IR4

Automated Idler Rebuild Solution

OUR Projects

Automated Idler Rebuild Solution

OUR Projects

Automated Variable Surface Profile

Efficient & Fast Induction Heating

Modular System Flexibility to meet budget &restraints

Significant Productivity Gains up to 3X

Automated Idler Rebuild Solution

The IR4 team engaged with Hastings Deering – Mackay, to provide a solution that could meet and exceed the challenges with rebuilding various track Idlers.

Through collaborative, innovative design, and utilising in-house IP, the IR4 team provided a system that has the capability to handle a full array of different sized idlers with individual wear profile variations.

The system provides significant productivity gains, not least of which is the minimal operator requirement which frees up skilled staff to be utilised elsewhere.

IR4 would be pleased to provide a comparative ROI analysis with your current operation.

THE JOB
  • Provide a solution that removes the requirement for the operator to be present the entire process
  • Eliminate exposure to open flame gas heating pre-heating
  • Build system that accounts for a full array of Idlers and individual wear profiles.
  • Eliminate exposure to dust associated with flux from the SAW process
  • Rebuild worn profile back to manufacturers specification with minimal operator intervention
  • Significantly improve efficiency and productivity
SCOPE OF WORK
  • Efficiently and safely heating Idler to Pre-weld temperature
  • Maintaining inter-pass temperature while rebuilding
  • Scanning uneven wear profiles and automatically generating weld paths based on wear
  • Rebuilding uneven tread and sidewall surfaces to manufacturer specification without manual intervention
  • Automatically Welding of Idler Bore and Bore Face
  • 2 Axis Rotator integrated into system
  • Eliminating the requirement for the operator to be stationed at the process removing exposure to fume and dust
  • Automated grinding capability providing solution for cleaning up the outer edge of Idler post rebuild
  • Track Roller rebuild capability
  • Automatically handling of Idlers from staging to rebuilding to post cooling area requiring no manual handling
  • Provide solution for post-rebuild controlled cooling
  • Significantly improve overall rebuild times while creating safe working environment
  • System KPI’s including:
    • Reducing pre-heat time
    • Reducing skilled labour requirement and hours operator is present during rebuild
    • Cycle time of Idler rebuild including pre-heat
    • Quality of finish in accordance with Manufacturers specification
MODULAR SYSTEM FLEXIBILITY
The Standardised IR4 Idler Rebuild Solution comes in modular format, giving smaller customers a viable solution that still offers many of the system benefits and capability can be added at a later date if required. The IR4 team realise that not every operations has significant volumes so have designed the system to also be viable for smaller operations
Standard System:
  • Fixed Pedal Stool Robot + 185 degrees – 185 degrees
  • Single Axis Rotator
  • Welding Equipment
  • Scanning
  • Parametric Programming
Added Capability:
  • Induction Heating
  • 2-Axis Rotator
  • 2 x 2 Axis Rotator on 7th Axis Track
  • 3D Scanning
  • Automated Grinding
  • Material Handling up to 1T
Added Capability Outside of Idler Rebuilds:
  • Further programming to potentially weld other parts
  • Laser Ablation
  • Laser Welding
  • Automated Tungsten Feeding
THE DELIVERABLES
  • System capable of processing up to 6,000 series Idlers
  • System that eliminates the need for open flame pre-heating
  • System that goes away from traditional Sub-Arc & Flux
  • Provides significant productivity improvements and isolates the operator from the process
  • Automatically calculates weld paths based on wear profile with  manual intervention
  • Provides high deposition rates and high-quality welds with no requirement for machining
  • Capable of repairing bore and bore faces without manual intervention
  • Provides solution for handling of the Idlers before and after rebuilding
  • While Idler is being rebuilt enables operator to be completing other tasks freeing up skilled staff
  • Capable of welding tread sidewalls with no manual intervention
  • Provides significant ROI compared to current process
Entrie Idler System