Subject of This Blog on Welding Rotator:
A. Importance: Welding Rotator, the other names include: Welding Roller Bed, Welding Turning Roll, has very large using 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 guide for new learner, an overview for a veteran on this important welding equipment.
Usage and Application of Welding Rotator
Classification and Main Specifications of Welding Roller Bed
Function Views on Welding Turning Roll
Technical Performance of Welding Turning Roller
A. Usage and Application of Welding Rotator:
1. Usage of Welding Rotator:
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 Column and Boom, Welding Rotator can also be tailor made into various Welding Center.
B. Classification and Main Specifications of Welding Roller Bed:
The 3 most often seen categories of Welding Roller Bed include Self Adjusting, Bolt Adjusting, and Leadscrew Adjusting:
1. HGZ series Self Adjusting Welding Roller Bed: (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 Self Adjusting Welding Rotator cover the range from 5 Ton (HGZ5) to 250 Ton (HGZ250);
2. HGK series Leadscrew Adjusting Welding Roller Bed: (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) to 60 Ton (HGK60);
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: (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) to 1000 Ton (HLK1000); Special Welding Roller Bed can be up to 2000 Ton (HLK2000).
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 of Welding Rotator: Its two or more sets of Welding Roller Bed are fixed into floor;
2. Motor drive Moving Welding Roller Bed: (Fig.4)
Sometimes customers request on Welding Rotator with moving function, which is realized with installation of traveling wheels and driving motor;
3. Anti-Drifting Welding Roller Bed: (Fig.5)
1) This is sophisticated version of Bolt Adjusting Welding Roller Bed. It is for preventing the cylindrical working parts from drifting during revolve on the Welding Roller Bed, so that to get accurate finished circumferential welding seam on workpieces;
2) Applicable loading capacity of Anti-Drifting Welding Roller Bed is from 40 Ton to 600Ton;
4. Down Pressure type Special Welding Roller Bed: (Fig.6)
1) Purpose: This is Special Welding Roller Bed specifically for welding 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: (Fig.7)
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 Rotator is fit alongside the Welding Roller Bed;
2) There are control pushbuttons, switches, and lamps on the door of Welding Rotator control board;
3) Besides, a remote pendant is used to manage the Welding Rotator conveniently;
3. Material of Welding Turning Roll: (Fig.9)
Based on loading capacity of Welding Roller Bed, there are 3 main types of materials: Polyurethane, rubber, and metallic.
