UNIKraft Techno LLP

VALVE CLADDING SYSTEM

PREAMBLE:-
Weld cladding is a very efficient & cost effective solution for the surface treatment of oilfield
components/valves used in highly corrosive & erosive “metal loss” environment. It offers a proven
Long-term solution against other corrosive resistance alternatives. The Unikraft core technology is the
design and manufacture of the mechanized weld cladding work stations and the associated control
systems that coordinate welding conditions with the physical movements of the welding head and
the work piece. Page 1/4

Work Address:- Contact Us:-

Gala No.62, Parmar Industrial Complex, Email:- info@unikraft.in,unikrafttechno@yahoo.in
Survey No.142/1, Chinchwad, Cell:- +91-9552592593 / 9922535540
Pune 411019. Tel. No.:- 020 27452593
Web.:-www.unikraft.in
 UNIKraft Techno LLP

VALVE CLADDING SYSTEM

MACHINE DESCRIPTION:-
1. This is a fully programmed automated system. Auto Mode – If the torches are not in their home position,
and if the “HOME” Position Button is pressed then X &Y Slides will go to their (Machine Zero) Home
Position. On reaching the “HOME” position the green light will glow. Home Position will be detected with
the help of sensor.
2. Load the job into the fixture.
3. Press the Clamp push button. The hydraulically operated chuck will clamp job.
4. Select the job size from HMI & Press “Weld Home” push button & torch will come at weld home position.
If distance between torch & job is not appropriate then adjust the torch manually with help of HMI
or Mechanical slides.
5. Set the parameters (I.e. voltage and wire feed speed) from the welding machine. Press the wire inch button
on Remote Pendent of Control Panel to take out some wire & cut the wire.
6. For heating the job at required temperature adjust the heating Induction coil manually with help of
“Induction Coil UP” & “Induction Coil Down” push Buttons. Then press “Induction Heater ON” push Button,
temperature will be sensed by sensor and displayed on heater panel. After reaching required temperature
press induction heater off push button.
7. Then press the Cycle Start Push Button. Now as per the pre-set data in selected program & based on the
Job size, Job rotation and Welding will start simultaneously.
8. After completion of 1st, 2nd, 3rd and 4th run (depending on program parameter) of welding, the Welding
and rotation will stop.

WELDING QUALITY IMAGES:-

Page 2/4

Work Address:- Contact Us:-

Gala No.62, Parmar Industrial Complex, Email:- info@unikraft.in,unikrafttechno@yahoo.in
Survey No.142/1, Chinchwad, Cell:- +91-9552592593 / 9922535540
Pune 411019. Tel. No.:- 020 27452593
Web.:-www.unikraft.in
 UNIKraft Techno LLP

VALVE WELDING SYSTEM

SALIENT FEATURES:-
1. Valve is centered on the turntable with the help of self centering chuck .
2. 15 to 20 minutes to preheat the part to 250 deg Celsius using induction heating system.
3. The torch can be positioned manually or is programmable.
4. Welding process is Thin wire submerges arc welding: this prevents the substrate from overheating, allowing for a
Higher quality weld.
5. Each layer requires 2 to 3 minutes of arc on time.
6. With each step, the machine automatically changes speed for continual welding.
7. Heavy duty slides with 24” horizontal travel and 24” vertical travel.
8. Standard 20” diameter X 1 ton turn table with built in special direct earthing arrangement which prevents the return
current from passing through the bearing, shaft gear or gears.
9. Rugged and strong power source, boom mounted welding head, wire feed mechanism, spool holder allowing for a
higher weld quality.
10. Swiveling arrangement of induction coil.
11. Flux hopper of adequate capacity (10kgs/7litr) with recovery & recycling system ensures long and interrupted weld seams.
VALVE CLADDING SYSTEM PRODUCTIVITY CHARTS:-
TOTAL NON-VALUE PREHEATING ARC TIME
S.N. OPERATION SEQUENCE
ADDED TIME (MIN.) TIME (MIN.) (MIN.)
1 Load the Job on the machine using dedicated jib crane 1
2 Clamp the Job 0.2
Bring the Induction coil to heating position using the
3 0.25
swivel bracket & Induction slide
4 Preheat the Valve Face using induction Heating 15
Select the Program for welding from HMI as per the job
5
size & press Cycle Start 0.25
6 Groove cladding of valve – 4 to 5 No of run 12
7 Cleaning the groove surface after each run 0.5
8 Unload the Job & reverse the valve body for bottom surface cladding 1
9 Clamp the Job 0.2
10 Press Cycle Start 0.25
Bring the Induction coil to heating position using the swivel
11 0.25
bracket & Induction slide
12 Preheat the Valve Face using induction Heating 15
13 Groove cladding of valve – 4 to 5 No of run 12
14 Cleaning the job surface after each run 0.5
15 Unload the Job on the machine using dedicated jib crane 1
Total Time (In Min ) 5.4 30 24
Total Time (in Min for one valve body+ Non Value added time ) 60 (59.4)
No. of Valve body per shift ( 8 Hour shift ) 8
No. Valve body Per Days ( 3 Shifts ) 24
Note: - Filling up of Flux , Loading the Wire, Preheating of Flux etc are not included in our timing Calculation .Time Calculated is actual time of Page 3/4
operation. Pre-processed Valve should be stored near each station.

Work Address:- Contact Us:-

Gala No.62, Parmar Industrial Complex, Email:- info@unikraft.in,unikrafttechno@yahoo.in
Survey No.142/1, Chinchwad, Cell:- +91-9552592593 / 9922535540
Pune 411019. Tel. No.:- 020 27452593
Web.:-www.unikraft.in
 UNIKraft Techno LLP

VALVE CLADDING SYSTEM

BENEFIT OF VALVE CLADDING SYSTEM:-
The benefits of our well-engineered cladding systems range from improved weld quality to
decreased variable labor costs. The most prominent advantages are:

1. Improved Weld Quality: Our Mechanized welding system improves the welding
consistency and repeatability.

2. Increased Output/Volume: Production weld speed is decided by the machine's capability.

It does not deteriorate with Welder's fatigue. With minimized part set up time, and higher
weld speeds, the output is increased.

3. Decreased Scrap / Rework: Since the Welder's skill is not required, there will be less
chances for the mistakes & rework.

4. Decreased Variable Labor Costs: Reliance on human welders dramatically increases a

manufacturer's labor costs. Welding is a Hazardous Occupation. UV Flash, fumes,
Electric Shock, sparks and heat make manual welding a taxing and hazardous job. Nowadays,
getting a skilled welder is becoming more difficult due to other options available for their occupation.
The Human welder's skill and concentration deteriorates from the beginning of the shift towards
the end of the shift. With Auto welding, the Occupational Hazard as well as the demand for a
qualified welder is reduced. Insurance and accident related costs are reduced considerably.

OPTIONAL FEATURES WE OFFERED WITH MACHINE AT EXTRA COST:-

· Separate Standalone Induction Pre Heating System for Pre Heating Valve up to 250 Deg to reduce
the cycle time.
· Integration of Control panel with Welding Machine to control the Welding current & Voltage.
· Weld Protection Curtain for MIG cladding application – to avoid the Hazardous UV light from affecting
the other workers working nearby.

Please send your enquiries to the following address, for further details & our immediate response.

Page 4/4

Work Address:- Contact Us:-

Gala No.62, Parmar Industrial Complex, Email:- info@unikraft.in,unikrafttechno@yahoo.in
Survey No.142/1, Chinchwad, Cell:- +91-9552592593 / 9922535540
Pune 411019. Tel. No.:- 020 27452593
Web.:-www.unikraft.in