Autonomous Robotic Manipulator

Autonomous Robotic Manipulators (ARM) for Ring Rolling Unit-2 Vendor's compliance (Acceptable/ Not Acceptable)

Introduction: HAL, Foundry and Forge Division requires implementation of automation systems for hot part handling by Autonomous Robotic Manipulators for both 4000 ton press and Ring Rolling Mill for manufacturing of seamless rolled rings at Ring Rolling unit-2. Seamless rolled rings are manufactured in Ring Rolling Unit -2 using a 4000-ton press and a Ring Rolling Mill. The 4000-ton press makes ring performs, and the Ring rolling mill carries out ring rolling operation to make seamless rolled rings. These Autonomous Robotic Manipulators shall carryout automatic loading of parts into the furnace from loading tables, transfer of hot parts from the furnace to 4000 Ton press/ring rolling mill and also to unload the parts after completion of forging/rolling.

Supplier shall carry out design, supply, installation, commissioning, integration, and prove out of the following: 1) Autonomous Robotic manipulators(ARM) with rails for handling of hot parts of Ring Rolling mill and 4000 Ton press as per below specifications 2) Loading stations: One Loading station for each manipulator 3) Two unloading stations for each manipulator 4) Necessary control panels, operator station with an industrial PC along with software for each manipulator 5) Integration of each ARM with 3 existing furnaces and also provide scope for the addition of another two furnaces. Layout of the Ring Rolling Unit, consisting of Ring Rolling machine and 4000 Ton press with indicative positions of furnaces is attached at Annexure-1 for reference.

Detailed requirements for each manipulator are given below.

1 Autonomous Robotic manipulator for Ring rolling Mill

1.1 Supplier shall carry out design, supply, installation, commissioning, integration, and prove out of the following: 1) Rail bound Autonomous Robotic Manipulator (ARM) with rails for handling of hot parts ( ring pre-forms/ semi rolled rings/ finish rolled rings) to and from high-temperature furnaces Ring rolling mill. 2) Loading station:- for automatic loading of parts to the furnace by ARM. 3) Two unloading stations for unloading parts from the ring rolling mill. 4) Necessary control panels with an industrial PC, along with the required software. 5) Integration of ARM with existing furnaces and also provide scope for the addition of new furnaces. Layout consisting of Ring Rolling machine with indicative positions of furnaces is attached at Annexures-2 for reference. The layout can be re-arranged subject to feasibility at the site for improvement of performance of the machine.

2 Operations to be performed by the manipulator of Ring Rolling

2.1 Manipulator to pick up the parts from the loading platform and place them inside the furnace as per the furnace loading plan selected by the operator.

2.2 After pre-heating of parts for a defined time, the robotic manipulator should pick the parts from the high-temperature furnaces. Automation control system has to open furnace door and then manipulator should enter the furnace and pick the part from the desired location in the furnace and in the desired sequence.

2.3 After picking up the part from the furnace, the Manipulator should quickly transfer the part to the press/ring rolling mill and place it accurately on the bottom die or the rolling table at the given co-ordinates.

2.4 After forging/rolling is completed, the manipulator should unload the ring pre-form / rolled ring and place it on the unloading tray in the pattern selected by the operator.

2.5 In fully automatic mode, all the operations shall be performed as per the selected programme for the full batch quantity with out the need for manual intervention from part to part.

3 Loading station

3.1 A loading station should be designed such that parts can be loaded manually by the forklift onto the loading station.

3.2 Manipulator should be able to pick parts from loading station with out manual intervention.

3.3 Loading platform should facilitate easy loading of parts onto the station/ platform without the need for precise location of parts by operator.

3.4 The loading station should have a facility to align the parts to suit proper pick-up of parts by the manipulator.

3.5 The manipulator should be able to pick the parts in the pre-defined sequence for loading into the furnace.

3.6 A loading station should consist of a conveyor where 15 parts can be loaded in sequence at one time

3.7 The loading conveyor should be able to carry the weight of 15 parts of 500 kg

3.8 Necessary sensors and integration for smooth and seamless operation is to be carried by vendor

4 Integration of manipulator with existing systems

4.1 Integration with furnaces

4.1.1 All existing furnaces are electrical resistance-heated high-temperature furnaces with operating range from 800- 1180 degrees celcius.

4.1.2 Supplier shall integrate the manipulator with the existing furnaces for the following operations

4.1.3 Loading of parts from loading station to the furnace as per pre-defined program

4.1.4 The manipulator should communicate with the furnace to receive the furnace-ready signal. Furnace ready signal is given based on two functions A. All temperature recording channels in furnace reach the pre-defined temperature w.r.t to set temperature. B. Mandatory time gap between unloading of each part for forging operation.

4.1.5 The furnace ready signal is to be obtained from the Furnace control system by the manipulator control system. Necessary communication and wiring is to be carried by the Supplier.

4.1.6 The manipulator should position itself in the best position, aligning itself to the part which has to be picked to minimize the time of furnace door opening to minimize the time for which furnace door has to be kept open.

4.1.7 The manipulator would receive a signal from a press/ring rolling mill operator to start the cycle.

4.1.8 The manipulator should give control signal for furnace door opening after receiving the clearance from the ring rolling machine or the operator.

4.1.9 After the furnace door is opened to a defined height, the manipulator should enter the furnace and pick the part from the pre-defined location as per the required sequence. Door limit switches feedback needs to be taken from the furnace control system. Additional Safety interlock to be added to avoid furnace door closing when the manipulator is inside the furnace.

4.1.10 After part is picked from the furnace, manipulator should travel to a point with sufficient clearance and give signal for door closure and locking.

4.1.11 Door opening and closing mechanism are pre-installed on the furnaces along with a PLC and vendor shall communicate between furnace PLC and manipulator.

5 Furnaces specifications

5.1 All the furnaces available in this facility are electrical resistance heated furnaces.

5.2 The manipulator should avoid contact with heating elements or furnace wall to avoid damage to the furnace and the manipulator.

5.3 The supplier should propose the best layout for the rail bound manipulator based on the available space and capacity of the manipulator.

5.4 At present two furnaces are available at press and Three furnaces at ring rolling mill for integration to the manipulator. The supplier should provide option to integrate another two furnaces to the system at both manipulators .

Dimensions of the furnaces (Indicative only)

5.6.1 Overall outer dimensions of furnace : B= 2800 mm Door width L= 2740 mm depth of furnace H= 2068 mm Total Height.

5.6.2 Furnace volume : Dimensions of the furnace cavity B= 1650 mm Door width L= 2360 mm depth of furnace H= 930 mm Height.

5.6.3 Working Volume inside the furnace: B= 1500 mm Door width L= 1800 mm depth of furnace H= 800 mm Height.

5.6.4 Height of furnace hearth from floor where the parts have to be positioned for heating 860mm

5.7.1 Overall outer dimensions of furnace : B= 3000mm Door width L= 3200 mm depth of furnace H= 1200 mm Height.

5.7.2 Furnace volume : Dimensions of the furnace cavity B= 1550 mm Door width L= 2030 mm depth of furnace H= 1040 mm Height.

5.7.3 Working Volume inside the furnace: B= 1200 mm Door width L= 1800 mm depth of furnace H= 600 mm Height.

5.7.4 Hearth Height from floor where billets are kept: 960mm

5.8 Furnace - New ( Tentative dimensions )

5.8.1 Overall outer dimensions of furnace : B= 3000mm Door width L= 3200 mm depth of furnace H= 1200 mm Height.

5.8.2 Furnace volume : Dimensions of the furnace cavity B= 2030 mm Door width L= 2040 mm depth of furnace H= 1200 mm Height.

5.8.3 Working Volume inside the furnace: B= 2000 mm Door width L= 2000 mm depth of furnace H= 1000 mm Height.

5.8.4 Hearth Height from floor where parts are to be positioned and stacked. 960mm

6 Integration with Ring Rolling machine

6.1 Operator should be able to define the co-ordinates of part placement on rolling mill. These co-ordinates will be changed based on the loading position of different size of parts.

6.2 Operator should be able to teach the position of the loading position of the part by moving the manipulator to the required position and recording the co-ordinates.

6.3 These co-ordinates should be editable by the operator based on the loading position defined in the rolling mill software.

6.4 The manipulator should be able to receive ready signal from the ring rolling machine through interaction with PLC or by a push button by the operator on control desk or by touch screen input.

6.5 Manipulator should give output signal after finishing of placement of the part and retracting to a collision-free position for the rolling mill to start through a indicator bulb on the control desk

6.6 Manipulator should be able to communicate with the rolling mill to identify completion of rolling.

6.7 Manipulator should approach the rolling machine after completion of rolling and then unload the part.

6.8 After unloading the part and moving to a collision-free position, manipulator should give input to the rolling machine to enable tool cooling.

7 Basic Specifications of the Rolling Mill

7.1 Horizontal Radial Axial ring rolling machine

7.2 Make : Mitsubishi Nagasaki Machinery.

7.3 Capacity: 400 Ton Radial / 250 Ton Axial

7.4 Min. Ring Diameter: 400 mm

7.5 Max. Ring Diameter: 3000 mm

7.6 Min. thickness/Height of part : 30 mm

7.7 Max. thickness / Height of part : 550 mm

7.8 Height of the loading table from floor: 400 mm

7.9 Clearance height from rolling mill table to upper frame 600 mm

8 Technical details

8.1.10 Minimum weight to be carried by the manipulator at maximum reach distance from the centre line of the manipulator. 500 Kg

8.1.11 Reach from the centre line of the rails in maximum extended position. ( This can be modified based on the agreed layout. ) 5,500mm

8.1.12 Maximum distance from the centre of the rails in retracted position to avoid collision with machine elements and furnace. (This can be modified based on the agreed layout). 2500 mm

8.1.13 Rolling mill table height from floor. Part to be placed on this table in horizontal position. ( manipulator arm should be parallel to floor) 400mm

8.1.14 Travel distance required as per site conditions( Approximate) 20,000mm

8.1.15 Positioning Accuracy ( High speed mode) ±10mm

8.1.16 Positioning Accuracy required in high precision mode (for positioning ring rolling mill centre position). ± 2.5mm

8.1.17 Transfer time allowed from instance furnace door opening start to placing part on rolling mill 35 Sec

8.1.18 Additional Transfer time allowed for precision mode ( Maximum) 5 Sec

8.2 Tong Open/Close

8.2.1 Opening and closing speed minimum 300mm/Sec

8.2.2 Tong Opening (Maximum) 1000mm

8.2.3 Tong Opening ( Minimum) 100mm

8.2.4 Drive Hydraulic Cylinder

8.2.5 Control Proportional valve/Servo

8.3 Tong Up/Down

8.3.1 Minimum level on floor ( parallel to ground) 400mm

8.3.2 Minimum reach from floor level (higher is acceptable) 1,800mm

8.3.3 Stroke Min 1,200mm 1600mm

8.3.4 Vertical stroke up/down speed minimum 400mm/sec

8.3.5 Drive Hydraulic Cylinder

8.3.6 Control servo-controlled proportional valve

8.3.7 Actual value determination encoder

8.3.8 Position accuracy +/- 2.0 mm

8.4 Tong rotation

8.4.1 Rotation 360 Degrees

8.4.2 Speed 60 Degrees/sec 1600mm

8.4.3 Drive Hydraulic Motor/Servo Motor

8.4.4 Control servo-controlled proportional valve

8.4.5 Actual value determination encoder

8.4.6 Position accuracy +/- 0.1 Degree

8.5.1 Tilt up 5 Degrees

8.5.2 Tilt down 15 Degrees 15 Degrees

8.5.3 Speed 0-5 Degrees/sec 1600mm

8.5.4 Drive Hydraulic Cylinder

8.5.5 Control proportional valve

8.5.6 Actual value determination encoder

8.6 Tong retraction/extension from centre of rail

8.6.3 Stroke Minimum. (However it can vary depending on the agreed layout) 3,700mm 1600mm

8.6.4 Speed minimum 1,500mm/sec

8.6.5 Drive Hydraulic Cylinder

8.6.6 Control servo-controlled proportional valve

8.6.7 Actual value determination encoder

8.6.8 Position accuracy +/- 2.0 mm

8.7 Long travel

8.7.1 Travel length 20,000mm

8.7.2 speed minimum 1,500mm/sec

8.7.3 Drive hydraulic Motor/Servo Motor

8.7.4 Control servo-controlled proportional valve

8.7.5 Actual value determination encoder

8.7.6 Position accuracy +/- 2.0 mm

8.8.1 Slewing 270 Degrees Min

8.8.2 speed 0-50 Degress/sec

8.8.2 Drive hydraulic Motor/Servo Motor

10.8 Control servo-controlled proportional valve

8.8.3 Actual value determination encoder

11.8 Position accuracy +/- 2.0 mm

8.8.4 Rail to rail distance To be optimally designed by Vendor

9 Manipulator system for 4000 Ton press

9.1 Supplier shall carry out design, supply, installation, commissioning , integration and prove out of the following: 1. Autonomous Robotic manipulator (ARM) for handling of hot parts ( billets/performs/finished forgings) to and from high temperature furnaces and press. 2. The Autonomous robotic manipulator should be rail bound and should function in fully automatic mode, semi automatic, manual mode. 3. Conveyor type loading station : Automatic loading of billets to the furnace by ARM. The billets to be vertically positioned for forging operation 4. Integration of ARM with 3 Nos existing furnace and also provide scope for addition of 2 Nos of furnaces. 5. Two unloading stations with metal pallets for stacking of parts after unloading from press Layout consisting of press and with indicative positions of furnaces is attached at Annexures-3 for reference.

10 Operations to be performed by the manipulator for 4000 Ton press

10.1 Manipulator to pick up the parts from the loading platform and place them inside the furnace as per the recipe program for a batch selected by the operator.

10.2 After pre-heating of parts for a defined time, robotic manipulator should pick parts from the high temperature furnaces. Manipulator control system has to open furnace door and then manipulator should enter the furnace and pick the part from the desired location in the furnace and in the desired sequence.

10.3 When the furnace gives a ready signal to the manipulator, it should position itself in front of the furnace aligned to the part which needs to be picked. To reduce the time taken for pick up after door opening.

10.4 After furnace door opens to sufficient height, manipulator should enter the furnace and pick the part from the desired location in the desired sequence.

10.5 Manipulator should quickly transfer the part to the press and place it accurately on the press centre co-ordinates.

10.6 After completion of forging, signal is given by the press operator, manipulator should unload the perform/forging carefully without dropping the part and place it on the unloading table in the form array as selected by the operator. In fully automatic mode, all the operations shall be performed as per selected program for a batch quantity

11 Loading station.

11.1 A loading station should be designed such that cut billets/mults can be loaded manually on to the loading station with axis in horizontal direction.

11.2 Manipulator should be able to pick parts from loading station with out manual intervention.

11.3 Loading platform should facilitate easy loading of parts onto the station/ platform with out the need for precise location of parts.

11.4 The loading station should have facility to alter positioning of the cut billets to suit proper pick up of parts by the manipulator.

11.5 The manipulator should be able to pick the parts in the pre-defined sequence for loading into furnace.

11.6 A loading station should consist of a conveyor where 15 parts can be loaded in sequence in one go.

11.7 Loading conveyor should be able to carry weight of 15 parts of 1000 kg each.

11.8 The manipulator should load the billets in horizontal axis direction and place the billets in the furnace in vertical axis direction on bed of furnace.

12 Integration of manipulator for 4000 Ton press with existing systems

12.1 Integration with furnaces

12.1.1 All furnace are electrical resistance heated furnaces.

12.1.2 Supplier shall integrate the manipulator with the furnace for following operations

12.1.3 Loading of parts from loading station to the furnace as per pre-defined Furnace loading plan

12.1.4 The manipulator should communicate with furnace to receive the Furnace ready signal. Furnace ready signal is based on two functions A. All temperature recording channels in furnace reach the pre-defined temperature w.r.t to set temperature. B. Mandatory time gap between unloading of each part for forging operation.

12.1.5 The furnace ready signal is provided by the Furnace control system

12.1.6 The manipulator should position itself in the best position, aligning itself to the part which has to be picked to minimize the time of furnace door opening to minimize the time for which furnace door has to be kept open.

12.1.7 The manipulator would receive signal from a press/operator to start the cycle.

12.1.8 The manipulator should give control signal for furnace door opening after receiving the clearance from the press machine or the operator.

12.1.9 After furnace door is opened to defined height, manipulator should enter the furnace and pick the part from the pre-defined location as per the required sequence. Door limit switches feedback need to be taken from the furnace control system

12.1.10 After part is picked from the furnace, manipulator should travel to a point with sufficient clearance and give a signal for door closure and locking.

12.1.11 Door opening and closing mechanism are pre-installed on the furnaces along with a PLC and vendor shall communicate between furnace PLC and manipulator.

13.1 All the furnaces available in this facility are electrical resistance heated furnaces.

13.2 The manipulator should avoid contact with heating elements.

13.3 The supplier should propose the best layout for the rail-bound manipulator based on the available space and capacity of the manipulator.

13.4 At present two furnaces are available for integration to the manipulator. The supplier should provide option to integrate another two furnaces to the system.

14 Dimensions of the furnaces (Indicative)

14.1.1 Overall outer dimensions of furnace : B= 2800 mm Door width L= 2740 mm depth of furnace H= 2068 mm Total Height.

14.1.2 Furnace volume : Dimensions of the furnace cavity B= 1650 mm Door width L= 2360 mm depth of furnace H= 930 mm Height.

14.1.3 Working Volume inside the furnace: B= 1500 mm Door width L= 1800 mm depth of furnace H= 800 mm Height.

14.1.4 Height of furnace hearth from floor where the parts have to be positioned for heating 860 mm

14.2.1 Overall outer dimensions of furnace : B= 3180 mm Door width L= 2740 mm depth of furnace H= 2320 mm Height.

14.2.2 Furnace volume : Dimensions of the furnace cavity B= 2030 mm Door width L= 2040 mm depth of furnace H= 1200 mm Height.

14.2.3 Working Volume inside the furnace: B= 2000 mm Door width L= 2000 mm depth of furnace H= 800 mm Height.

14.2.4 Hearth Height from floor where billets are kept: 1250 mm

14.3 New Furnace

14.3.1 Overall outer dimensions of furnace : B= 2800 mm Door width L= 2740 mm depth of furnace H= 2068 mm Total Height.

14.3.2 Furnace volume : Dimensions of the furnace cavity B= 1650 mm Door width L= 2360 mm depth of furnace H= 930 mm Height.

14.3.3 Working Volume inside the furnace: B= 1500 mm Door width L= 1800 mm depth of furnace H= 800 mm Height.

14.3.4 Height of furnace hearth from floor where the parts have to be positioned for heating 860 mm

14.4 Integration with press machine

14.4.1 Operator should be able to define the co ordinates of part placement on press. These co ordinates will be changed based on the loading position of different size of parts.

14.4.2 Operator should be able to teach the position of the loading position of the part by moving the manipulator to the required position and recording the co ordinates.

14.4.3 These co-ordinates should be editable by the operator based on the loading position

14.4.4 The manipulator should be able to receive ready signal from the press machine. By a push button by the operator on control desk or by touch screen input.

14.4.5 Manipulator should give an output signal after finishing of placement of the part and retracting to a collision-free position for the press to start. by an indicator bulb on the control desk

14.4.6 Manipulator should be able to communicate with the press to identify completion of forging.

14.4.7 Manipulator should approach the press machine after completion of forging and then unload the part.

14.4.8 After unloading the part and moving to a collision free position, manipulator should give input to the press machine to enable tool cooling.

15 Basic Specifications of hydraulic press

15.1 Top down multi station Hydraulic press

15.2 Capacity: 4000 Ton

15.3 Make ;TTPCL

15.4 Top - 2 moving stations. Bottom- 3 moving stations with Moving bed on floor.

15.5 Automatic operation for forging of ring pre-forms

15.6 Daylight : 1800 mm

15.7 Distance between the columns : 2500 mm

15.8 Bottom flat die from floor level : 800 mm

15.9 Piercing station from floor level : 800 mm

15.10 Clearance height from piercing station to top forging punch station : 800 MM

16 Technical details for 4000 Ton press Manipulator

16.1 Minimum weight to be carried by the manipulator at maximum reach distance from the centre line of the manipulator. 1000 Kg

16.2 Reach from the centre line of the rails in maximum extended position. ( Higher is acceptable) 8400mm

16.3 Maximum distance from the centre of the rails in retracted position to avoid collision with machine elements and furnace. (This can be modified based on the agreed layout). 4200mm

16.4 press table height from floor. Part to be placed on this table in horizontal position. ( manipulator arm should be parallel to floor) 800 mm

16.5 Travel distance required as per site conditions( Approximate) 17,000mm

16.6 Positioning Accuracy ( High speed mode) ±10mm

16.7 Positioning Accuracy required in high precision mode (for positioning press centre position). ± 2.5mm

16.8 Transfer time allowed from furnace door opening to placing part on press 35 Sec

16.9 Additional Transfer time allowed for precision mode ( Maximum) 5 Sec

16.2 Tong Open/Close

16.2.1 opening and closing speed minimum 300mm/Sec

16.2.2 Tong Opening (Maximum) 1000mm

16.2.3 Tong Opening ( Minimum) 100mm

16.2.4 Drive Hydraulic Cylinder

16.2.5 Control Proportional valve/Servo

16.3 Tong Up/Down

16.3.1 Minimum level on floor ( parallel to floor) 600 mm

16.3.2 Desirable Maximum level on floor(can be more) 1,800mm

16.3.3 Stroke Min 1,200mm 1600mm

16.3.4 Vertical stroke up/down speed minimum 400mm/sec

16.3.5 Drive Hydraulic Cylinder

16.3.6 Control servo-controlled proportional valve

16.3.7 Actual value determination encoder

16.3.8 Position accuracy +/- 2.0 mm

16.4 Tong rotation

16.4.1 Rotation 360 Degrees

16.4.2 Speed 60 Degrees/sec 1600mm

16.4.3 Drive Hydraulic Motor/Servo Motor

16.4.4 Control servo-controlled proportional valve

16.4.5 Actual value determination encoder

16.4.6 Position accuracy +/- 0.1 Degree

16.5.1 Tilt up 5 Degrees

16.5.2 Tilt down 15 Degrees 15 Degrees

16.5.3 Speed 0-5 Degrees/sec 1600mm

16.5.4 Drive Hydraulic Cylinder

16.5.5 Control proportional valve

16.5.6 Actual value determination encoder

16.6 Tong retraction/extension from centre of rail

16.6.1 Stroke Min (However it can vary depending on the agreed layout) 4200mm 1600mm

16.6.2 speed minimum 1,500mm/sec

16.6.3 Drive Hydraulic Cylinder

16.6.4 Control servo-controlled proportional valve

16.6.5 Actual value determination encoder

16.6.6 Position accuracy +/- 2.0 mm

16.7 Long travel

16.7.1 Travel length 17,000mm

16.7.2 speed minimum 1,500mm/sec

16.7.3 Drive hydra. Motor/Servo Motor

16.7.4 Control servo-controlled proportional valve

16.7.5 Actual value determination encoder

16.7.6 Position accuracy +/- 2.0 mm

16.8.1 Slewing 270 Degrees Min

16.8.2 speed 0-50 Degress/sec

16.8.3 Drive hydr. Motor/Servo Motor

16.8.4 Control servo-controlled proportional valve

16.8.5 Actual value determination encoder

16.8.6 Position accuracy +/- 2.0 mm

16.8.7 Rail to rail distance To be optimally designed by Vendor

17 General Requirements ( Applicable for both manipulators)

17.1 Main Assembly Groups:

Power : Power and control cables to the manipulator shall be routed through a heavy duty drag chain which is to be installed on the floor.

17.1.1 Tong and Tong Carrier: Parts are to be held by a tong and clamp with adjustable gripping force. The tongs shall have rotational capability to place the billets / ring pre-forms, semi rolled rings, finish rolled rings in the furnace or o n the press/ ring rolling mill in desired orientation.

17.1.2 Bending arm: Bending arm boom shall be designed as double lever parallelogram with two hydraulic cylinders for the feed motion and lifting motion The bending arm consists of upper arm, forearm elbow joints and guide bars. The bending arm boom has high resistance to twisting. Minimum no. of levers to obtain optimum of rigidity and accuracy.

17.1.3 Main Frame: Main frame mounted on the ball bearing slewing rim, swivel able.

17.1.4 Drive Trolley: The drive trolley shall be sturdy and welded design driving on four wheels. Exact positioning shall be done by integrated rotary absolute encoder. The drive shall operate fully integrated for automatic/semi-automatic/manual machine control

17.1.5 Hydraulic equipment: All machine motions shall be hydraulic-driven driven/Electric. The whole hydraulic equipment shall be easily accessible on the manipulator, which consists of servo valves, oil tank, electric drive motor with pumps for working, cooling, and filter circuit, proportional valves including feedback, filters, air/oil cooler, cylinders, and hydraulic motors To avoid oil leakages, all high-pressure lines shall be equipped with welded cones and o-ring seals. The hydraulic system is hermetically sealed against influences from contaminated and wet ambient air. Emergency operation: The tongs shall be lifted and retracted manually by hand-operated valves and a hydraulic accumulator

17.1.6 Operators cabin: Operator's cabin should consist of control desk with control and supervisory elements as well as a adjustable seat and a front protection hood with heat resistant glass to protect operator from heat. Machine shall be manually controlled by means of master joysticks arranged at left and right side of the operator. Operator cabin shall have air-conditioning.

17.1.7 Remote control desk/ station: Vendor shall provide remote control desk for operation of the rail bound manipulator from the Ring Rolling control room. All necessary wiring shall be carried out by the vendor. Automatic/Semi automatic/Manual modes of operation shall be available.

18 Main Assembly Groups:

18.10 The robotic system shall withstand high temperature of 1180 Deg C and proper insulation shall be provided for all the sensitive parts which are prone to damage due to high temperature.

18.2 Manipulator travel shall be backlash free.

18.3 Vendor shall provide Eaton/Moog/Rexroth/Vickers make hydraulic items such as hydraulic pump, solenoid valves, servo valves, proportional valves etc.

18.4 Vendor shall provide MIMC of manipulator exact position. Vendor shall use position transducer / encoder/ Temposonic transducer to accurately identify and control the movements of all axis. These position sensors shall be utilized for simultaneous movements of axis for transfer of parts in the required time.

18.5 The Manipulator shall not have mis-alignment issues, jerky and unsafe movements. All necessary precautions shall be taken for safe, trouble free operation of manipulator.

18.6 Control Systems: Advanced servo hydraulic systems shall be used for smooth and precise control of hydraulic functions, positioning and speed control

18.7 The vendor shall prioritize ease of maintenance while carryout the design of hydraulic systems, routing of hydraulic lines.

18.8 The manipulator shall work on extremely tight tolerances. Long term accuracy and repeatability shall be considered while designing the system.

18.9 Encoders: Encoders provide precision position feedback. These feedbacks are essential for enhanced control and accuracy. Encoder shall enable closed loop control systems. Encoders contribute to high repeatability and axis can return to same position.

18.10 PID control: Movement Axis shall be controlled by PID action for accurate control

18.11 Vendor may incorporate any changes in above specification to achieve faster transfer time and better functionality without safety and operational issues.

19 Operation Modes for both Manipulators

19.1 The Autonomous robotic manipulator should be rail bound and should function in fully automatic, semi-automatic, and manual modes. The supplier should provide all the hardware and control systems, Industrial PC with monitor and any other systems which are required for fully automatic, semi-automatic, and manual modes of operation.

20 Fully Automatic

20.1 Manipulator should work in fully automatic mode/ Autonomous mode to complete operations for one full batch of parts without any operator intervention.

20.2 The required data for operation shall be fed to the control system by the operator. The data input screens should be simplified for ease of entry and should be mistake proof to avoid damage to any equipment, parts and people.

20.3 Manipulator should perform all the functions listed in Section-2 in fully automatic mode as per the programmed or inputs fed by the operator and without need of operator inputs for each part.

20.4 Operator should have provision to swith over from automatic to manual mode for fine adjustments and should be able to switch back to continue the cycle in automatic mode.

20.5 There should not be a need to re-start the automatic cycle from the beginning.

21 Semi Automatic

21.1 The semi automatic mode is intended to be used when the part is off the programmed location or if the part is having a irregular shape.

21.2 In Semi-Automatic mode operator picks and releases the part manually and all the remaining operations in transporting the part between defined locations should be done by the manipulator itself.

21.3 For all controlled axes target points to be programmed. Program for one target point to the next is to be entered in advance. Through actuation of a corresponding target button, this program cycle starts automatically from any initial position with checking of all programmed interlocking conditions. After completion of this program cycle, i. e. at the stopping point (target), all motions can be controlled manually via the master switches. After actuating of a subsequent target button, this new target is then approached automatically. The most important feature of the automatic target approach system is a rapid automatic point-to-point motion within a set motion cycle with axes, which switches automatically to manual operation when the set target is reached. The pre-set stop positions and axis motions will be entered via the touch display. These positions or motions for each axis will be entered directly through the touch display as data in a table or by moving the manipulator to a desired position and then touching a button on a touch display thus accepting the information. Due to the use of absolute encoders there is no need of reference points (home position). In case of a power failure the machine could start from its last position again. The operator would be able to stop or “pause“ the manipulator at any time dubillet a semi- automatic move by actuating a “cycle stop“ function on the control joystick. The move can be re-started by initiating the “cycle start“ function on the joystick.

21.4 Operator should have a screen where he can select the next location of the manipulator.

22.1 In manual mode, all the operations including pick and release of parts and also the travel of the manipulator is taken care by the operator.

22.2 In case of manual operating the main axes shall be infinitely variable by master switches with a built-in-potentiometer from a control desk, arranged in driver’s cabin on the manipulator. All other movements are operated by push-buttons or foot-pedals, if necessary, with constant speed. All interlocking conditions remain in function. The joysticks and foot pedal shall be positioned in the operator’s cabin so that fatigue on the operator is minimized. The manual controls of the controlled axis will be used to assist in programming the target points for the semi-automatic mode (teach/learn). The joysticks and foot pedal to be programmed to provide a non-linear response with respect to handle position versus valve position. The joystick dubillet the first part of its motion allow the operator to drive slowly or creep into position. The remainder of the joystick motion is to be programmed to provide a rapidly increasing output signal and corresponding valve position thus allowing the operator to rapid traverse towards the target.

22.3 The control system should be able to switch over between manual and semi automatic and fully automatic mode in a seamless manner with out loosing time.

23 Setting mode & Simulation

23.1 Setting mode should be available for performing the setup of operation/maintenance

23.2 In setting mode the movements of the manipulator should be in inching mode only. There should not be any automatic movements.

23.3 There should be facility to run the simulation of entire cycle of operation to verify correctness of operator inputs.

23.4 There should be facility to test run of loading cycle to the furnace.

23.5 There should be facility to perform the test run and adjust for loading position on press with help of a dummy part.

23.6 There should be facility to run a simulation of only a selected part of the cycle. For example. only furnace loading , or only part loading to press. Or only unloading operation.

23.7 Simulation should occur in slow mode to avoid unintended collisions etc.

24 Unloading table ( Applicable for both manipulators)

24.1 There should be two unloading tables with metal pallets.

24.2 The metal pallets should be of minimum size 1250 mm x 2250 mm should have slots for lifting and transporting with forklift.

24.3 The operator should be able to select unloading table and the stacking pattern in the control screen.

24.4 The manipulator should be able to stack the parts in vertical stacks of 8 Nos accurately one over another forgings after forging

24.5 When required the manipulator should be capable of loading parts directly to another furnace with out moving the part to the unloading table.

25 Work piece ( Applicable for both manipulators)

25.1 The maximum temperature of the parts to be transported is upto 1180 Deg C.

25.2 The parts to be transported by the manipulator are three types.. A. Billets B. Ring Performs C. Finished forgings

25.3 Maximum outer diameter of part 1000 mm

25.4 Minimum outer diameter of part 100 mm

25.5 Minimum height of the part 30 mm

25.6 Maximum height of the part 400 mm

25.7 The parts can be having ovality manipulator should be able to handle such oval shaped performs upto ovality of 40mm.

25.8 The semi rolled rings may have war page up to 10 MM, Manipulator should be able to handle these parts.

26 Part clamping mechanism ( Applicable for both manipulators)

26.1 The manipulator should be able to clamp the parts on OD of the part

26.2 The manipulator should hold the part such that part is self centered between the holding jaws for accurate positioning of parts inside the furnace and the press

26.3 Part clamping pressure should be adjusted based on pre defined control table in the control system of the manipulator.

26.4 Parts will require different clamping force before and after press.

26.5 Part should not fall off the jaws during transit.

26.6 Various parts of the manipulator should be protected against any major damage due to falling of hot part. There should not be any plastic parts which can be damaged if the hot parts fall on them.

26.7 Manipulator should adjust the jaws position to the nearest position of the part which it is supposed to open.

26.8 The manipulator should be able to detect any anamoly such as incorrect part holding through pressure sensing and position sensing and give alarm to the operator for change over to manual mode and take a corrective action.

26.9 The finish forging are having less wall thickness and are susceptible to deformation if the clamping force is high

27 Furnace loading plan ( Applicable for both manipulators)

27.1 A furnace loading plan represents the pattern and sequence in which the parts have to be loaded inside the furnace.

27.2 A furnace loading plan defines the pattern of loading parts inside the furnace ensuring that all the parts are within the working volume defined for each furnace.

27.3 The manipulator control stem shall have pre installed loading patterns which the operator can select for each furnace. This shall be done as part of recipe management

27.4 When the parts are large and can not be placed within the working working volume of the furnace in one level, stacking of parts has to be done by the manipulator. Stacking is usually done in two and three levels

27.5 When stacking has to be done the manipulator should be able to stack the parts inside the furnace.

27.6 Stacking of parts with spacers is done manually at the loading station by manipulator in manual mode.

27.7 The manipulator should have memory of the loading pattern and sequence in which parts are loaded in the furnace. The manipulator should have memory of sequence of parts when loaded with stacking also.

27.8 Manipulator should transport the stacked performs in a jerk free smooth movements to avoid the parts falling off the stack.

28 Rails embedded in the floor ( Applicable for both manipulators)

28.1 The Autonomous Robotic manipulator should be mounted on suitably designed rails which are embedded in the flooring. The rails shall not obstruct the movement of vehicle/forging manipulator.

28.2 The rails has to be flushed to the ground level without causing any hindrance to movement of other automobile equipment.

28.3 The rails should have metal guard on the wheel flange side to avoid breaking of concrete edges during movement of other vehicles.

28.4 The foundation of the rails has to be designed to have bare minimum concrete breaking at the site to avoid disruption to production.

29 Civil works ( Applicable for both manipulators)

29.1 Civil works shall be carried out by HAL based on the foundation drawings provided by the supplier.

29.2 Rails and supporting structure have to be provided by the supplier at a agreed schedule.

29.3 The design of the rails or the track should be mutually agreed to minimize down time of rolling mill and press for the purpose of civil works.

29.4 The timeline for completion of civil works will be as per mutually agreed schedule between supplier and HAL.

29.5 Civil works shall be inspected for alignment by the supplier before and after pouring of concrete at their own expenses. HAL will intimate for inspection before 15 days.

30 Electrical Main Data ( Applicable for both manipulators)

Power Supply Approx. values

30.1 Electric Design and specifications

30.1.1 Electric power supply available 415 V +/-10%, 50 Hz +/-3%, 3 phase, 4 wire, A.C. system

30.1.2 Type of network TN -S network

30.1.3 Neutral conductor Unloaded

30.1.4 Control voltage 230 V AC / 24 V DC

30.1.5 Design specifications (excluding single core marking) IEC

30.2 Switchgear assemblies / system technology

30.2.1 Type of protection inside of switch cabinet rooms IP20

30.2.2 Type of protection outside of switch cabinet rooms IP54

30.2.3 Switch cabinets inside of switch cabinet rooms with doors and suitable air conditioning

30.2.4 PLC design Remote I/O

30.2.5 Network Industrial Ethernet (TCP/ IP)

30.2.6 Protocol Ethernet

30.2.7 Cables All shall be copper flexible cables with ground wire, Make: Finolex/Polycab/LAPP/Havell's

30.2.8 Surge protection Required

30.2.9 Digital muli function Energy meter with RS485/Ethernet in the switch cabinets Required

30.2.10 Cable entry Bottom Entry

30.2.11 PC – operating systems: MS Windows

30.2.12 Additional PLC hardware and program To add two more furnaces

30.3 Brand specifications

30.3.1 Switch cabinets / control boxes Rittal (Test certificate from Rittal to be provided)

30.3.2 Desks Rittal (Test certificate from Rittal to be provided)

30.3.3 Main switches Siemens/ABB/L&T/Crompton/GE/Schneider/ C&S

30.3.4 Switchgear Siemens/ABB/L&T/Crompton/GE/Schneider/ C&S

30.3.5 Frequency converters Siemens/ABB/GE/Schneider

30.3.6 Soft start devices Siemens/ABB/GE/Schneider

30.3.7 PLC system Siemens

30.3.8 SCADA Siemens Wincc

30.3.9 Safety control PILZ/Sick

30.3.10 Visualization Simatic

30.3.11 Industry PC Siemens

30.3.12 Network components: Suitable to PLC system

30.3.13 UPS for PC system with 20 minutes backup APC/POWERWARE/EATON/Power one

30.3.14 Proportional valves, hydraulic pumps Rexroth/Eaton/Moog/Vickers

30.3.15 Servo valves Rexroth, Moog

30.3.16 AC for panels Rittal/Dai-chi/Werner Finley

31 Data Acquisition, Handling and Management System ( Applicable for both manipulators)

31.1 All the key parameters such as forces, position of each axis and key I/O signals should be captured in data logger .

31.2 This data should be displayed in the running chart while the operation is in progress.

31.3 This data should be stored in form of log file and should be retrievable for review.

31.4 Graphic representation measured parameters in form of trend graph. Minimum memory upto 500 GB shall be provided for this feature.

31.5 Export / import function for archived files

31.6 There should be facility for periodic back up the log data

31.7 There should be assignment of a log no for each part cycle and should be linked to programme name and serial number.

32 Alarm logger/History ( Applicable for both manipulators)

32.1 The alarm history should be have provision for backup for defined period.

32.2 The operator should have option to enter remarks for each type of alarm. Remarks would consist of brief of actions taken to resolve the issue. This remarks should be shown when the same alarm comes up the next time so that it is useful for quick resolution of the alarm/ fault.

32.3 Vendor shall provide remedy to solve the error for each fault. The remedy description shall be displayed by selecting the fault.

33 Recipe and Programme management ( Applicable for both manipulators)

33.1 Vendor shall develop recipe and program structure in such a way that the operator need to enter minimum parameters preferably at one screen. The manipulator should be able to save part specific recipe of minimum 5000 parts in memory and should be able to recall the recipe when needed.

33.2 Recipe consists of Part No, Part Description, Input part and rolled ring dimensions/ billet dimensions and forged pre-form dimensions, Quantity, Furnace Loading plan. Program entry shall enable the operator to specify the part transfer from one station to the next station by the manipulator like Loading table, Furnace No, unloading table.

33.3 The stored recipe should be retrievable and operator should be able edit data such as dimensions of the part in the recipe before execution.

33.4 Recipe program shall be designed such that the operator shall work with minimal data entry and settings and shall be user friendly for ease of operation with safety.

33.5 Creating a product library and Storage (data back-up)

33.6 Overview of the programs stored on the hard disc of minimum capacity of 2 TB

34 Industry PC and remote operating station ( Applicable for both manipulators)

34.1 1 No. Industry PC with minimum 24" Monitor should be provided for operation, control and visualization. This PC shall store alarm history, recipe management etc. PC along with CCTV monitor is to installed ergonomically at machine control panel for operation by the machine operator only. Suitable desk table shall be provided

34.2 Display of various process parameters and positions in graphical form should be available on the screen.

34.3 Remote control desk/ station: Vendor shall provide remote control desk for operation of the rail bound manipulator from the Ring Rolling control room. All necessary wiring shall be carried out by the vendor. Necessary operating pushbuttons, joysticks, emergency stop, fault indicators etc to be provided. Fully automatic mode, Semi automatic and manual modes shall be available.

34.4 A screen showing the sequence of operations and all the I/O signals should be shown in graphical form so that operator can understand the issue quickly and to resolve the issue quickly.

35 Process visualization ( Applicable for both manipulators)

35.1 Vendor shall provide high definition 3 nos. of CCTV along with networking and storage systems. The CCTV shall display the operation of forging on a separate 43" monitor for displaying CCTV video. The Cameras shall withstand high temperature.

35.2 One high temperature camera should be mounted at suitable location to show the red hot .parts inside the high temperature furnaces as the parts are being picked up or being loaded.

35.3 For the purpose of monitoring the automatic operation, the display in monitor should automatically switch between the camera views as pre-programmed based on location of manipulator to show the best view corresponding to the part movement without need for the operator to select individual camera views manually.

35.4 There should be video recording of the feed from the cameras with time stamp. This is to help with trouble shooting incase of any unforeseen incidents.

35.5 Video back up should be available for 15 days after which it can be over written with new data.

36 Repeatability ( Applicable for both manipulators)

36.1 The manipulator should be able to repeat the positioning accuracy and should not have part to part variation exceeding the tolerances specified.

37 Calibration of axis. ( Applicable for both manipulators)

37.1 The manipulator should have facility for auto / manual calibration of position of all axis to minimize the errors.

37.2 The values of the parameters adjusted during Auto/manual calibration should be shown in a calibration screen.

38 Operator cabin ( Applicable for both manipulators)

38.1 An operator cabin with air-conditioning should be provided on the the manipulator in a safe location.

38.2 The operator cabin shall be provided with Air conditioned cabin.

38.3 Control desk shall have all necessary joysticks and push buttons for operation

38.4 Operator should have ability control the manipulator and also the furnace door open signal.

39 Safety Interlock ( Applicable for both manipulators)

39.1 Additional safety interlock to be provided to ensure that furnace door can not be closed when the manipulator is inside the furnace to fetch or load the parts.

39.2 All the electrical circuits shall be protected by MCB of suitable rating

39.3 Audio visual annunciation for all necessary faults with acknowledges and reset push button

39.4 Vendor shall design and implement safety measures for Work piece safety, Equipment safety, Human safety.

39.5 A safety fence has to be provided at loading and unloading area and at all possible areas of human access around the machine.

39.6 5 Nos of Emergency stops, hooters for manipulator are to be provided for safe operation.

40 Experience / Qualification criteria

40.1 Supplier/OEM shall have experience of supplying minimum Two rail bound robotic manipulator systems of 500 kg or above capacity. The oldest rail bound handling manipulator shall be at least 5 years and proof shall be given for the same. Supplier shall submit list of installations and proof of PO / customer specification/ design and implementation. if the supplier is not OEM, supplier shall enclose authorization certificate from the OEM and undertaking that OEM shall support the design, installation, prove out and maintenance support to HAL for project.

40.2 Supplier/OEM should have prior experience in fully automated manipulator by integration of the manipulator with furnaces and machine for auto loading, unloading and transfer of the load. Supplier shall submit proof of PO / customer specification/ design and implementation of 1No. Of such facility.

40.3 The supplier/OEM should have prior experience in building similar manipulators with Siemens S7 PLC and for integration with Siemens PLC and scada. Supplier shall submit proof of PO / customer performance certificate.

40.4 HAL may visit or enquire with the customer at any of the references provided for verification of performance of the equipment provided by the supplier/OEM. In case performance of previously supplied equipment is not satisfactory such offers will not be considered.

41 Warranty & Support

41.1 Two year comprehensive warranty to be provided

41.2 Cost of AMC for a period of two years after warranty period should be provided as optional.

41.3 The system shall have facility to perform trouble shooting through online or remote mode.

41.4 Online support should be included for first two years during warranty period.

42.1 A full set of oil filters and oil seals shall be provide

42.2 Spare pressure transducers and encoders to be provided along with the machine ( 1no. of each type of encoders and 2 Nos pressure transmitters to be provided)

42.3 List of bought out items with their product code should be provided

43 Technical evaluation by committee

43.1 The supplier shall present the details of the proposed system to the technical evaluation committee of HAL through VC or offline mode. HAL will intimate the schedule and vendor shall make arrangements to present technical specification compliance report to the committee.

43.2 The supplier should present the proof of execution of such system through videos and graphical representations and drawings.

43.3 The supplier shall also explain how all the requirements of the specification will be executed by the supplier.

43.4 If the supplier does not provide details on their previous experience and how the requirements specified in this specification will be implemented in their system, the offers will be rejected on technical grounds and will not be considered for commercial evaluation.

44 List of documents to be provided with the offer

44.1 The supplier should provide a general arrangement drawing of the proposed manipulator with dimensions.

44.2 Supplier shall provide a short video of autonomous operation of a similar manipulator along with the offer. If vendor could not upload in GEM portal, Vendor shall submit a Pen drive with short video. The pen drive enclosed in a cover mentioning Tender Number shall be sent to Purchase, Foundry and Forge Division, HAL to reach before the due date or vendor may drop in the tender box provided at F&F,HALbefore due date and time.

44.3 Since this system is a complex system which has to be integrated with the existing machinery and layout, the vendor shall visit the site for his own assessment of feasibility and the work involved before submitting the offer.

44.4 The vendor shall obtain the MOM at the time of visit and shall include a copy of MOM along with offer.The offer will be rejected,if the supplier fails to submit the MOM document and offer will not considered for technical evaluation.

45 Post Order placement

45.1 It is the responsibility of the vendor to depute their engineers to take precise measurements of the existing layout and machinery for purpose of designing the system. Layout / dimensions provided in the RFQ are only for understanding purpose.

45.2 After placement of purchase order the vendor shall design the system to meet all the requirements of the specification and make a presentation to HAL with suitable videos and 3D animation in the actual layout.

45.3 If the vendor is unable to provide a suitable solution meeting the requirements of the specification, HAL has right to cancel the purchase order at this stage.

45.4 Manufacturing should be taken up only after implementing the feedback points from HAL.

46 Pre-Dispatch Inspection

46.1 Supplier shall demonstrate dummy trail runs with manipulator (With out furnaces and machine) of auto loading of billets/performs, removal of billets/performs and positioning of these billets on Rolling mill. Supplier shall prove transfer timings except travelling time of manipulator on rail. Vendor has to successfully display all sub assemblies functioning, material certificates, electrical and PLC panels, hydraulic system and OEM certificates for bought out parts( brands shall meet the requirement of tender). Detailed list of activities to be done during PDI shall be informed by HAL before PDI.

46.2 HAL reserves right to waive off PDI.

47 Installation and Commissioning

47.1 Installation and commissioning of the equipment should be carried out under the guidance and in presence of engineers from OEM.

47.2 Installation and Commissioning have to be carried out in Ring Rolling Unit-2 without disturbing the regular production of Ring mill and 4000 Ton Press.

47.3 Installation of each manipulator shall be carried out within 30 days of commencement to avoid production holdup.

47.4 Cost of Lodging, Boarding, and transportation expenses of the personnel deputed for installation and commissioning should be borne by the supplier.

48 Documentation:

48.1 Documentation of 3 copies of hard copy and 1 soft copy on a Pen drive shall be provided.

48.2 Operating instructions in English

48.3 Parts list

48.4 Assembly drawings of the sub assemblies

48.5 Parts list Electric and hydraulics

48.6 Circuit drawings - Electric & Hydraulic

48.7 Maintenance documentation and lubrication plan

49.1 HAL shall carry out an extensive acceptance test process for 10 days period each on both manipulator systems.

49.2 Vendor shall develop and prove out recipe program for minimum 10 different batches having different dimensions and shapes for each manipulator system.

49.3 Acceptance test shall be carried out after Vendor specialist declares the system is ready for hot trials.

50.1 After successful completion of acceptance test, Vendor specialists shall train HAL's operation and service personnel for 7 days ( for schedule of 7 days, 8 hours/day.)

50.2 The total time for Supply, Erection, Commissioning, Acceptance and Training shall not exceed 18 months from the date of purchase order.

51 General Terms and Conditions

51.1 Layout, General arrangements and civil foundation drawings are to be submitted along with the offer.

51.2 Minor changes in above specifications are allowed as per OEM's proved design. However the functional requirements shall be met.

51.3 Supplier will be responsible for the installation, commissioning and complete integration of the system on turnkey basis. Vendor should also consider the Miscellaneous spares which are used for Installation and commissioning of the whole project.

51.4 Supplier has to prove the system by conducting the trial runs at HAL works.

51.5 On the site training to be imparted to Operators and Officers on the use, Dos & Donts and safe shut down etc.

51.6 Supplier has to bring his own tools and tackles for installation and commissioning of the system.

51.7 HAL will provide power supply to the main panel of the system supplied by the supplier. Further power distribution will be carried out by the supplier.

51.8 Supplier has to provide list of spares for the operation of 2 years as OPTIONAL in the quote.

51.9 Supplier has to provide minimum 3 copies of the equipment operation and Electrical and mechanical drawings in English.

51.10 The machine/ equipment supplier to ensure/ give an undertaking that the equipment will be supported for the next 10 years of operation.

51.11 Supplier should mention the future AMC cost per anum. However Cost of AMC is for information only and not considered in tender evaluaion.