SOW WAAM Cell.pdf

SOW

Project Overview:

Rock Island Arsenal Joint Manufacturing Technology Center (JMTC) currently has a Genesis Robotic cell set up for Direct Energy Deposition. The objective of this service is to update the Digital Twin to make a replica of the physical Genesis DED system that integrates Lincoln Hyperfill Technology and Powermill CAM software. Also calibrate the Powermill digital twin model and validate the Powermill post processor functionality, and finally demonstrate on the Genesis cell a single bead weld on plate that validates both the powermill and Lincoln Hyperfill Technology.

Task 1 – Update the Genesis System DED Digital Twin Model and Post- Processor Update the digital twin model for the JMTC system with Lincoln’s HyperFill technology. Digital twin will be a digital replica of the physical Genesis System’s Fanuc robotic welding system.

Task 2 – Genesis Robotic DED System Calibration

• Perform a series of tests to calibrate the digital twin to the physical system.

• Testing robotic and welding system functionality and verifying components (robot, positioner, collision sensor, welding torch (HyperFill), cleaning station, etc.) geometric and move configurations.

Dry runs will be used to calibrate the digital twin for each robot drive axis coordinates and move control. A single bead on plate weld will be for a simple calibration build that demonstrates tool point accuracy and repeatability.

Task 3 – Reporting and Communication

• Monthly project teleconferences

• Microsoft PowerPoint summary final report

Deliverables

• Microsoft PowerPoint-based report

• Updated PowerMill Digital Twin

• Calibrated work cell

• Backups of all systems (before and after)

Expected Outcomes

• Add the Lincoln HyperFill technology to JMTC’s Genesis robotic welding system to expand their DED AM system and establish test-bed capabilities

Key Assumptions

• JMTC will ensure that the Lincoln HyperFill system is installed onto the robotic system, validated, and all parts changed from the last digital twin update are provided to the contractor before traveling on-site.

• JMTC will supply a staff member to support on-site activities. The staff member will support the contractor who will update the digital twin and calibrate the cell.

• JMTC will provide build platform test materials and welding consumables (wire, gas, contact tips, etc.).

• JMTC will need to have at least one active seat of PowerMill Ultimate and PowerShape software to support on-going on-site operations.