Innovative low-cost technologies for

manufacturing high-strong metal structures

Voronezh 2014

Project Manager: Muravjev Ivan

This innovative technology developed for the ribbed panels (mikropaneles) and profiles, which  widely used in building of long welded structures, shipbuilding and construction of bridges.

Basic concepts and definitions.

The basic problems in the manufacture of these constructions consist in increase the strength characteristics of the load-bearing structures with lowing deformation products after welding to the level of allowable values.

Basic technology

At this time the basic technology of assembly and welding ribbed panels is multistage, laborious and consists of the 7 operations, including:

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1. Assembly and glove ribs to the sheet with a preliminary pressing of.

2. Automatic welding ribs to the sheet with a preliminary inverse deflection.

3. Scraping weld in places tacks.

Press portal

Welding tractor

Abrasive disk

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Edit the longitudinal and transverse deformationsgas burner

gas burner

2. Welding simultaneously 2-3 ribs portal installation

Consists of two operations:1. Fixation and loading ribs in the stand.

Innovative technology

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1.Internal stresses (no pot and thermomechanical edits after welding)2.Stress concentrators (the absence of lack).

The increase static and fatigue strength is achieved due to the significant reduction:

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Stress concentrat

or

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Stable Gap

Photo prototypes

Lack of penetration (existing technology) - is the area of the weld compound with no alloying between the welded parts, i.e. defect.

Area full penetration (innovative technology) - this is an area with penetration weld joint between the welded parts, i.e. without defect

The scientific component of the project is the introduction of the mechanical load of ribs by the special scheme, providing compensation welding deformations directly in the process of welding. The high dependence of deformations from potholders ribs to grazing sheet has defined its replacement by commit ribs relatively sheet at the special stand.

Innovative technology and installation allow you to give the optimal gap between the leaf and ribs, it provides full penetration in the connection between the edge and the sheet, and consequently, increase of static and fatigue strength.

Scientific innovation

-Increase of static and fatigue strength of load-bearing structures in 2 to 4 times or decrease in weight; -Reduction of labour input of manufacture of panels 6 times;-Reducing the cost of its production in 2.3 times;-Reduction of production space in 3 times;-Improvement of sanitary and hygienic conditions labour;-Ease of installation of structures through increase accuracy of manufacturing of incomingdetails.

The results of introduction of innovative technologies

1. The technology is protected by patent RF.

2. Manufactured by experienced tooling and put into production 96 real bridge structures. There is an act of implementation

3.The positive conclusion of an independent examination of the «Agency for innovation and development».

4. Innovative technology has no analogues in the world.

5. Positive feedback were got from two central design offices of Sevastopol «Chernomorets» and «Coral».

At the moment

1. Robotic equipment for automatic welding of complex cross-panel set;

2. Ability to manufacture panels with small curvature (important for shipbuilding);

3. Replacing extrusions cheaper welded.

Prospects for further development of innovative technologies

COMPETITORS

technology number of operations

required space, m2

cost of one unit, € .

IMG* (Germany) 5 1800 6 million

our decision 2 600 1 million

* IMG launches production lines for the manufacture of panels for the old technology with all the above negative moments.

Customers• shipyards• bridge-building plants• factories of metal construction

The Russian market is more than 140 plants.

Market

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2014 2015 2016 2017 2018

Mln.r

fixed costs

variable costs

breakeven point

revenue

Financial Model - the breakeven point of the project (mln.r)

Based on the calculation of breakeven point that the planned production volume of innovative installation LLC "Stroyinpromteh" in 2014-2018gg. provides a cost-effective operation of the project, making a profit and payment of current liabilities.

TEAM

Director, Ph.D.Muravjev I.I.

Manager – Economist,Popova V.A.

Deputy. Director, LawyerKornev S.U.

Estimator - prochnist, Ph.D.,Sventikov A.A.

Deputy. Director new technologiesPodvalnyy M.L.

«Воронежский ГАСУ»

ООО«СпецСтальТехМонт

аж»In collaboration with

ОАО«Электромашиностроительный

завод»(Симферополь)

ООО«Велдинг Групп»

(Самара)

ООО«Стройинпромтех»

TEAM OF THE PROJECT

THANK YOU FOR YOUR ATTENTION!