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Innovative low-cost technologies for manufacturing high-strong metal structures

Innovative low-cost technologies for manufacturing high-strong metal structures. Project Manager: Muravjev Ivan. Voronezh 2014. Basic concepts and definitions.

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Innovative low-cost technologies for manufacturing high-strong metal structures

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  1. Innovative low-cost technologies for manufacturing high-strong metal structures Project Manager: MuravjevIvan Voronezh2014

  2. Basic concepts and definitions. This innovative technology developed for the ribbed panels (mikropaneles) and profiles, which  widely used in building of long welded structures, shipbuilding and construction of bridges. The basic problems in the manufacture of these constructions consist in increase the strength characteristics of the load-bearing structures with lowing deformation products after welding to the level of allowable values.

  3. Press portal 1. Assembly and glove ribs to the sheet with a preliminary pressing of. 2. Automatic welding ribs to the sheet with a preliminary inverse deflection. Welding tractor Abrasivedisk 3. Scraping weld in places tacks. Basic technology At this time the basic technology of assembly and welding ribbed panels is multistage, laborious and consists of the 7 operations, including:

  4. Basic technology 4.Правка продольных и поперечных деформаций. Edit the longitudinal and transverse deformations gas burner gas burner

  5. Innovative technology 2. Welding simultaneously 2-3 ribs portal installation Consists of two operations: 1. Fixation and loading ribs in the stand.

  6. The increase static and fatigue strength is achieved due to the significant reduction: 1.Internal stresses (no pot and thermomechanical edits after welding) 2.Stress concentrators (the absence of lack). Stress concentrator Stable Gap

  7. Photo prototypes Lack of penetration (existing technology)- is the area of the weld compound with no alloying between the welded parts, i.e. defect. Area full penetration (innovative technology)- this is an area with penetration weld joint between the welded parts, i.e.without defect

  8. Scientific innovation The scientific component of the project is the introduction of the mechanical load of ribs by the special scheme, providing compensation welding deformations directly in the process of welding. The high dependence of deformations from potholders ribs to grazing sheet has defined its replacement by commit ribs relatively sheet at the special stand. Innovative technology and installation allow you to give the optimal gap between the leaf and ribs, it provides full penetration in the connection between the edge and the sheet, and consequently, increase of static and fatigue strength.

  9. The results of introduction of innovative technologies -Increase of static and fatigue strength of load-bearing structures in 2 to 4 times or decrease in weight; -Reduction of labour input of manufacture of panels 6 times; -Reducing the cost of its production in 2.3times;-Reduction of production space in 3 times; -Improvement of sanitary and hygienic conditionslabour;-Ease of installation of structures through increase accuracy of manufacturing of incomingdetails.

  10. At the moment 1.The technology is protected by patentRF. 2. Manufactured by experienced tooling and put into production 96 real bridge structures. There is an act of implementation 3.The positive conclusion of an independent examination of the «Agency for innovation and development». 4. Innovative technology has no analogues in the world. 5. Positive feedback were got from two central design offices of Sevastopol «Chernomorets» and «Coral».

  11. Prospects for further development of innovative technologies 1. Robotic equipment for automatic welding of complex cross-panel set; 2. Ability to manufacture panels with small curvature (important for shipbuilding); 3. Replacingextrusionscheaperwelded.

  12. COMPETITORS * IMG launches production lines for the manufacture of panels for the old technology with all the above negative moments.

  13. Market • Customers • shipyards • bridge-buildingplants • factoriesofmetalconstruction TheRussianmarketis morethan 140 plants.

  14. Financial Model - the breakeven point of the project (mln.r) Based on the calculation of breakeven point that the planned production volume of innovative installation LLC "Stroyinpromteh" in 2014-2018gg. provides a cost-effective operation of the project, making a profit and payment of current liabilities.

  15. TEAM Manager – Economist, Popova V.A. Deputy. Director, Lawyer Kornev S.U. Director, Ph.D. Muravjev I.I. Estimator - prochnist, Ph.D., Sventikov A.A. Deputy. Director new technologies Podvalnyy M.L.

  16. TEAM OF THE PROJECT ООО «Стройинпромтех» ООО «СпецСтальТехМонтаж» «Воронежский ГАСУ» In collaboration with ОАО «Электромашиностроительный завод» (Симферополь) ООО «Велдинг Групп» (Самара)

  17. THANK YOU FOR YOUR ATTENTION!

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