Industrial Equipment

Boltron Flange Bolting Robot

“Boltron” is an automated industrial flange bolting robot, typically used on industrial sites, refineries, power stations and production facilities. Replacing manual bolting practices, the system provides an efficient, safe, reliable and accurate method of tightening and loosening flange bolts. With the ability to suit a range of flange diameters and thicknesses, “Boltron” is a high value piece of equipment for site-based bolting activities.

Features

The TMT Bolting Robot has the following features:

1. Automated bolting programs,
• Star patterns
• Staged bolting
• Obstruction identification

2. Multi-Arm Base Mount:
• Equipped with high-strength, switchable magnets for secure mounting on steel surfaces
• Custom designed leg quantity and spacing to suit specific flange geometry

3. Electric Radial Slew Drive:
• 360 degrees of motion with features including backlash control, and positional read out
• Rated to IP65/IP50 for environmental protection

4. Structural Radial Arm:
• Fine adjustment of radial length via an electrical actuator
• Structural adjustment for compatibility with various flange diameters

5. Structural Z-Axis Arm:
• Mounted to the radial arm track for fine vertical adjustment via an electrical actuator
• Configurable for different flange configurations

6. Two-Speed Pneumatic Torque Gun:
• High-speed, precision torque gun (RAD 25GX-2) with maximum torque of 3400 Nm
• Customized torque arm for cracking seized nuts and applying consistent torque
• Options for Electric and Hydraulic torque guns

7. Spring-Loaded Sleeved Socket:
• Allows precise alignment of the torque gun on studs

8. Rear Nut Holder:
• Custom hardware to secure back nuts, adaptable to specific flange and nut sizes

9. Targeting Camera:
• High-resolution camera providing a live stream for bolt alignment and obstruction detection

10. IP50-Rated Control Cabinet:
• Houses all electrical, electronic and pneumatic control components with a mounted screen for system interaction via GUI

11. Comprehensive Operating Software:
• Includes features for calibration, alignment, custom programming, real-time monitoring, post-torquing reports

12. Calibration Tool
• Strain gauge rod (fitted between front and rear nut holders)

Description

“Boltron” has been developed specifically for use in harsh environmental conditions including high temperatures, acidic and caustic environments, precipitation, dust and fluids. With a robust design, the system handles heavy duty torquing machinery and high torque bolting activities.

With the ability to handle bolting activities on double sided flanges/nut and adjustable to suit a range of bolt flange diameters, “Boltron” provides operators and service providers with a unique and beneficial capability.

Applicable to a wide range of applications, “Boltron” can service equipment on sites including oil refineries, alumina refineries, chemical production, pharmaceutical production, paper mills and power stations. Suitable bolted flanges are typically found on heat exchangers, pressure vessels, condensers and wind turbine hubs.

TMT’s flange bolting robots deliver a wide range of benefits to operators and service providers including;
– Removal of operators from strenuous and dangerous work activities,
– Avoidance of injuries including fall from heights, physical injuries, muscular strains, chemical burns, heat stroke, noise exposure,
– High quality, reliable nut torquing execution,
– Negation or reduction of scaffolding requirements,
– Ability to operate continuously, unmanned,
– A wide range of employee operator types, providing worker diversity options,

Delivering a wide range of efficiency, safety, cost, employee and quality benefits, “Boltron” is a unique and highly beneficial piece of equipment for use at a wide range of industrial sites.

Specifications

Boltron is customised to suit each application however a typical system specification is as follows;

Boltron Tool
• Overall Dimensions: 1200 x 2050 x 1800 mm
• Theta-Axis Rotation Range: 0 – 370°
• Theta-Axis Maximum Speed: 2 RPM
• R-Axis Stroke: 400 mm
• R-Axis Maximum Speed: 100 mm/s
• Z-Axis Stroke: 1100 mm
• Z-Axis Maximum Speed: 130 mm/s
• Nut Holder Stroke: 150 mm
• Flange Thickness: 1245 – 270 mm
• MGW: 420 kg
• Torque Tool: RAD Torque 25GX-2
• Torque Capacity: 950 – 3400 Nm (700 – 2500 ft.lb)
• Torque Accuracy: +/- 4%
• Magnet PCD: 1030 mm
• Bolting PCD: 1900 – 2700 mm
• EE Reach: -400 to +1050 mm
• Grease Type: Shell Gadus S2 or similar
• Temperature Rating: 5 – 50°C (-5 – 70°C Storage)
• Protection Class: IP 65

Control Station
• Overall Dimensions: 1030 x 1000 x 2000 mm
• MGW: 500 kg
• Power Supply: 400 VAC / 32A, 3ph / 50Hz, 5-pin straight plug
• Pneumatic Supply: 7 – 8 bar @ 850 LPM, [100 – 120 psi @ 30 cfm], Clean, dry air required, JIC M ¾” Connection
• Oil Type: ISO6521-1 / 6743-11 Air Tool Oil
• Temperature Rating: 5 – 50°C (-5 – 70°C Storage)
• Protection Class: IP 54

Deployment Crate
• Overall Dimensions: 1420 x 2520 x 2150 mm
• MGW: 1500 kg
• Protection Class: IP 64

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