Robotics

Revolutionizing Crankline Repairs with Robotic Welding

At Fairbanks Morse Defense, innovation drives everything we do. By integrating state-of-the-art robotic welding systems, we’ve transformed the welding process to deliver unmatched precision, efficiency, and reliability. Our approach combines the speed and consistency of robotic technology with the expertise of skilled welders, creating a powerful synergy that sets a new standard in welding excellence.

FMD Robotic Welding Solution

Our robotic welding system is designed to address traditional welding challenges by automating and optimizing the product rebuild process. Key features include:

Automated Path Planning: The robot scans the are needing repair, models weld zones, and generates its own path, significantly reducing setup time.
Integrated Weld Conditioning: A secondary arm performs peening as part of a continuous weld cycle, enhancing weld quality and durability.
In-Process NDT (Non-Destructive Testing): Real-time weld quality monitoring using vision and sensor data eliminates the need for extensive post-weld inspections.
Track-Based Precision: The system enables precise passes over block saddles, building up material for machining—ideal for submarine and LSD OP engines.

Key Features of Robotic Welding

Modular and Portable Design: Engineered for confined shipboard spaces, the system is portable and easy to deploy in challenging environments.

Automated Path Planning: The robot scans the crankcase, models weld zones, and generates its own path, minimizing setup time.

Integrated Weld Conditioning: A secondary arm performs peening as part of a continuous weld cycle, enhancing weld durability.

In-Process NDT (Non-Destructive Testing): Real-time weld quality monitoring using AI and sensor data reduces the need for post-weld inspections.

Track-Based Precision: Enables precise passes over block saddles to build up material for machining, ideal for submarine and LSD OP engines.

Machine Learning Integration: AI identifies weld quality in real time, enabling continuous process improvement.

Benefits of Robotic Welding

Reduced Downtime: Automating the process allows for round-the-clock operation under technical supervision, cutting repair timelines dramatically.

Improved Consistency: Robotic precision ensures high-quality, repeatable welds using Navy-certified procedures, reducing errors and rework.

Cost Savings: By minimizing delays and optimizing workflows, robotic welding significantly lowers overall repair costs.

Enhanced Safety: Automation reduces the physical strain on skilled welders, allowing them to focus on complex, high-value tasks.

Workforce Support: Robotic welding complements skilled welders, allowing them to focus on complex, high-value tasks such as peening, porosity correction, and hazardous work.

Enhanced Productivity: Robotic welders work up to 3× faster than manual welding, cutting timelines significantly

Aligned with Submarine Modernization

This robotic welding initiative supports submarine modernization efforts and leverages advancements in commercial CPBPT welding technology. By partnering with additive manufacturing vendors, we’re driving innovation and ensuring our solutions meet the Navy’s rigorous standards.

Proven Success

Our robotic welding system has already demonstrated its value in early prototyping and supplier engagement, paving the way for validated Navy use. With its ability to deliver faster, safer, and more consistent repairs, this technology is setting a new standard for overhauls and repairs.

USS Florida – Submarine Repair Project: Successfully completed an emergent crank line repair with speed and precision, showcasing the system’s reliability in mission-critical operations.

USS West Virginia: Reduced crankline repair timelines by weeks, saving significant costs and improving operational readiness.