A. Function and Application of LHD1000 Long Pipe and Rod Moving Gantry Welding Machine:
1. What For: This machine is for welding on long length workpieces( Such as steel pipes/ rods) after joint spot welding. The welded workpiece is placed on the V shaped bracket:
Long pipe laid on 2 pieces of V brackets for welding: (Fig.1)
2. Type of Welding: It can be back welding after spot welding, or finished welding, in the form of external longitudinal welds:
Finished longitudinal CO2 welding seams on long pipe, fabricated from the Long Pipe Welding Machine: (Fig.2)
3. Welding Modes: CO2 GMAW or SAW Submerged arc welding;
4. Applied Industry: This Long Rod Welding Machine is necessary equipment in all manufacturing sectors, where long pipes as working parts: Oil and Gas Transportation/ Petrochemical/ Oil Derrick, etc. It has flexible structure and arrangement.
B. Working Principle of LHD1000 Longitudinal Seam Long Rod Welding Machine:
1. Working Way of the Gantry type Long Pipe Welding Machine:
1) Welding Seam Position: The SAW (Submerged arc welding) gun on the gantry is aligned with the welding seam at the 12 o'clock position, directly above the welded pipe;
2) Welding Operation: The SAW welding gun moves together with gantry moving under the machine adjustable welding speed, along the entire length of the long length workpiece, and carry out SAW welding on the workpiece at the same time;
3) Lateral view on welding torch mechanism on moving gantry, workpiece (Long pipe), and welding operation arrangement in Gantry type Long Pipe Welding Machine: (Fig.3)
2. Position Adjustment: When welding, you need to adjust on the height of the V shaped bracket at the lower part of the workpiece welding rod, so that welding seam at the 12 o'clock position on the upper part of the workpiece (Welding rod/ welding pipe) is at horizontal position;
3. Welding Seam Trace in Gantry type Long Rod Welding Machine:
1) Significance: Correct and on time tracing on welding seam of welding tip, is prerequisite on welding quality assurance of the machine;
2) Way of Welding Seam Trace: The real time alignment of welding torch on welding seam is traced with laser point. Manual cross slide on welding torch unit is used for fine tuning on welding tip position control, making welding gun to be adjusted to align with the welding seam all the while, during the entire welding period;
3) Welding torch device, its manual cross slides, laser point of LHD1000 Long Pipe Longitudinal Seam Welding Machine: (Fig.4)
4. Welding Speed of the Long Rod Longitudinal Seam Welding Machine:
1) Then, welding power source can be turned on for welding;
2) The walking speed of the motor drive moving gantry is welding speed of the machine, which can be adjusted continuously with variable frequency A.C. inverter, and digitally displayed on operating panel;
3) The welding speed can be adjusted freely by operator, by turning speed knob of the operating pendant;
5. Automatic Welding: The Long Pipe Longitudinal Seam Welding Machine is equipped with welding wire reel bracket, welding wire conveying tube, to realize automatic welding on workpiece: Long length welded rods and pipes.
C. Technical Performance and Characteristic of LHD1000 Longitudinal Seam Long Pipe Welding Machine:
1. Main Units of the Long Pipe Longitudinal Seam Welding Machine:
1) Business Background: This machine is developed by our company based on requirements and workpiece design prints from customer, for carrying out SAW submerged arc welding of long welding seams on workpieces, combined with our company's many years of technical experience in developing welding equipment;
2) Main Units: This Moving Gantry Welding Machine mainly consists of a motor drive moving gantry, a motor drive moving carriage mechanism, a welding gun adjustment device, a SAW submerged arc welding power supply, electrical control system, etc.;
3) Design prints of workpiece long rod from Russian customer: (Fig.5)
2. Gantry Moving: The gantry is the skeleton part of the Long Pipe Welding Machine. The gantry moving mechanism is driven bilaterally with two pieces of A.C. motors through frequency conversion control, A.C. inverter. There is a wheel supporting mechanism on the side of the rail to ensure the smooth and safe running speed of the gantry;
3. Adjusting Welding Gun Position on Gantry Beam of Long Pipe Longitudinal Seam Welding Machine:
1) Welding Arm on Gantry Front Beam: Through multiple sets of adjustable eccentric rollers and high precision rectangular guide rails, the welding gun and head can run smoothly up and down, left and right;
2) Fitting on Workpiece Sizes: The welding arm moves up and down using a reducer and a gear and rack mechanism to adjust the position of the welding gun, to adapt to the welding of different specifications of workpieces, ensuring smooth and reliable operation:
3) Front view: Welding arm device arrangement on Gantry type Long Pipe Welding Machine, and workpiece (Long pipe or rod) placement: (Fig.6)
4. Welding Seam Tracking Mechanism in Gantry type Long Rod Welding Machine:
1) Usage: This unit traces on the welding seam with a red laser point in front of the welding gun;
2) The welding gun at the back is adjusted to the welding seam with a manual cross slide;
3) The welding gun is adjusted to the welding seam for implementing on SAW submerged arc welding of long straight welds;
4) This method of weld alignment adjustment is suitable for welding long straight welds such as light poles;
5. SAW Submerged Arc Welding in Longitudinal Seam Long Pipe Welding Machine:
1) Moving speed of the motorized moving gantry is also welding speed of the machine. This speed is continuously adjusted with the frequency converter (A.C. inverter), the welding speed is in the range of 200-800mm/min.;
2) Welding Operation: For the spot welds when the long workpieces (Such as light poles) are jointed, they are also welded at the same set speed;
3) SAW Merit: Large current SAW submerged arc welding welds have good appearance, and of good quality from the Longitudinal Seam Long Rod Welding Machine;
4) Power Supply of SAW Submerged Arc Welding: We select Chinese HUAYUAN brand LG-100IGBT power supply as the submerged arc welding power supply. The rated output current is 1000A, the rated output voltage is 44V, and the duty cycle is 100%. See picture below:
5) Chinese HUAYUAN SAW power supply equipped with the Long Pipe Welding Machine: (Fig.7)
6. Welding Supporting Units of Long Pipe Longitudinal Seam Welding Machine:
1) Submerged Arc Welding Flux Conveying and Recycling System:
a) There is a welding flux conveying and recycling machine with a full load capacity of 100kg;
b) The welding flux is automatically sent to the position of the welding gun for SAW welding;
c) There is a welding flux suction nozzle at the back to recover the un-sintered welding flux and recycle it;
2) Submerged Arc Welding Conductive in Long Rod Longitudinal Seam Welding Machine:
a) The cables of the motor drive traveling gantry are connected through the hanging wire bracket next to the gantry;
b) The power cord and welding ground cable of machine and SAW power supply are reliably connected;
c) This makes sure on: The SAW submerged arc welding current is stable, and the weld seam is well formed;
7. Electric Control in LHD1000 Gantry type Long Pipe Welding Machine:
1) Gantry Moving: The motorized gantry traveling motor adopts variable frequency stepless speed regulation, which is A.C. inverter. The gantry moving speed is digitally displayed;
2) Control Logic: The start up of the SAW submerged arc welding power supply and the movement of the gantry are controlled in a linkage manner.
D. Supply Scope of LHD1000 Long Rod Longitudinal Seam Welding Machine:
1. Gantry Assembly, including： Gantry frame, moving drive and transmission device, motor drive welding torch carriage；
2. Welding Arm Mechanism, including： Welding arm, mechanical transmission mechanisms and accessories;
3. Welding Arc Guide Device, including： Welding gun adjustment cross slides, welding gun;
4. Electric Control System, including： Electric control board of the Gantry type Long Rod Welding Machine, A.C. inverter, operating pendant, illuminating lamp, alarm lamp, etc.；
5. Piping and Cable Routing System, including： Power cord and control cable of SAW welding power supply, welding cable, gantry moving control cable, gas supply pipe, cable hanging sliding rack, etc.；
6. SAW Submerged Arc Welding System, including： 1 set of Chinese Chengdu HUAYUAN SAW welding power supply ZD7-1000IGBT and welding wire feeder；
7. SAW Submerged Arc Welding Flux Recycling Machine and spare parts, including： 1 set，2 pieces of conduct tip, push buttons, fuse respectively；
8. Technical Documents： Manual book（Include electric diagram）of LHD1000 Longitudinal Seam Long Pipe Welding Machine, A.C. inverter manual book, SAW welding power supply manual book, machine certificate of quality, machine packing list, machine foundation drawing, drawing of customer self-made parts.
E. Technical Parameters of LHD1000 Long Pipe Longitudinal Seam Welding Machine:
No. | Parameter | Specification | Note |
1 | Welding Pipe Diameter | Φ200－Φ1000mm |
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2 | Welding Pipe Length | 5—12m |
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3 | Moving Gantry Rail Span | 2500mm |
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4 | Gantry Rail Length | 14000mm |
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5 | Welding Speed | 200－2400mm/min. | Double Drive |
6 | Welding Seam Position | 12 O’clock |
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7 | SAW Power Supply | Chengdu HUAYUAN MZ-1000 |
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8 | SAW Welding Wire Size | φ2.4－5.0 mm |
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9 | SAW Welding Flux Sending and Recycling Machine | 1 set, 100kg welding flux capacity，power 3.0KW | Automatic send and recycle |
10 | Total Power of Machine | Machine：Around 7.0kW |
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11 | Rated Power of SAW Power Supply | Around 53 kVA，1 set |
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12 | Electricity | 3 Phase AC380V 50Hz |
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