Background of This Article on Welding Roller Rotator:
1. Business Case: During technical communication between an East European customer and Wuxi JACK engineering team in Nov. to Dec. 2024, several technical details are discussed on configuration of these customer ordered Welding Turning Roller:
1) Movable or stationary Welding Roller Bed;
2) With hydraulic drive on workpiece lifting or not;
3) Max. loading capacity of loaded workpiece tonnage;
4) Way of adjusting span (Center distance) of Welding Turning Roller: Self adjust/ Bolt adjust/ Leadscrew adjust;
This gives us clue on write an article, to have a brief discussion on this welding equipment of various configured Welding Roller Rotator:
2. Topics Covered Here on Welding Roller Bed:
General View on Welding Turning Roller;
Structure and Usage of Hydraulic Welding Roller Rotator;
“High End” Product: Anti-Drifting Welding Roller Rotator;
Design on Some Special Welding Roller Bed;
Summary on Wuxi JACK Welding Roller Rotator
A. General View on Welding Turning Roller:
1. Wide Use: For welding on external and internal circumferential seams on cylindrical parts, Welding Roller Rotator sees extensive use across industries, which is one of the most largest selling volume welding equipment:
Wuxi JACK HLK80 model bolt adjusting Hydraulic Welding Roller Bed of 80 ton loading capacity, works at Russian customer facility, fabricating on large tanks: (Fig.1)
2. Technical Characteristic of Welding Roller Rotator:
1) Label: Giving first glance, Welding Roller Rotator is a kind of “Simple” product, compared with other types of welding equipment;
2) This is mainly in terms of structure: With a set of Welding Roller Bed, installed with groups of Welding Turning Rollers on its top, and driven with motor reducers, the welding equipment can be put into use:
a) A typical set of Wuxi JACK HGZ5 model stationary self adjusting Welding Roller Rotator of 5 ton loading capacity: (Fig.2)
b) With wheels at the bottom, Wuxi JACK movable Welding Roller Bed: (Fig.3)
3. Nowadays Market Supply Condition on Welding Turning Roller:
1) "Easy” Product: This makes Welding Roller Bed a kind of typical “Low threshold” product, that nearly all companies in Welding and Cutting Industry can produce this kind of equipment, even without technical support of engineers;
2) Fierce Competition: And because of this, Welding Turning Roller gradually becomes the fiercest competitive product in the market: that price of this product grows lower and lower, nowadays sometimes even looks unreasonable lower than manufacturing cost, just for companies to win orders from customers;
3) Breakthrough: So, under such market condition, how to acquire on favorable competitive position? The answer for Wuxi JACK engineering team is, to develop more Special Design Welding Roller Rotator with personalized functions and technical capabilities, relying on our strong and leading technical abilities.
B. Structure and Usage of Hydraulic Welding Roller Rotator:
1. Applicating Background of Hydraulic Welding Turning Roller:
1) Which kind of Workpieces: When customers produce tanks with joint segment, which means, the external circumferential welding is butt joint welding between 2 pieces of workpiece, very often the height of the 2 segments need to be adjusted to make sure its perfect alignment, especially for tanks with large diameters (Φ1000mm and above):
2) Large tanks for joint circumferential welding with Hydraulic Welding Roller Rotator: (Fig.4)
2. Working Principle and Application of Hydraulic Welding Roller Bed:
1) Manual Way of Height Alignment: Under such conditions, sometimes customers adopt with manual adjust: That height of Welding Turning Roller, which is support base of workpiece, is adjusted by operator manually, and confirmed with visual check. Advantage of such height adjustment is easy/ low cost/ quick operation, and disadvantage is low precision of height alignment, and toilful work of operator, especially when diameter of workpiece grows larger. By this time, Hydraulic Welding Roller Bed becomes useful machine tool for customers:
2) Hydraulic Drive Lift: As shown in below small photo, at idle side of Wuxi JACK Hydraulic Welding Roller Bed, hydraulic oil cylinder is installed in upright orientation, which, under drive of hydraulic pump station, pushes Welding Turning Roller upward in certain stroke, which in turn pushes workpiece upward accordingly:
Wuxi JACK production site on movable Hydraulic Welding Roller Rotator, oil cylinder (In yellow color square frame) and its driving source hydraulic pump station (In orange color square frame): (Fig.5)
3) Benefit: With such useful design, the lifting function Hydraulic Welding Turning Roller can be applied effectively at customer facility, for fabricating on large diameter tanks with high productivity and good performance:
Applicating site of Wuxi JACK Welding Center: LHZ5050 Welding Manipulator and HLK80 Hydraulic Welding Roller Rotator: (Fig.6)
C. "High End": Product: Anti-Drifting Welding Roller Rotator:
1. Technical Feature of Anti-Drifting Welding Roller Bed:
1) Label of “Large” and “Complicated”: Anti-drifting type Welding Turning Roller has some “Relationship” with the previous segment discussed hydraulic drive lifting version, but with more complicated design and working principle. This is mainly especially in terms of electric control system of the welding equipment;
2) Way of Welding Turning Roller Span Adjustment: Accordingly, anti-drifting type product is usually HLK series bolt adjusting type, which is suitable on heavy loading tonnage, with loading capacity of 100 Ton and above:
Wuxi JACK HK200 model heavy duty large Anti-Drifting Welding Roller Rotator: (Fig.7)
2. Application Scenario of Anti-Drifting Welding Turning Roller:
1) Applicable Workpieces: Also being suitable for used on fabricating on large diameter tanks, here Anti-Drifting Welding Roller Rotator is more focused on large workpieces with large pipe wall thickness (30mm and plus): For welding on such thick tanks, usually single pass of welding is not sufficient, and multiple passes of welding (2 ~ 3 times or more) is must, to make sure complete fusion of welding seam;
2) Why Need Anti-Drifting Welding Turning Roller: In the period of multiple passes of welding operation, the welding torch is easy to drift away from welding seam, thus brings along negative effect on welding quality, and produces inferior quality welding seams on tanks. By this time, special measures need to be taken, to manage on welding torch position always precisely aiming on welding seam. Here comes introduction of Anti-Drifting Welding Roller Rotator:
3. Work Principle of Anti-Drifting Welding Roller Bed:
The way of realizing anti-drifting capability is mainly by means of its electric control system:
1) Different from hydraulic drive lifting version, the electric control here is closed loop: There is displacement sensor embedded in electric control system of the equipment, which is installed at tip of welding torch, and firmly touches with end face of workpiece wall;
2) During multiple passes welding operation, suppose welding torch drifts away from proper position, the displacement sensor gives alarm signal immediately: This is real time feedback;
3) Displacement Enforcement: And according to signal from sensor, the control center of Anti-Drifting Welding Roller Bed gives out command on adjusting moving stroke of welding torch. Accordingly, welding torch moves to its instructed position;
4) Control Loop: Thus completes single circle of: Welding torch position detect → Sends out alarm signal if necessary → Give command on displacement → Welding torch moves. The entire closed loop control is effective all the while from begin to end, during operation period of Anti-Drifting Welding Roller Rotator.
D. Design on Some Wuxi JACK Special Welding Roller Bed:
With such “simple” structure of the equipment as mentioned previously, Wuxi JACK ingenious engineers develop special design Welding Roller Rotator, to best fit on customer requirement. Here we just give two examples as below:
1. Integrated Way of Welding Turning Roller Adjustment: Self plus Bolt:
1) Why Need Such Design: HGZ series self-adjusting Welding Roller Bed has advantages of convenient and quick operation: Just load workpiece onto its Welding Turning Roller, then the turning rollers will swing automatically according to diameter of the workpiece. Meanwhile, the constraint of such structure is its limited range of applicable workpieces:
Wuxi JACK HGZ5 Self Adjusting Welding Roller Rotator: (Fig.8)
2) Solution: To widen accommodating workpiece diameter scope, Wuxi JACK engineers design a kind of mixed way of center span adjustment: Self-adjustment integrated with bolt adjustment, which greatly expands applicable workpiece diameters of the welding equipment. Shown in below photo:
Mixed form: Self adjusting Welding Turning Roller being assembled onto bolt adjusting Welding Roller Bed: (Fig.9)
2. Hexagonal Prism Intensify Rigidity of Leadscrew Adjusting Welding Roller Rotator:
1) Why Such Design: For HGK model leadscrew adjusting type equipment, it has advantage of continuous adjusting on span of Welding Turning Roller, which is compared with HLK models bolt adjusting type. This gives customer more accurate management on center span. Of course, leadscrew adjusting Welding Roller Bed also has disadvantage, which is relatively obvious light loading capability, from several hundreds kilogram to 60 tons, the common seen 2 ton to 10 ton:
Wuxi JACK HGK5 model Leadscrew Adjusting Welding Roller of 5 ton loading tonnage: (Fig.10)
2) Increase Rigidity and In Phase Revolve of Leadscrew Adjusting Welding Turning Roller: To expand working capability of the equipment, Wuxi JACK engineers introduce hexagonal prism into drive and idler sections of Welding Roller Bed, which, not only greatly increases rigidity of mechanical system, but also make sure complete simultaneous revolve of both sides Welding Turning Rollers:
Wuxi JACK HGK20 model Special Design Welding Roller Rotator: With hexagonal prism, of 20 ton loading tonnage: (Fig.11)
E. Summary on Wuxi JACK Welding Roller Rotator:
1. Wuxi JACK Leading Edge: As can be concluded from the above brief discussion, relying our powerful engineering team, we distinguish ourself in this field of Welding Roller Rotator supply, by developing various personalized products for customers. This is different from other suppliers with very few engineers, who can only supply standard models for customers;
2. We expect more and more customers to give us opportunity to render service and bring great value for you, with our superior Welding Roller Rotator.
