Page 28 - ITAtube Journal 1 2024

Technical Papers
Thermatool Corp
Data Collection and Implementa- tion of IIoT-Enabled Equipment for HF Welding in the Tube and Pipe
Industry
Author: Olexandra Tupalo (Manager, Thermatool Labs), March 1, 2024
Introduction
Data collection and data analytics have become the new norm in most industries. Collecting and utilizing data can improve ef- ficiency, ensure quality control, and increase overall productivity. Although the tube and pipe industry has undergone significant evolution and development from its initial manual processes phase, it has yet to fully embrace data-driven HF welding operations. This article covers the aspects of data- driven HF welding operations: setup, process control, condition-based moni- toring, and preventive maintenance and troubleshooting. The article discusses
the importance of data collection during high frequency welding and how it can be related to the quality of the final product.
It also explores how the use of data can reduce human error and increase overall product yield. Additionally, this paper offers suggestions for incorporating IIoT-enabled equipment and preparing for upcoming advances in automation.
The Importance of Data Collection
Data has always been an important part of
any welding process, but in the era of IIoT and Industry 4.0 process data has moved from paper process data sheets to digital records and has become an immensely powerful tool.
With the ability to store and retrieve rich data sets, operations personnel can institu- tionalize knowledge, improve information sharing, and accelerate process improve- ments. In the past, the pace of industry development was limited by tribal knowl- edge and related human experience, as well as long learning curves. Each company has its own level of process and data knowledge.
Currently, most mills continue to rely on manual entry of weld process data on varying types of weld process datasheets (which are often company-specific). Manual data collection quickly becomes a very time-consuming task and, therefore, is often incomplete. Many companies heavily rely on their skilled operators’ expertise and have only partial data records. This can result in variations in process parameters. A robust and repeatable process cannot be operator-dependent. Advanced software technologies employing automated data collection and IIoT-enabled equipment are key to maintaining a complete data record over time. The use of these data records provides efficient and effective solutions to limit variability and keep quality consistent even when faced with high operator turn- over. Using data to drive decisions helps operators pinpoint slowdowns or other problem areas on the tube and pipe mill and contributes to profitability.
Data Collection during HF Welding
If we look at a standard tube mill, there are
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ITAtube Journal April 2024