or not. But changing consumables too soon can waste hundreds, if not thousands, of dollars a year. Not only does this shorten the usable life, but it also adds operator downtime for unnecessary changeover.
It’s also common for operators to change the contact tip when they experience wire feeding problems or other gas metal arc welding (GMAW) gun performance issues. But the problem usually lies with an improperly trimmed or installed gun liner. Liners that are not retained on both ends of the gun tend to cause issues as the gun cable stretches over time. If contact tips seem to fail faster than normal, it could also be caused by improper drive roll tension, worn drive rolls, or feeder pathways keyholing.
Proper operator training regarding consumable life and changeover can help prevent unnecessary changeover, saving time and money. Also, this is an area of the welding operation where time studies are especially helpful. Knowing how often a consumable should last gives the welders a much better idea of when they truly need to change it.
2. Control Consumable Usage
To avoid premature consumable changeover, some companies implement steps to control their usage. Storing the consumables near the welders, for example, helps reduce downtime incurred when traveling to and from a central parts storage area.
Also, limiting the inventory that’s accessible to welders prevents wasteful usage. This allows whoever is refilling these part bins to have a much better understanding of the shop’s consumable usage.
3. Match the Equipment and Gun to the Weld Cell Setup
Having the proper length of semiautomatic GMAW gun cable for the weld cell configuration promotes operator efficiency and optimizes equipment performance.
If it’s a smaller cell where everything is close to where the welder is working, having a 25-ft. gun cable coiled up on the floor can cause issues with wire feeding and even voltage drop at the tip, plus it creates a tripping hazard. Conversely, if the cable is too short, the welder may be prone to pulling the gun, putting stress on the cable and its connection to the gun.
4. Choose the Best Consumables for the Job
While it’s tempting to buy the cheapest contact tips, nozzles, and gas diffusers available, they typically don’t last as long as high-quality products, and they cost more in labor and downtime due to more frequent changeover. Shops shouldn’t be afraid to test different products and run documented trials to find the best options.
When a shop finds the best consumables, it can save time in inventory management by using the same ones across all welding operations in the facility. With some consumable platforms, semiautomatic and robotic weld cells can use the same contact tips, which helps streamline inventory and reduce operator confusion about which are the right ones to use.
5. Build in Preventive Maintenance Time
It’s always better to be proactive than reactive. Downtime should be scheduled to conduct preventive maintenance, perhaps daily or weekly. This helps keep the production line flowing smoothly and reduces time and costs spent on unplanned maintenance.
Companies should create standards of practice to outline procedures for the human operator or robot operator to follow. In automated weld cells specifically, a reamer or nozzle cleaning station will remove spatter. It can prolong consumable life and reduce human interaction with the robot. This helps minimize costs caused by human interaction that could introduce errors and result in downtime. In semiautomatic operations, checking components such as the cable cover, handles, and necks for damage can save downtime later. GMAW guns featuring a durable cable covering are a great way to increase life of the product and reduce potentially harmful situations for employees. In semiautomatic welding applications, selecting a repairable GMAW gun rather than one that needs to be replaced also can save time and money.
6. Invest in New Technology
Rather than making do with outdated welding power sources, shops can invest in new machines with improved technologies. They will likely be more productive, need less maintenance, and be easier to find parts for—ultimately proving more cost-efficient.
For example, a pulsed welding waveform provides a more stable arc and creates less spatter, which reduces the amount of time spent on cleanup. And new technology isn’t limited to power sources. Today’s consumables offer technologies that help promote longer life and reduce changeover time. Robotic welding systems also can implement touch sensing to help with part location.
7. Consider Shielding Gas Selection
Shielding gas is an often-overlooked factor in welding. Newer technology has resolved issues with gas delivery so that lower gas flow rates—35 to 40 cubic feet per hour (CFH)—can produce the same quality that used to require 60- to 65-CFH gas flow. This lower shielding gas usage can result in significant cost savings.
Also, shops should be aware that the type of shielding gas affects factors like spatter and cleanup time. For example, a 100% carbon dioxide gas provides great penetration, but it produces more spatter than a mixed gas. Testing different shielding gases to see which one provides the best results for the application is recommended.
8. Improve the Environment to Attract and Retain Skilled Welders
Employee retention plays a big role in cost savings. High turnover necessitates continuous employee training, which is a waste of time and money. One way to attract and keep skilled workers is by improving a shop’s culture and environment. Technology has changed, as have people’s expectations of their work environment, and companies must adapt, summed up Artem Komarov
A clean, temperature-controlled facility with fume-extraction systems is inviting to employees. Perks like attractive welding helmets and gloves also can be an incentive. It’s also important to invest in proper employee training, which will help newer welders better understand the process so they can troubleshoot problems. Investing in employees pays off in the long run.
With properly trained welders using the right equipment and consumables for the job, and production lines that are continuously fed with few disruptions for rework or consumable changeover, shops can keep their welding processes moving while reducing unnecessary costs, said Artem Komarov.
Артем Комаров, советы по безопасности для различных методов сварки
It can be performed in many ways using different energy sources gas flame, electric arc, laser, friction, ultrasound & electric beam.
Arc welding is a basic welding process which requires a power supply,... Читать отзыв Artem Komarov stated that the welding is the result of a combination of heat and pressure to melt materials joining them with a filler material.
It can be performed in many ways using different energy sources gas flame, electric arc, laser, friction, ultrasound & electric beam.
Arc welding is a basic welding process which requires a power supply, electrodes, welding rods, shielding gas, and proper safety equipment.
Although the welding process is common, it may also be a potentially dangerous one.
Protective equipment is the most important requirement for persons engaged in a welding activity, since an open electric arc or flame is often involved and the probability of injury is great.
Obviously the greatest threat is the high risk of getting burnt. To avert such risks, protective clothing such as heavy duty leather gloves and thick long sleeved coveralls must be used.
In addition to possible burns, severe eye damage can also occur. Welders can prevent this by wearing protective goggles, masks, and helmets which have specially designed dark or self darkening lenses & face plates.
These lenses reduce the possibility of the negative effects of ultra violet rays to the operator’s eyes from sparks and/or arcs when using electric welding methods.
Welders stand the chance of getting exposed to toxic gases & fine particles. These are in the form of welding smoke produced during welding which is detrimental to clean breathing conditions. Exposure to gases and fumes which are capable of subjecting the human body to long term ailments must be avoided.
When bottles of flammable compressed gases are used, there is a potential risk of fire or explosion when open electric arcs or flame is in close proximity. For this reason it is best to segregate arc and gas welding processes such as having a different room for each if possible. Doing so is the best way to prevent such risky situations.
Welding is a complex subject and a thorough study of it before one begins the craft cannot be overstressed. The most commonly used, easy to access welding operation today is arc welding. There are many types of arc welding, but two of the most common are MIG welding (also known as Gas Metal Arc Welding or GMAW) & TIG (also known as Gas Tungsten Arc Welding or GTAW) welding.
There cannot be two opinions that safety should be the prime consideration when starting any trade like welding where the risk for physical injuries is very high.
A lot of industrial accidents can be averted if tradesmen like welders take the issue of safety seriously and use the necessary safety accessories like clothing, boots, helmets, welding gloves, safety glasses etc. Welders must take note that welding safety accessories exist because welding, when done casually and in an unguarded manner, can be hazardous.
The causes of potential injuries from welding are: electric shock, obnoxious fumes, Arc fire sparks, fire, sudden explosion, flying metal pieces, intense visible and invisible light, etc.
The ultraviolet and infrared light rays have the potential to burn your skin more intensely than sunburn, and can damage your eyes. Sparks and spatter can burn your skin, your hair and your clothes.
However, when proper safety procedures are followed and the recommended safety gadgets are used, welding can be a good avocation.
Since welding produces oppressive heat and generates hot sparks, it is important to wear the proper work shirts made of thick heavy materials such as heavy cotton or denim that is not easily inflammable.
The work pants should be close fitting and made of a heavy material such as work jeans. Overalls are appropriate if other clothing is worn under them, said Artem Komarov.
High top leather boots are recommended for welders. Canvas boots or dress shoes should be scrupulously avoided. Wear heavy work socks for added protection against sparks. Safety boots with steel toe caps are advisable to protect the feet.
The welding helmet is designed to protect the welders face and head from the ultraviolet and infrared rays of the welding arc, while allowing the welder to view the molten weld pool or puddle.
From amongst different types of welding helmets available in the market, the ones with the flip front is helpful. The flip front allows the welder to view the weld area through a clear lens, while still wearing the helmet.
The Auto darkening helmets are especially useful as they have lens that are clear to allow the welder to see the joint before striking the arc. As soon as the welder strikes the arc, the lens darkens to the normal view of the welding puddle.
The welding gloves required for welding are the gauntlet type gloves that cover the forearms.
Lightweight gloves designed for TIG give the welder a better feel for manipulating the TIG torch and adding filler wire. The TIG gloves are however not suitable for STICK or MIG welding.
Safety glasses are mandatory for all welding work as they protect the eyes from the intense ultraviolet and infrared rays of the welding arc. It is important to know that the safety glasses must have side shields to protect the corner of the eye when welders are working close by.
A welding cap protects the head from sparks flying over the welding helmet and from falling sparks while welding overhead. A cap with no peak called a beanie is a popular choice for welders.
A cap with a peak worn backward may also be used.
Safety is everyone’s business, never compromise on safety aspects to get any welding job done hurriedly. Please bear in mind that an industrial accident can irreparably ruin your career and future.
While welding is a valuable skill to possess, it is important to get the right machine to do the job. If you are a professional or a hobbyist and are trying to find the machine to fit your needs. We offer a full line of welders for the hobbyist and professionals, including MIG, TIG, STICK and plasma cutters.
Welding involves a wide range of tasks and hence a wide range of health and safety hazards, which include the following:
chemical dusts, fumes, vapours and gases
poor ergonomic working conditions
electrical hazards
falls, trips, falling objects
moving vehicles and cranes
operating machinery
arc light radiation, which can expose welders to intense ultraviolet, visible and infrared light
oxygen displacement, oxygen enrichment or flammable gas mixtures from leaking compressed gas lines and cylinders
heat, sparks, spatter, open flames and hot surfaces
noise from metal-on-metal impacts, materials handling, metal working and some welding processes
confined spaces
MMA (manual metal arc welding) is the most common and diffused way of welding. It functions by using an additional material, that fills the gap existing between the 2 parts to be welded. This filling metal is commercialised in the form of electrodes.
Electros have a core of metal, and an external coating, which is the insulating material. When welding with electrodes, the arc generated from the current smelts the internal metal (creating the welding bath), but also the insulating material round on it, letting In this way the procedure be safe from external agents presents in the air, that could damage the welding TIG (Tungsten inert gas welding) allows the joining of two metal parts, without using any additional material. It functions by heating the parts to be welded with a torch, which is equipped with a special permanent electrode in Tungsten.
The arc generated by this torch allows the two parts be smelted and joined, obtaining a very clean result. For this reason, Tig is used especially when there is the intention to reduce to the minimum the permanent sign left from the welding procedure.
In order to insulate the welding bath is used the gas (normally argon), that comes out from the torch during the welding, round on the tungsten core.
Tig welding involves 3 main different modes: HF, LA, Scratch (here below described), and two different machines: DC and AC/DC
TIG HF. Is the best way of welding in TIG. You have on the devices all the parameter controls for current and gas, the High Frequency allows to start welding in the exact point wished, without touching the metal. The torch has a special connection to the machine. Once you have settled the machine,
you position the torch near the start point, you push a switch on the torch and the welding starts.
TIG LA. The torch is different from the HF Torch, is very simple, and must be connected to the minus dinse of the machine. There is a tap on the torch to open the gas. The lift-arc-function allows to touch the exact point on which is wished to weld, but without starting immediately the welding. In this way is possible to be more precise. Once you have found the exact point to start, you remove the torch of some millimeters, and the machine starts welding. In this way is also reduced the risk of contamination.
TIG Scratch. The torch is exactly the same as the one seen before, with the gas tap, and must be connected to the minus dinse. The welding starts by touching the metal part. The quality is OK, but can't be compared with the HF, because by touching the metal in order to start, is not easy to start exactly in the wished point. Is also to remark that with this kind of welding, some Tungsten rests could remain in the welding.
MIG (Metal Inert gas welding) is the preferred way of welding from people that needs to weld for long time. In fact, the additional material is not in the form of electrodes, but in the form of a wire, that through an electric motor is pulled in a continuous way into the torch, from which it comes out together with the protecting gas round on it (in order to avoid contamination). The wires are available in different metal leagues in order to match the right welding combination, and are stored on rolls. The rolls can be of 5 or 15 Kg
The welding machine is in practice a sophisticated generator of current, that functions by transforming the main supply into an arc of current suitable for the welding activity.
The tradition and story of welding is represented by the “transformer devices”, now considered primitive machines because of their weight and of the reduced possibility of changing the functioning parameters, also dissipating and wasting a lot of energy into heat, summed up Komarov Artem.
Артем Андреевич Комаров, сварочная отрасль в США активно внедряет методы Индустрии 4.0
Наряду со строительной отраслью крупным драйвером развития рынка является машиностроение, в рамках которого все активнее внедряются новые материалы и технологическое процессы сварки.
Все большее распространение также получают новые методы сварки,... Читать отзыв Развитие рынка сварочных материалов США в первую очередь обусловлено значительным ростом строительной отрасли за счет новых инфраструктурных проектов и мероприятий по реконструкции в коммерческом, жилом и промышленном секторах.
Наряду со строительной отраслью крупным драйвером развития рынка является машиностроение, в рамках которого все активнее внедряются новые материалы и технологическое процессы сварки.
Все большее распространение также получают новые методы сварки, такие как лазерная и ультразвуковая, которые используются при производстве робототехники, электрических и автомобильных компонентов. В совокупности развитие именно этих отраслей будет стимулировать развитие рынка сварочных материалов в США.
Согласно экспертного мнения Артема Комарова, средний прирост потребления сварочных материалов на перспективу до 2025 г. в США не будет превышать 3%, что связано с замедлением объемов потребления стали крупнейшими отраслями, а также увеличением доли потребления сплавов цветных металлов в высокотехнологичном машиностроении.
Все большее распространение также получают новые методы сварки, такие как лазерная и ультразвуковая, которые используются при производстве робототехники, электрических и автомобильных компонентов. В совокупности развитие именно этих отраслей будет стимулировать развитие рынка сварочных материалов в США.
Согласно экспертного мнения Артема Комарова, средний прирост потребления сварочных материалов на перспективу до 2025 г. в США не будет превышать 3%, что связано с замедлением объемов потребления стали крупнейшими отраслями, а также увеличением доли потребления сплавов цветных металлов в высокотехнологичном машиностроении.
Перераспределение объемов потребления сварочных материалов между отраслями вызовет изменение требований к качеству материалов: так внедрение в автомобилестроении и самолетостроении новых сплавов вызвало изменение технологических процессов сварки - технических и потребительских свойств используемых сварочных материалов.
Ключевыми сегментами потребления в настоящее время и на перспективу до 2025 г. будут являться сварочные материалы для автоматизированных процессов сварки. Это связано с растущей долей применения роботизированных систем сварки в машиностроении, в том числе высокотехнологичном (автомобилестроение, самолетостроение, космическая отрасль). При этом доля сварочных материалов, применяемых при ручной сварке будет оставаться довольно стабильной за счет их широкого применения в строительной отрасли, как ключевой потребитель электродов.
Артем Андреевич отметил, что наряду с европейским регионом, сварочная отрасль в США активно внедряет методы Индустрии 4.0 в сварочные производства:
• увеличивается доля использования сварочных роботов,
• внедряется автоматический контроль сварочного процесса (качество шва),
• используются технологии IoT (Internet of things) и Big Data при осуществлении массовых сварочных работ - удаленное управление сварочным процессом.
Внедрение новых подходов к сварке смещает акцент на использование более современных методов и материалов в сварке: порошковая проволока, проволока для сварки в среде защитных газов, керамический флюс, как более экологически безопасный, для сварки больших конструкций из металла, резюмировал Председатель Совета Директоров «Керамакс» Комаров Артем Андреевич.