Transforming Indian blue chip companies with Indian technology that is a curve ahead of the curve

On Sep 25, 2013

We have re-written the rule books earlier and we are re-writing the rule-books even now with
Mega leaps in Technology.

by Hughen, Chairman, Plazma Technologies Pvt. Ltd.

Industries based on metal fabrication across the globe need robotized systems to survive, thrive and be competitive. In the automotive industry, Toyota’s use of robotic production systems has been copied throughout the auto industry and exemplifies the transformative economic power of robotized systems. In the fabrication industry, prohibitively expensive manual labour has traditionally been the only way to deal with the shortcomings of 2D drawings, varying raw material dimensions and damaged raw material through costly rework and repeated production interruptions. Recently, recession-driven price undercutting among fabricators and loss of global projects to competitors from low-labour cost countries is driving companies towards robotized automation.

Plazma Technologies Pvt. Ltd. is a customer dedicated Innovation company in India with the focus in mind to make its customer an equal player with an unequalled edge using ROBOPLAZMA™ System. We have re-written the rule books earlier and we are re-writing the rule-books even now with Mega leaps in Technology. We at Plazma respect sheer ‘Customer Innovation’.

Robotic Plasma Cutting System – RoboPlazma
Plazma’s Robotic Plasma Cutting system is made of standardized configurable robotic modules with unique proprietary software and patented high performance plasma torches. Successfully proven on shop floors with over 30 customers in India, and abroad. This technology is ready to be taken to a large scale global platform. We are currently growing R&D, manufacturing and software development based on a global model that leverages specific local advantages.

Award winning Roboswift proprietary software drives the world’s first intelligent and self-learning robotic plasma cutting system. It senses, adapts, and compensates for the inaccuracies associated with manual production inefficiencies. Traditionally, robots repeat a single task in a controlled environment with fixtures and highly accurate job data input. Unlike conventional robots, RoboPlazma generates new programs continuously, as required, during production. Plazma’s patented proprietary RoboSwift online software, awarded the best application idea by Kuka of Germany, senses and compensates for raw material variations and inaccurate data input using a floating data base that digitizes the cutting job.

Roboplazma Universal Structural Steel Profiler :

Case Study – I
India’s largest offshore platform fabricator, L&T achieves payback in 2 months.
Offshore platform of 25,000 tons costing over Rs.500 Crores

Challenge

Manual beam cutting of mouse hole took 3.5 hours
Project running behind schedule

Roboplazma Solution

Beam cutting time reduced to 15 minutes
Project went ahead of schedule following two months of production with Roboplazma

Roboplazma Measurable Business Value

1,400 Beams cut in record two months at 15 min per beam
Beam nesting saves a phenomenal 2% – 5 % raw material cost
World’s first ever plasma torch mouse hole profile cutting
Smarter software & hardware with complete material handling system
Program creating in just three mouse clicks requiring zero programming skills
Multiple profile processing including beam square tubes, channels, angles & large plates

For India’s largest offshore platform fabricator, the payback was just two months. RoboPlazma Universal structural steel profiler system is ‘The ideal solution’ for the small, medium and large fabricators that are looking for A single machine solution to fabricate Beams, Channels, Angles, Tubes, Pipes and also have Plate processing covered with the same machine. It also eliminates the high capital, training, and servicing costs for maintaining multiple machines.

The RoboPlazma™ system helps you to :

Eliminate manpower attrition affecting your fabrication output
Eliminate material handling problems which create a logistic nightmare with your production and delivery schedules
Eliminate labour-intensive and time-consuming processes such as sawing, drilling, coping, grinding, manual lay-out and marking for fit-up
Eliminate Your dependence on skilled labor

RoboPlazma Universal Structural Steel Profile Cutting Applications

Processing of Beams, Columns, Channels and Angles
Nesting of jobs for higher utilization of material
Produces all Standard & Non standard Cope
Produces Miter Cuts, Compound Miters & Double Compound Miters
Beam Splitting & Beam Castellation
J-Allen, Rat-holes, Close-Copes easily possible
Processing of round Pipes, Tubes without rotating
Single & Double Beveling with Root & Contour
Notching, Coating
Structural Steel Application

All kinds of structural steel fabrication can be carried out with this machine. RoboPlazma can be configured with Plazma’s internationally patented high performance plasma torches or Hypertherm and Esab plazma as preferred by the customer.

Roboplazma Hot Plate Yield Maximiser :
Case Study – II
JSL, Jajpur Roboplazma Hot Plate Mill

The World’s first robotic unmanned self-intelligent red-hot steel cutting plasma system

Embedded with a plasma torch design that performs precise metal cutting at red-hot temperatures
Mounted on an 8-axies robot
Governed by proprietary self-calibrating software that governs the operation, diagnostics and troubleshooting, eliminating the complexities of controlling a cutting system

Engineered with a systems interface compatible with current steel production systems that facilitate the line integrations process and minimizes production disruption

Advantages
Enhance Efficiency, Accuracy and Save Costs with Innovative product design & Intelligent software
1. More Efficient

Real-time Monitoring of the system’s health and performance, with self-diagnosis features that report faults, reduce the downtime for service
Interface compatibility with steel mill online systems reduces system integration time.
Fast cutting action done completely online removes the bottleneck

2. More Accurate

The system has built-in intelligence to compensate for plates’ shape fluctuations, eliminating inaccuracies in cutting
The system software can command the robot to perform multiple subsequent uninterrupted cuts in materials of different dimensions
System measures and calibrates its cutting scheme; no need for manual measurement

3. Saves Costs

Direct square cutting of hot plate on the conveyor enables faster throughput
A unique protective cloak allows the robot to perform flawlessly without damaging its inner mechanisms
Reduction in inventory costs
Proprietary torch nozzle system allows precise cuts minimizing material yield loss.
Automation eliminates the need for direct operator interaction: no safety risks associated with the processing of red hot metal

Plazma’s Mission
Our mission is to be a dominant global supplier of artificial intelligence driven, vision enhanced robots that drastically reduce manufacturing cycle times and expand the scope of RoboPlazma products beyond cutting to welding and other applications. w