Long-Time Partnership with Lincoln Electric Contributes to Company’s Success
Other equipment being manufactured by the company includes whole tree chippers, brush chippers, stump grinders, and shredders.
Fabrications weighing in at up to 56 tons roll off Morbark’s numerous production lines. The company uses manual, semi-automatic and robotic welding processes in its operations. Here is a closer look at how welding has contributed to this 55-year-old company’s success.
From Its Roots
While Morbark equipment is used on trees of all sizes, its own roots go back to 1957 when Norval Morey, a sawmill owner, was approached by Robert M. Baker with an idea – to create a machine that easily removes bark from logs. This machine soon became the basis of a multi-million dollar a year company with an extensive portfolio of products being used around the globe.
To understand how critical Morbark's welding operations are, you just have to look at the capabilities of some of the manufacturer's equipment.
The 2355, 2455, and 2755 model flails also feature an optional cab and loader, all of which are manufactured onsite at the Winn facility.
With two shifts and four team members, this welding area includes a six-axis, servo-controlled robot loaded with Touch Sensing and Through Arc Seam Tracking (TAST) application software and capable of 1/10 mm repeatability.
“We are a build-to-order shop, anticipating customer needs and building our equipment so that it's ready to go as soon as possible after an order is placed,” Barry Sellers, Morbark Production Supervisor, explains.
Since tack and weld time can range from two hours on a smaller machine up to four weeks on larger equipment, efficient planning and production methods are critical for Morbark.
The company uses Lincoln Electric’s pulse welding process for many of its applications. This process reduces heat input enabling welding on thinner materials without burnthrough. Increased control over distortion is made possible because of the ability to more closely control the heat input.
Morbark has instituted Lincoln Electric Production Monitoring™ software on as many of its welding power sources as possible, which is an advanced web-based weld data collection and monitoring tool.
The company’s team can easily monitor wire feed speed, welding current and voltage and other parameters associated with each weld. They can store and share files, monitor production tasks, set weld limits and tolerances and track consumable use. Diagnostic troubleshooting can be performed from any remote location.
The welding engineer can set welding limits from his office, collect and store short- and long-term weld history, execute actions or develop communication alerts when out of limit. It also allows him to monitor productivity by machine and by shift, evaluating production cycles and individual welder arc-on time.
“We use more than 75 different welding procedure settings and the monitoring allows us to uniformly control the machines across the board and create consistency between welders,” Sellers states.
The manufacturer has also transitioned to Lincoln Electric’s Magnum® PRO Copper Plus® contact tips for their welding guns and torches wherever possible.
“The Magnum® PRO tips last three to four weeks versus one week on what we were previously using,” Sellers says.