Subject of This Blog on Welding Rotator:
A. Wide Use: The other names of the equipment include: Welding Roller Bed, Welding Turning Roll, has very large applicating volume in Industries: Wherever there exist demand on cylindrical parts fabrication, there exists demand on Welding Rotator;
B. Subject: In everyday application, Welding Turning Roller comes in wide variety of structure and specifications, to cater for multifarious change of workpieces. This blog aims on serving as “One Page Summary” on Welding Rotator: A guideline for new learner, an overview for a veteran on this important welding equipment.
A. Usage and Application of Welding Rotator:
1. Task:
This is a kind of general purpose welding equipment for Welding, Assembly, Testing on different diameters of cylindrical parts, such as pipe, tube, vessel, tank, etc.;
2. Application of Welding Rotator:
1) Welding Rotator has wide application in many industries, especially concentrated in Petrochemical, Pressure Vessel, Boiler, Offshore Wind Tower, Oil and Gas Transportation, etc.;
2) Welding Rotator is the one of the most widely applied welding equipment. Working together with robots/ Welding Manipulator (Column and Boom welding machine), Welding Rotator can also be tailor made into various Welding Center.
B. Classification on and Main Specifications of Welding Roller Bed:
The 3 most often seen categories of Welding Roller Bed include automatic Self Adjusting, Bolt Adjusting, and Leadscrew Adjusting:
1. HGZ Series Automatic Self Adjusting Welding Roller Bed:
Batch production on HGZ80 at Wuxi JACK workshop: (Fig.1)
1) Structure and Working Style: The surrounding angle of its two pieces of Welding Turning Roll is adjusted automatically based on diameter and deadweight of workpiece put onto it;
2) Appearance: One set of Self Adjusting Welding Rotator has four pieces of Welding Turning Roller in each set of its Welding Roller Bed;
3) Loading Capacity: Standard models of the Self Adjusting Welding Rotator cover the range from 5 Ton (HGZ5 model) to 250 Ton (HGZ250 model);
2. HGK Series Leadscrew Adjusting Welding Roller Bed:
HGK5 model 5 ton loading capacity after painted at Wuxi JACK workshop: (Fig.2)
1) Structure and Working Style: This kind of Welding Rotator make adjustment on the center distance between the two pieces of Welding Turning Roll in the way of turning leadscrew, either by manual turning, or motor drive;
2) Loading Capacity: Standard models of Leadscrew Adjusting Welding Roller Bed cover the range from 2 Ton (HGK2 model) to 60 Ton (HGK60 model);
3) Characteristic: By means of leadscrew turning, the center distance adjustment on Welding Turning Roll features in stepless and continuous change;
3. HLK Series Bolt Adjusting Welding Roller Bed:
Batch production on HLK80 model 80 ton loading capacity at Wuxi JACK workshop: (Fig.3)
1) Structure and Working Style: Adjusts center distance between the two pieces of Welding Turning Roller, by means of fitting the securing bolts into different grades of mounting holes;
2) Loading Capacity: Standard models cover the range from 2 Ton (HLK2 model) to 1000 Ton (HLK1000 model); Special Welding Roller Bed can be up to 2000 Ton (HLK2000 model).
C. Function Views on Welding Turning Roll:
On the basis of the above mentioned differentiation on Welding Rotator, there are also some sub categories within each branch:
1. Stationary Welding Roller Bed:
This is main stream product of Welding Rotator: Its two or more sets of Welding Roller Bed are fixed into floor;
2. Motor drive Moving Welding Roller Bed:
Wuxi JACK movable HGZ20 model: (Fig.4)
Sometimes customers request on Welding Rotator with moving function, which is realized with installation of moving wheels and driving motor;
3. Anti-Drifting Welding Roller Bed:
Batch production on exported to Russia HLK80 model hydraulic drive at Wuxi JACK workshop: (Fig.5)
1) This is sophisticated version of Bolt Adjusting Welding Roller Bed. It is for preventing the large diameter cylindrical working parts from drifting during revolve on the Welding Roller Bed, so that to acquire accurate finished circumferential welding seam on workpieces;
2) Applicable loading capacity is from 40 Ton to 600 Ton;
4. Down Pressure type Special Welding Roller Bed:
Wuxi JACK HGK5 model leadscrew adjust downward pressing type: (Fig.6)
1) Purpose: This is Special Welding Roller Bed specifically for fabricating on small diameter tubes under firm clamping;
2) Structure: Besides the conventional Welding Roller Bed, it has an overhead downstroke pressing roller for holding the workpiece tightly during welding, together with corresponding mechanical structure and driving unit;
5. High Precision Bolt Adjusting Welding Roller Bed:
Close distance vertical view on HLK20 model: (Fig.7)
Specialty: By means of specially machined 6 edge rod connecting the two pieces of Welding Turning Roll, their revolving can be perfectly in phase. In this way, cylindrical workpiece revolves in the most stable and controllable manner
D. Technical Performance of Welding Turning Roller:
1. Rotating Linear Speed of Welding Turning Roller:
1) This is welding speed of the entire set Welding Rotator, which is the crucial process control parameter;
2) This linear rotating speed is adjusted with A.C. inverter, and shown in digit display. As for its management, operator turns the grey color speed control knob on operating pendant of Welding Rotator, based on welding technology and practical condition: (Fig.8)
2. Putting into Use of Welding Rotator:
1) Control board of the welding equipment is fit alongside the Welding Roller Bed;
2) There are control pushbuttons, switches, and lamps on the door of electric control board;
3) Besides, a hand held remote pendant is used to manage welding operation conveniently;
3. Material of Welding Turning Roll:
Different types of materials for bulding turning rolls of Wuxi JACK products: (Fig.9)
Based on loading capacity of Welding Roller Bed, there are 3 main types of materials: Polyurethane, rubber, and metallic.
