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1. In the Welding Center:
1) One set of LHZ5050 heavy duty Column and Boom Welding Manipulator Machine, with column manual revolve function, and mechanical base bed (trolley) moving along rails under motor drive;
2) Six sets of HLK80 model (80 Ton loading capacity of welding roller bed) Bolt adjusting Welding Roller Support;
3) One set of HB30 Two Axis conventional Welding Positioner;
1) One set of Sweden ESAB produced LAF1601 SAW power supply, equipped with 15m long cables;
2) Welding head A6S ARCMASTER (SAW twin wire, Φ3mm diameter, ratio 156:1), for carrying out SAW finished welding in the Welding Center;
3) Welding head 30-100mm A6, for implementing on Strip cladding in Column and Boom Welding Manipulator Machine, installed on the front end of the horizontal Boom;
1) Control panel PEK with motorized support 300 x 300mm; A6 cable and PEK 5m of the welding power supply;
2) Welding flux nozzle for A6 strip head;
3) GMH automatic welding seam tracker on the front end horizontal boom;
4) 2 sets of 30kg SAW welding wire spool;
5) A6 welding wire straightening unit;
6) Complect TWIN 2x3mm;
7) 10L capacity welding flux hopper installed on the horizontal boom of Column and Boom Welding Manipulator Machine;
8) SAW twin arc welding torch installed;
9) 2 x Φ3.0mm twin welding wire feeding system;
10) Laser generator point and lamp for tracing welding seam during welding stage;
11) Strip belt reel, for acquiring on stripping cladding welding;
ESAB engineers tried on SAW Twin Arc and Strip Cladding welding heads at Wuxi JACK Facility:
1) The welding mode in this sophisticated Welding Machinery group is SAW (Submerged arc welding). SAW welding mode is applicable for fabricating on workpieces made of medium to thick thickness carbon steel;
2) Double Function Welding Heads: Specific in Welding Machinery of this Welding Center, the welding heads installed in the LHZ5050 Column and Boom Welding Manipulator Machine can implement on 2 kinds of SAW welding: The conventional single arc SAW finished welding, as well as Strip Cladding (Built up welding). The welding heads for carrying out the 2 kinds of SAW modes are different;
3) Top Level Welding Seam Produced: The SAW Strip cladding operation has high deposition rate, high welding quality, and low penetration rate. This high end welding head will produce a layer of 60mm width x 0.5mm thickness on surface of workpieces:
4) The strip cladding welding seam, delivered from built up welding head in the LHZ5050 Column and Boom Welding Manipulator Machine: (Fig.1)
5) Strip Cladding heads of the LHZ5050 SAW large Welding Center: (Fig.2)
6) Anti-drifting: The HLK80 leadscrew adjusting Welding Roller Support being equipped in this SAW Welding Center is hydraulic drive anti-drifting type welding roller bed;
The Max. Vertical Stroke of Horizontal Boom | 4000 mm |
The Max. Horizontal Stroke of Horizontal Boom | 5000 mm |
Diameter Range of Workpiece Tank | Φ1000 ~Φ4500 mm |
Boom Horizontal Extending and Retracting Speed | 120 ~1200 mm/min. |
Adjustment Way of Boom Horizontal Extending Speed | VFD (Variable frequency drive) A.C. inverter |
Boom Vertical Up and Down Moving Speed | 1000 mm/min., Constant |
Boom Horizontal Extending and Retracting Transmission | Gear and rack |
Boom Vertical Up and Down Movement Transmission | Chain and sprocket |
Cross slides Stroke | Vertical and horizontal 300mm, ESAB |
Welding Power Supply Brand and Model | LAF1601, ESAB |
Welding Wire Feeder | A6S twin wire ratio 156:1, ESAB |
Welding Control Console Panel | PEH type, ESAB |
Welding Seam Automatic Tracking Device | GMH type, ESAB |
Saddle for Operator | One set |
Video Camera | One set |
SAW Welding Flux Recovery Unit | One set |
Configuration of Welding Manipulator Machine | Motor drive trolley and manual turning column |
1) Customer is from a Chinese pharmaceutical industry;
2) Task: Produces thin wall (2~3 mm thickness) small to medium diameter pipes made of stainless steel;
3) Main Welding Operation: The required welding operations in this Welding Center are external longitudinal seam welding and circumferential seam welding on pipes;
4) Applicable Welding Mode: The workpieces pipe have wall thickness ranging from 1mm to 5mm, which should be adopted with CO2 GMAW Welding.
Application: For going on Oil and gas pipeline production:
1) The busy working site of this Wuxi JACK heavy duty SAW large Welding Center:
2) Customer: This heavy duty SAW large Welding Machinery group was designed and produced by Wuxi JACK for an Indonesia customer of Petrochemical Plant;
3) Task: As shown in the above photos, it has the task of producing large size pipelines;
4) Welding Operations: External and internal longitudinal and circumferential seam welding on large tanks;
5) Stiffener Bars inside Large Pipes: When carrying out internal welding inside the large diameter and thin wall tanks, as shown in the above photos, there should be cross arranged stiffening bars propping inside the tanks, to prevent the large tanks from deformation.
1. Characteristics: Compared with the previous 3 business cases of medium to large duty, here workpieces and equipment of this MIG Welding Center has light weight and compact size;
2. Function and Working Feature: It is used for welding various specifications of pipe flange parts in the optimum welding position, with welding mode of MIG (Metal inert gas welding);
3. Applied Welding Machinery: As can be observed from the above photos, this MIG Welding Center is composed of special made Welding Positioner, special made tilting type leadscrew adjusting Welding Roller Support, and tailor made Welding Fixture;
4. Easy Handling: Due to its light weight and flexible arrangement, such kind of MIG Welding Center can be installed and relocated easily and conveniently at customer sites.