Longitudinal welding center is composed of welding manipulator (fixed and rotating base), 1000A submerged arc welding power, flux recycling system, 5t conventional welding rotator and electrical control system .
Technical specification
1. Longitudinal welding center
1.1 Introduction
This center is composed of welding manipulator (fixed and rotating base), 1000A submerged arc welding power, flux recycling system, 5t conventional welding rotator and electrical control system .
The welding manipulator (fixed and rotating base) not only for inside/outside longitudinal welding, but also for the flange welding. The manipulator vertical and boom is joint by coupling (with guide roller), which make sure it have stable security and supply max loading.
The elevating part has falling protector that makes sure reliable safety .Wherever the boom, if there have any danger, the protector will lock the boom and prevent falling immediately. Boom can move position in horizontal and vertical direction. Precision gear rack drive part makes sure there have stable welding speed. Control system have integration function ；Vertical boom , boom ,welding head are controlled in the hand remote box.
It equips our company’s welder submerged arc welding power MZ-1000 and welding head on the manipulator .Flux conveying and recycling system is safe, reliable and stable that can meet all requirements. Reasonable flux conveying /recycling avoid overflow of flux, which reduce the flux amount usage .And keep clean.
Conventional welding rotator: It is composed of one driving roller and one idle roller .Welding rotator, welding manipulator and welding power these three parts form one set control. It is easy for operating.
In a word，this center have high production efficiency, so it is good equipment for welding .
1.2 Shells assembly
1.2.1 Longitudinal welding center
| Item | Name | Qty | Unit | Remarks |
| 1 | LCH3030 welding manipulator (fixed and rotating base) | 1 | set | |
| 2 | MZ-1000 welding system for LCH3030 | 1 | set | |
| 3 | Flux recycling system for LCH3030 | 1 | set | |
| 4 | 5t conventional welding rotator | 1 | set | |
| 5 | Electrical control system | 1 | set |
1.2.1 LCH3030 technical parameter
Model： LCH3030
Type： base fixing and rotating
Effective stroke of boom： 3000mm
Elevating speed of boom： 1000mm/min
Effective stroke of Boom： 3000mm
Boom expansion speed（stepless adjusting）：0.12-1.2m/min
Vertical rotating angle： ±180°(motorized )
Motorized cross adjusting of cross front-end： 100×100mm
Front end loading of boom： 250kg
Structural feature of welding manipulator:
This machine is composed of column (including lifting device, sliding carriage, anti falling device and balance weight device), boom (including rack and boom driving device), etc.
Column and boom are all welding structure, with good rigidity, and removed stress after welding, then plane and rubbing, thus ensure the high precision and wearing resistance of guide rail.
Material of guide rail is 16Mn, and through heat refining, this can extend the service time of guide rail.
Boom is fixed on the guide base, and uses the frequency stepless speed regulation; torque is big under a low speed. It can expansion along the sliding base, its expansion adopts AC motor driving reducer and then drive by rack and pinion. Guide base is fixed on column post, and can elevating in uniform speed along the post.
There is anti falling device on boom, it uses bar and pawl device, when the elevating chain broken, the pawl can insert into the bar quickly under the action of spring to prevent boom falling down.
There are fence and inspection platform on elevating motor reducer place, so that user can inspect and add oil easily.
There is cover on ladder above ground 2 meters to protect workers.
Main components list：
| Name | Company | Notes | |
| 1 | Button | Hangzhou SANLI | |
| 2 | Digital display | DONGQI | |
| 3 | Frequency | Taiwan TAIAN | |
| 4 | Manual operating box | Wuxi | |
| 5 | Contactor | TIANSHUI | |
| 6 | Expansion motor reducer | BONENG | |
| 7 | Elevating reducer | Wuxi TAINYI | |
| 8 | Others | CNHT | |
| 9 | Bearing | HA,LUO,WA bearing company |
1.2.2. Conventional welding rotator
Conventional welding rotator including one power and one idle, through adjust the center distance to suit for different diameter work-piece and satisfy customer’s requirement for welding work-piece. The transmission mechanism is adopt frequency speed adjust.
Technical parameter：
Model： GLHK-5T
Max load capacity: 5Tons
Suitable work-piece range: ф250-ф2500mm
Rubber roller diameter: ф250×100
Metal roller diameter: 2×ф240×20
Roll linear speed: 6-60 m/h
Speed adjust mode: frequency stepless speed adjusting
Motor power: 2*0.37KW
Structural feature of 5T conventional welding rotator:
It is made up of drive rotator and idle rotator
The drive rotator is made up of base, roller base, rollers, rotating driving motor and electric control system.
The idle rotator is made up of base, roller base, rollers and electric lead screw lifting driving motor.
It is driven by AC motor, and its speed is adjusted by frequency, It has a wide range of speed adjusting and strong low-speed characteristic, and can run smoothly.
The roller surface is made from PU, thus has a long service lift.
The bearing at roller rotating position uses HA, LUO, WA brand.
The frequency is from Taiwan TAIAN, other electric components use Schneider.
It is special designed, and is suitable for work piece with different diameters, and can ensure the welding seam is on a level position, easy for welding.
Special coating roller fits the cylinder, and convenient for welding.
1.2.3 MZ-1000 submerged arc welding system
MZ-1000 welding system includes ZX5-1000 SAW welding power, elevating type SAW head, control box, welding cable and control cable.
1.2.3.1 ZX5-1000 welding power
This power has easy electrical circuit and easy to repair. The main AC contactor has a long life and doesn’t have current switching. It can be used in submerged arc welding, carbon arc air gouging and electro-slag welding, easy and reliable to operate.
1.2.3.2 Elevating type SAW head
Combined type feeding wire wheel improves its useful time and production efficiency.
The deceleration system can ensure the stable of wire feeding.
The wire regulate device can ensure the good condition of wire
1.2.4 Welding flux automatic feeding and recovery system
The equipment adopts pressure feeding system and has a stable station and long feeding distance.
It uses vacuum pump type recovery system. When the machine working, the air in the recycling box will be aspirated by the blower through dirt catcher, and thus produces sub pressure, then the air together with welding fluid will come into the flux container. This recycling system has simple structure and high efficiency, and can be used conveniently.
Technical parameters:
- Type YS-GHS80
- Capacity 80L
- Maximum horizontal feeding speed： 8M
- Recovery speed: ≥28 kg/h
- Recovery linear distance: ≤10M
1.2.5 Control system
l The low-voltage electric parts uses Schneider brand
l The inverter comes from Taida.
l It has multi-protection/alarming function, such as over-voltage, over-current and under voltage;
l It has advanced trouble diagnosing function and trouble display function.;
l It has standard, normative and reliable earthing device;
l It has protection for short circuit and creepage, thus can protect the people and machine when power cut off or machine stop suddenly;
l All the cables are insulated and protected with rubber at the places of metal parts. Its cable support frame is against the wetness. Moving cable has cable chain or slip line device, and other cables in suitable protections;
l Its wiring is normative and beautiful. Fixing circuitry has pipe and pipe end has cap to protect pipe; mobile wire and cable also have protecting measure;
l It meets the national standard of quality and safety；
Second，its control system is unite designed and manufactured as a complete device. The control system is usable, convenient, and safe for users.
- There is remote control box on the manipulator
- The parts on the remote control box of manipulator:
(1) The power indicator, start button and stop button
(2) It can control the moving of car, the elevating and expansion of boom
(3) It can adjust and indicate the boom expansion speed
(4) Control the rotating direction and stop of rotator
(5) Control the speed of rotator
(6) On and Off of welding
3. The rotator has local control and remote control functions (remote control is on the manipulator control box)
4. There are power indicator, on button and emergency stop button on the manipulator main control box
