Centre of Excellence in Welding Engineering & Technology ... Minutes/PSG/3rd PRMC PSG 16... · 6...

Centre of Excellence in Welding Engineering & Technology

PSG college of Technology, Coimbatore

Venue: Board room PSG Tech

MINUTES of the Third Project Review and Monitoring Committee meeting

held on 16th February 2018

Issue Date: 27-02-2018

The minutes of the third Project Review and Monitoring Committee meeting is presented in the

following pages.

PRMC Members present

1. Dr.G. Madhusudhan Reddy, DMRL Chairman

2. Dr.M. Kamaraj, IIT Madras, Convener

3. Shri. Sanjay Chavre SDO, DHI

4. Shri P. Ramkumar VSSC., ISRO

5. Dr.K. Shaju Albert Head Materials div, IGCAR kalpakkam

6. Dr. S. Krishnan L&T Ltd.

Members from PSG College of Technology / COEWET

1. Dr.R.Rudramoorthy Principal, PSG tech

2. Dr.P.Radhakrishnan Driector IAS, PSG tech

3. Dr.P.Gopalakrishnan HOD metallurgical engineering

4. Dr S Suresh GM, COE weding

5. Dr B Vinod PI-Tech 1, Associate Professor

6. Dr M Sundaram PI-Tech 2, Assistant Professor

7. Shri.J.Chelladurai Co-PI, Tech 2

8. Dr V Balusamy PI -Tech 3, Associate Professor

9. Dr J Krishnamoorthi Co-PI, Tech 3

10. Dr R Sivasankari Co-PI, Tech 3

11. R. Balakrishanan Sr.Engr, COE

12. Shri.Alfrin Jarvis Sr.Engr, COE

13. Shri.K.Ravichandran Sr.Engr, COE

1.0 PRMC Committee:

Due to the sudden demise of the chairman of the PRMC on 6th January 2018, Dr. Baldev

Raj, Director NIAS, the committee unanimously nominated Dr. G. Madhusudhan Reddy,

Dr. G. Madhusudhan Reddy, Outstanding Scientist, Associate Director, DMRL

Hyderabad to officiate as chairman of the committee.

The third PRMC meeting was chaired by Dr. G. Madhusudhan Reddy.

The chairman in his opening remarks stated that the past chairman has set a very high

standard to be achieved in this project and hence requested the committee & all COE

officials to give their best, for achieving the milestone plans in time.

The director of COE, and Principal PSG Tech, also paid tributes to the past chairman

Dr. Baldev Raj and said that PSG tech would make all efforts to achieve the goals set.

1.1 Overall Progress: The overall progress was presented to the committee by Dr.S.Suresh, GM, COE welding.

GM, COE stated that all the purchase orders would be placed before the end of Feb

2018. He also explained the committee that the actual realization of the budget may



happen only by end of May 2018 as there are some few long lead items that require 8 to

10 weeks time for delivery.

2.0 Finance: 2.1 Grant received & Re-apportioned budget for the second year

The details of the grant received for each of the technologies, commitments made so far

and the utilization of the funds are given below in Table-1. For effective utilization of the

funds the allocation of the funds under various financial head has been accommodated

within the allocated budget. The re-apportioned budget was considered in detail.

Table-1 Grant sanctioned &Re-apportioned budget for the three technologies for the second year (2017-18)

Tech -1 Tech-2 Tech-3

DHI 240,00,000 137,00,000 218,00,000

Industry Contribution 61,00,000 37,00,000 62,00,000

Total 301,00,000 174,00,000 280,00,000

Sl.no Sanctioned Heads Re-apportioned budget for the 2nd year Rs.

1 Equipment 226,65,000 138,35,439 160,13,983

Recurring

2 Salary incl. Honorarium 46,00,000 24,54,561 57,86,017

3 Travel 3,00,000 1,00,000 3,00,000

4 Outsourcing 16,00,000 4,50,000 5,00,000

5 Maintenances 1,00,000 50,000 2,00,000

6 Consumables 5,50,000 3,00,000 50,00,000

7 Books, Standards and Journals 1,50,000 1,50,000 25,000

8 Contingency 1,35,000 1,00,000 1,75,000

TOTAL 301,00,000 174,00,000 280,00,000

After deliberations, the re-apportioned budget was considered as the total budget still

remains the same and the changes were of the order of up to 10% that may arise to cover

for the cost escalation and euro/dollar variations.

PRMC approved the re-apportioned budget for the second year as given in Table-1.

3.0 Procurement:

3.1 Status of the procurement for the second year

As on date 50% of the Purchase orders required for the three technologies have been placed.

The list of items to be procured for the three technologies 1,2 & 3 is given in Table-2,3,4

respectively. The list of items were scrutinized and considered for approval.

PRMC approved procurement of items listed in Tables 2,3 & 4 for the second year.



3.2 Approval for proprietary items:

In view of the proprietary nature of the some of the items and to meet certain specific/unique

technical requirements, the following equipments are to be procured from single proprietary

source.

List of items

No Description of item Nature of the item Remarks

1 Advanced TIG Welding Tech-2; Proprietary, Single tender through authorized distributor.

EWM, Germany

2 OPAL software Tech-2; Proprietary, Single tender through authorized distributor.

OPAL RT technologies, Bangalore

3 Spares & consumables for Gleeble

Tech-3; Single tender through Original equipment supplier.

Dynamic systems Inc. USA.

The proposal to purchase the above items through single tender was agreed in principle

by the committee. However, the committee ascertained that recommendations may also

be got from the technical and purchase committee with an additional expert member and

ratified by Governing council.

3.3 Procurement Process through partner organizations to protect IP rights:

For development work being carried out jointly with the industry/MOU/PSG-STEP partners,

certain specific components/equipments are required to suit the design of the equipment/system

being developed by COE. In addition, it is also not feasible to publicize the specification details

of the components/equipments to protect the IP rights.

So, it is proposed to purchase part of the components/equipments required through single

offer with these registered partners. The expenditure of these items would be covered thorough

industry contribution.

It was resolved that the above items may be procured through single offer basis with the

recommendation of the technical and purchase committee and an additional external

expert member and ratified by Governing council.

4.0 Technical Progress/Status of the Technologies:

The various development tasks identified for each of the three technologies and the progress

was presented by the Project investigators of the three projects. The progress presented

through milestone plans for the three technologies (Annex 1,2,3). During discussions the

following comments were given by the committee.

❖ It was suggested that a techno-economic report be made highlighting the comparison

between the existing machines and those that are being developed for SPMs.

❖ It was decided to invite the industry partners for the PRMC meeting.

❖ It was also suggested that material specific wave forms may be generated to solve

welding of new alloys.



❖ The chairman suggested that CoE can organize a one-day workshop on Effect of

material specific welding wave forms &their effect on metal transfer modes.

❖ He also commented that the mechanized stick welding machine is a good step towards

automation.

❖ The DHI representative suggested that CoE may explore organizing an exhibition jointly

with welding institutes/societies periodically& probably with IIW at Kochi in 2018 and

IWS 2k18 exhibition cum seminar at Mumbai in Nov 2018.

❖ The DHI representative also suggested that CoE should also participate in International

exhibitions like Hannover fair at Germany being organized in April 2018 etc.

❖ The director stated that COE can conduct an annual exhibition cum seminar jointly with

welding society at PSG tech at Coimbatore.

The developments were also demonstrated at the Centre. 5.0 Visits Planned abroad for specialized training & technology updation:

It is planned to depute senior COE staff and PI/Co-PI’s: to participate in advanced training at

EWM Germany in March 2018 as a part of worldwide customer Training program being

organized by EWM Germany. The expenditure for travel would be met through budget head of

Technology-3.

It is also proposed to depute senior COE Staff/Pi /Co-PI in March-April 2018, to visit Fronius,

Austria & KEMPPI, Finland for discussions to establish long term R&D co-operation & Brucker

Germany for Inspection/training of the NOH equipment. The expenditure for this travel would

be met through travel head of technology-1.

The committee approved the visits.

6.0 Recruitment process:

To compensate attrition (four staff members) & to speed up the developmental work, the

following persons have been recruited in three technologies after last meeting.

Sl Person name Tech. area

1 Yuvaraj-JRF, Raj Kamal-Tech. Assistant, Rathna Kumar-Technician Tech -1/ 3

2 E. Sriram-JRF, M.Mohanraj-JRF Tech -2/ 2

3 P.Dhavamaniraja-Sr.Engg., Gokul-Senior Engg.,U.Velmurugan-Lab Asst, Tech -3/ 3

The committee recommended the recruitment of the above staff members for formal

approval by Governing council.

7.0 Training Programs:

As planned in the DPR, Certified training programs have been duly commenced in the fourth quarter of

2017. The certification (training) programs conducted, seminars organized and attended were presented

to the committee.

The committee commended the above proposals.



8.0 Consultancy services:

To make available the facilities & expertise to industries, consultancy work has been commenced since last quarter of 2017. Some of the major customers served are given below:

Company Technical details Status

1 KAIRALI steels & fabrication,

Cochin

On the job training for Engineers, Supervisors

&Welders

Completed

2 TATA STEELS, Jamshedpur Training to Tata Steel executive on coated steel Completed

3 ANDRITZ, Chennai Establishment of Quality system for ISO 3834. Completed

4 ATLAS COPCO, Bangalore. Specialized training in Weld design Completed

5 L&T Defense/ Pune L&T Talegaon Pune/cracking of Al weld joints. Completed

6 Cochin ship yard, Kochi Training on Total Welding Management system Completed

7 Craftsman Coimbatore Failure Analysis of cracking in Diesel Engine casing. Completed

8 BEML, Palghat and Bangalore Establishment of welding procedures for new materials Enquiry stage

9 ELGI ULTRATEX Coimbatore Welding design of chassis of textile machinery Under progress

10 HMT Kalamaserry, Kochi Distortion analysis and control in DSS chute welding. Offer submitted.

The committee commended the above interactions with industries.

9.0 Plan for 2018-19:

❖ It is planned to complete the procurement and development activities as outlined in the

Milestone plan for the second year.

❖ It is planned to complete the procurement process by end of Feb and place all orders so

that the purchase activities for the second year can be completed by end of March 2018.

❖ It is planned to conduct a "International Workshop on Arc Welding Power Source

Testing and Quality Evaluation” in the month of Feb 2017 with Prof. Dietrich Refeldt

&Dr. Markus Refeldt of Germany, experts on power source testing and evaluation.

10.0 Other matters: 10.1 Memorandum of understanding:

To establish networking arrangements with major manufacturers and professional

institutions, an MOU was signed with M/s KEMPPI India Pvt Ltd.

10.2 Proposals for Phase II(extension) of the project:

To develop additional products / technologies in the three technology areas as a

part of Phase II scope and to extend the reach to industries, it is proposed to submit the

following proposals.

1 IOT based Welding automation& management system development Technology-1

2 Center for testing & evaluation of advanced welding power sources Technology-2

3 Development of special FCAW wires for hard facing Technology-3

The committee asked the COE to prepare a DPR and submit the same to DHI.



10.3 Tables and Annexes:

Table-1 Grant sanctioned &Re-apportioned budget for the three technologies for the second year (2017-18)

Tech -1 Tech-2 Tech-3

DHI 240,00,000 137,00,000 218,00,000

Industry Contribution 61,00,000 37,00,000 62,00,000

Total 301,00,000 174,00,000 280,00,000

sl.no Sanctioned Heads Re-apportioned budget for the 2nd year Rs.

1 Equipment 231,50,000 136,00,000 165,00,000

Recurring

2 Salary incl. Honorarium 46,50,000 25,50,000 57,00,000

3 Travel 4,50,000 2,00,000 2,50,000

4 Outsourcing 10,00,000 4,50,000 2,00,000

5 Maintenances 1,00,000 50,000 2,00,000

6 Consumables 5,50,000 3,00,000 50,00,000

7 Books, Standards and Journals 1,00,000 1,50,000 25,000

8 Contingency 1,00,000 1,00,000 1,25,000

TOTAL 301,00,000 174,00,000 280,00,000

Table-2 List of items to be procured in second year for Technology-1

DESCRIPTION PO/est. value

1 Laser seam tracking system 34,94,908

2 Software for Welding Simulation 8,02,400

3 Computational facilities for the above software 3,50,000

4 Simulation Software for Industrial Robot 2,35,410

5 Homogenous Multiple Gas Manifold and Gas Mixing System 19,16,910

6 MIG-MMA Digital Welding Power Source 350A suitable for Robot Interfacing 16,82,562

7 Six Axis Industrial Application Welding Robot with Welding Power Source 31,62,400

8 Weld Filter Mobile Extraction Unit, Filter & Double Arm for Fume Extraction 4,42,387

9 Weld Table with Two Axis Rotator 4,59,610

10 Gear box for arm-1 1,31,300



13 Gear box for arm-4 72,150



16 Display or Projector for Tech-1 1,42,025

17 Pillar Drilling Machine 59,000

18 Hydraulic Pallet for Material Handling 35,000

19 Electrode Testing Machine Model 2 2,00,000

20 Fanuc Robot Taxes 2,97,000

21 Packing and forwarding for FANUC robot 50,000

22 Sigmund Welding Table, Wiring and Programming 2,30,000



23 Robot pedestal, Chemical anchoring, Fences, Safety Switch, Floor Cable Trays 2,48,000

24 Sigmund welding clamps, Stabilizer for Robot 2,48,000

25 Interfacing of FANUC Robot with weld table and safety switches 1,20,000

26 UPS for FANUC Robot 1 1,50,000

27 UPS for FANUC Robot 2 1,50,000

28 Manipulator of Axis - 4 for Cartesian Robot 2,50,000

29 Manipulator of Axis - 5 for Cartesian Robot 2,50,000

30 Power Source and Wire Feeder for Left side Torch of SPM-1 2,00,000

31 Power Source and Wire Feeder for Right side Torch of SPM-1 2,00,000

32 Power Source Interfacing Card for Developing Robot 2,30,000

33 Power Source Interfacing Card for SPM – 1 2,30,000

34 Weighing machine for checking cylinder weight 50,000

35 Cartesian robot model for length Measurement 1,00,000

36 Fixturing Arrangement for Welding Table 1,50,000

37 Robot Controller Development 64,277

38 Hydraulic Pallet for Material Handling 50,000

Total 168,30,664

Table-3 List of items to be procured in second year for Technology-2

Item Description PO/est. value

1 AC/DC Probe 1,03,722

2 3-Phase Three-Level Three-Switch PWM Rectifier Module 2,10,000

3 Diode Bridge Rectifier with capacitor voltage filter 2,00,000

4 Electromagnetic Filtering Unit 2,00,000

5 Hardware Integration of the Vienna PFC stage with Rectifier 2,00,000

6 High Rated Casing for Welding Power Source Unit 1,50,000

7 HMI Module for Welding Power Source 2,10,000

8 Front End User Interface Control Module 1,20,000

9 Wire Feeder Processing Unit 2,00,000

10 Wire Feeder Controller Module 1,50,000

11 High Voltage Power Generation Modules 2,10,000

12 PWM generation unit for TIG welding power source 2,10,000

13 HF transformer TIG welding power source 2,00,000

14 40 W DCM Fly back converter 1,00,000

15 40 W CCM Fly back converter 1,00,000

16 200W Synchronous Buck converter 1,20,000

17 500W Boost PFC converter 2,00,000

18 Phase shifted full bridge IGBT inverter with PWM triggering board 1,94,700

19 Fast ADC module with CT/PT input and PI DSP controller board 1,88,800

20 Three phase planer passivated power bridge with filter & PFC board 1,82,900

21 Hybrid dual channel IGBT driver with integrated potential free power supply 1200v DC bus voltage 2,18,182

22 Servo wire feeder board with current feedback input- 2 Nos 2,00,600

23 SPI protocol-based input parameters tuning & HMI display for current & voltage 2,53,700

24 Ferrite modulated core based high frequency transformer with PTC mounting -2 nos. 88,618

25 Metal enclosure for printed circuit board assembly with trolley-2’x2’x1’ 59,000

26 OP4510 Real-Time Simulator 19,88,848

27 Resistive Test Load 2,08,860

28 Power Source - 2 Nos 35,00,000

29 HF/HV Differential probe 1,26,119



30 Current probe, 500A rms AC/DC, 2MHz 4,28,104

31 100MHz/30 Arms AC/DC Current Probe 2,47,910

32 Power Supply for the N2780-83A/B Current Probe 1,10,059

33 Magnetic flux meter (B) with accessories 2,75,000

34 BH curve tracer 15,00,000

35 Miscellaneous Item 8,55,295

Total 135,10,417

Table 4-List of items to be procured in second year for Technology-3

Sl.no Item Description PO/est. value*

1 Oxygen, Nitrogen and hydrogen analyzer 71,00,000

2 Welding Power Sources, demo table, welding simulator 39,00,000

3 Dedicate Thermo-Mechanical Analysis software for welding 33,30,007

4 Computational facilities for the above software 3,50,000

5 Universal Testing machine 15,02,140

6 Miscellaneous equipment 3,20,000

165,02,147



Annex -1 GANTT chart for Implementation for Technology-1[2016-17 & 2017-18] Development of Automated Welding System

Activity 2016-17 (Apr-Mar) 2017-18(Apr-Mar) Remarks

Time frame A

P R

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

JAn

FEB

MAR

AP R

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

JAn

FEB

MAR

1 Literature survey Completed

2 Recruitment of Research Associates

To take care of attrition

3 Visit to Industries 80%

Completed

4 Identifying cost effective sub system

85% Completed

5 Procurement of sub deliveries for development and capability building

5a First phase

Completion

by June as approved by 2nd GCM. after budgetreapport

ioning

5b Second phase

6 Development of Prototype

6a

Designing the prototype SPM-1

Nearing Completion

6b Designing the prototype SPM-2

75% Completed

6c Designing the prototype Articulated robot

I In progress

6d Designing the prototype Cartesian robot

Three axis Completed

7

Modeling and analysis of control system

Identified and controller development in progress

8 Development of fabricated sub systems

8a

SPM-1

Nearing completion

8b

SPM-2

75% Completed

8c

Articulated robots(R1 & R2)

R1. Design in progress

R2- completed

8d Cartesian robot Three Axis

Completed,

Additional two

axis design

and

fabrication in



progress

9 Firmware development

9a SPM-1

Existing Controller used

9b SPM-2

70% Completed

9c Articulated robot

Study in progress

9d Cartesian robot

90 % Completed

10

Identification and algorithm development for interfacing of generic controller

In progress

11

Integration of all subsystems with a welding machine platform

80% of Welding power source and Laser seam integrated

12

Testing at any one capital goods industry equipment manufacturer site.

In progress With RMD,HED and Angamali

13

Patenting of the development for SPM-1, SPM-2, Cartesian & Articulated robot.

In progress

16

Documentation and submission of results and reports

In progress

17

Transfer of technology to industries for product commercialization

In progress

Planned as per DPR Completed Would be completed as per plan



Annex-2 GANTT chart of milestone Plan for Technology-II [2016-17 & 2017-18] Development of Intelligent Welding Power Supply System with waveform shaping Techniques

Activity 2016-17 (Apr-Mar) 2017-18(Apr-Mar)

Remarks

Time frame AP R

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

JAN

FEB

MAR

AP R

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

JAN

FEB

MAR

TASK I

1 Literature survey Completed


Completed

3 Visit to MSME Industries To Explore the Recent Technology

To Explore the Recent Technology

4

Conducting the power quality survey Scope has been identified and needs improvement in Power Quality Related Issues in welding system.

Scope has

been

identified

and needs

improveme

nt in Power

Quality

Related

Issues in

welding

system.

5 Identifying the cost-effective method

Completed

6

Purchase of Equipments and Software: Completion by June as approved by 2nd GCM. after budget apportioning

PO’s for

second

year

budget in

progress

TASK II

7

Developing the design tool for different welding power systems

Completed

GTAW Power Source GMAW Power Source

8

Modeling and Analysis of intelligent adaptable welding power systems

Completed


9

Modeling and analysis of Harmonic solution circuits for welding power systems

Completed




10 Design and Optimization

GTAW

Power

Source completed

GMAW

Power

Source

in

progress


TASK III

11

Developing a smart control scheme through series of recursive algorithms using soft computing techniques to meet the Intelligent Adaptable Power Source

GTAW Power Source 60% completed GMAW Power Source in progress

GTAW Power Source GMAW Power SourceThe software kit was recd only by end of May. To be started from June 17.

12

Design of hardware components and associated circuits for sensing and controlling circuits

GTAW

Power

Source

completed

GMAW Power Source in progress


13 Interfacing of Intelligent embedded controller with power devices

GTAW

Power

Source

completed

GMAW

Power

Source

in

progress

GTAW Power Source

GMAW Power Source

14

The characteristics of HF Transformer, Common mode Chokes, XY capacitors are to be tested to meet the IEC

Completed



power quality standards


15

Integration and testing of developed power system with automatic welding machine

GTAW

Power

Source in

progress

GMAW Power Source IN Progress


16 Improvement of control algorithms based on the test results if required

GTAW

Power

Source

in

progress

GMAW

Power

Source

in

progress


TASK IV

17 Documentation and submission of reports

18 Apply for patents

19 Transfer of technology to MSME for product commercialization




Annex-3 GANTT chart of milestone Plan forTechnology-III[2016-17 & 2017-18] Alloy Design by Welding Simulation and Analysis for development of new welding

electrodes and filler metals Activity 2016-17 (Apr-Mar) 2017-18(Apr-Mar) Remarks

Month no starting from Apr to Mar.

AP R

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

JAn

FEB

MAR

AP R

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

JAn

FEB

MAR

1 Readiness of Land / Building for project

Second building in progress


3 Visit to Industries 75% completed

4 Purchase of equipments and Software

PO’s for second year budget in progress

First Phase

Second phase

5

Erection and commissioning of equipments.

Erection and commissioning of equipment’s completed

6 Modeling and analysis using computational methods

Alloy design using Thermo-Calc in progress

7 Physical simulation studies using simulator

Simulation studies for nickel in progress

8 Electrode & filler metal making (extrusion)

Extrusions are done using pilot plant (In-house)

a Nickel electrodes Prototype electrodes have met AWS Chemical requirements.

b Duplex Ss electrodes c Hard facing electrodes d HSLA electrodes e Chrome-moly

electrodes

9 Characterization and testing of electrodes.

In progress for prototype electrodes

10

Electrode and filler metal fabrication

Procurement of consumables in progress. Pre mixed powders are outsourced

11 Patenting

12

Documentation and submission of results and reports

13

Transfer of technology to industries for product commercialization



14

Procurement of equipments and training ware for skill development

Phased array, UT procured. PO’s for power sources in progress

15

Commencing skill development programs

IWS Fresh engineer and NDT courses were conducted


******************End of Minutes of PRMC-3 document *************************

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