How to operate the Welding Rotator?

Main Idea of This Blog on Pipe Welding Turning Rotator:

1)       Wide Application: Pipe Welding Rotator can be seen everywhere endowed with cylindrical working parts, the most typical ones are pipes of various diameters and wall thickness;

2)       Wide Variety: In practical application of the Pipe Welding Roller Rotator, there are numerous types of Structure/ Loading Capacity/ Consumable and Spare Parts (Welding Rotating Turning Roller), which differ among each other, aiming on specific applicating field;

3)       Aim of This Blog: This blog is to have a general overview on the product family of Pipe Welding Rotator, so that customers and readers can get hint on proper selection and operation on the Welding Turning Rotator;

4)      Topics on Welding Rotating Roller Table in This Blog:

• What is Pipe Welding Rotator and its Function/ Classification;

• Working Principle of Welding Rotating Turning Roller;

• Operation Merits of Welding Rotating Roller Table;

• Maintenance on the Pipe Welding Roller Rotator;

• Summary on Product Family of Pipe Welding Turning Rotator

A.      What is Pipe Welding Rotator and its Function/ Classification:

1.       Task and Applicable Field of Welding Turning Rotator:

1)       Purpose: Welding Roller Rotator is kind of automatic welding equipment, specifically for performing circumferential seam welding on cylindrical parts;

2)       Nomination: It has synonyms of Welding Rotating Roller Table, Welding Rotating Turning Roller, Welding Roller Rotator, etc.;

3)       Available Operations: Besides welding, Rotating Roller Table can also complete process steps of painting/ assembling/ testing, etc.;

4)       Importance: Pipe Welding Rotator has strong and flexible applicability, and is widely used across the industries;

5)       Other Frequently Applied Welding Equipment: Welding Rotator, Welding Positioner and Welding Column and Boom are top three selected welding equipment in industry;

6)       Wuxi JACK HLK80 Welding Rotating Roller Table with its workpieces: Φ2000mm diameter large tank, together with LHZ5x5 Welding Column and Boom, at Russian customer plant: (Fig.1)

2.       Classification on the Welding Rotating Turning Roller:

Based on way of adjustment on center span of its Welding Rotating Turning Roller, the product group of conventional Welding Roller Rotator can be classified into three categories of:

1)       HGZ series self adjusting Welding Turning Rotator;

2)       HGK series manual leadscrew adjusting Pipe Welding Rotator;

3)       HLK series manual operating bolt adjusting Welding Rotating Roller Table;

3.       Besides, there are also many special design Welding Turning Rotator, which are designed and produced on the basis of personalized demand from customer, such as Anti-drifting Pipe Welding Rotator.

B.       Working Principle of Welding Rotating Turning Roller:

1.       Structure and Composition of Pipe Welding Turning Rotator:

1)       One set of Pipe Welding Rotator has a mechanical frame of Welding Rotating Roller Table, which is installed with symmetrically arranged Welding Rotating Turning Roller:

2)       The Welding Rotating Roller Table can be either fixed style, or movable along rails, with traveling wheels installed beneath:

3)       Wuxi JACK HLK80 Moving style bolt adjusting Welding Rotating Roller Table: (Fig.2)

2.       Actions during Running of Pipe Welding Rotator:

1)       Revolving: Pipe Welding Rotator uses the friction force generated between cylindrical workpiece and its Welding Rotating Turning Roller, to drive the workpiece into rotation, so as to complete welding and or other actions, such as assembly, painting;

2)      Center Span Adjustment in Welding Turning Rotator:

a)       By adjusting the center distance of Welding Rotating Turning Roller in the Welding Rotating Roller Table, the complete group of Welding Turning Rotator is applicable for working on barrels of different diameters;

b)       The Welding Rotating Roller Table relies on free swing of its Welding Rotating Turning Roller, to automatically modulate the center distance of Welding Roller Rotator within specified range;

c)       Design sketch on Wuxi JACK HGK series leadscrew adjusting Pipe Welding Rotator: (Fig.3)

d)       Wuxi JACK HGK2 (2 Ton loading capacity) Welding Rotating Roller Table: (Fig.4)

3.       Operation and Revolving Speed Regulation on the Welding Rotating Roller Table:

1)       Workpiece Placement: The workpiece pipe is placed smoothly on the Welding Rotating Turning Roller of the Welding Rotating Roller Table;

2)       Precondition: During operating period of the Welding Turning Rotator, the 2 or 4 pieces of Welding Rotating Turning Roller should always be maintained on the same horizontal axis, so that the workpiece will not be deformed and slipped during rotation;

3)      Working Speed of Workpiece Pipe on the Welding Rotating Turning Roller:

a)       This can be adjusted by adjusting rotating speed of Welding Rotating Turning Roller on the Pipe Welding Rotator;

b)       Driven and managed with A.C. motor and A.C. inverter, then turning speed knob on the operating panel of the Pipe Welding Rotator, continuous revolving speed regulation is fulfilled in wide range and stable running;

c)       Working speed modulation and displaying in Wuxi JACK Welding Roller Rotator: (Fig.5)

4.       Various Forms of Welding Rotating Turning Roller in the Pipe Welding Rotator:

1)      Light to Medium duty Welding Turning Rotator:

a)       This range of Pipe Welding Rotator adopts with combined Welding Rotating Turning Roller, which are steel wheels covered with rubber layer;

b)       In this way, transmission of Welding Rotating Roller Table is stable, friction force between Welding Rotating Turning Roller and workpiece is sufficient, and service life of the entire Pipe Welding Rotator is long;

c)       Combined Welding Rotating Turning Roller in Wuxi JACK medium duty Welding Rotating Roller Table: (Fig.6)

2)      Heavy duty Welding Roller Rotator:

Full steel Welding Rotating Turning Roller in Wuxi JACK heavy duty Welding Turning Rotator: (Fig.7)

C.       Operation Merits of Welding Rotating Roller Table:

Pipe Welding Rotator can be combined flexibly according to weight and length of workpiece pipe, which is convenient and easy to use:

1)       Welding Turning Rotator automatically adjusts center span of its Welding Rotating Turning Roller within specified range, suitable for workpieces of different diameters;

2)       The workpiece can be laid stably onto Welding Rotating Roller Table;

3)       Welding Roller Rotator is driven with a A.C. motor, controlled with inverter, realizing smooth revolving velocity regulation, gaining wide range of stable welding speed for the workpiece;

4)       Its Welding Rotating Turning Roller is integrated from steel core and exterior rubber layer, with merits of smooth transmission, high friction, and long using life;

5)       During work of Pipe Welding Rotator, its Welding Rotating Turning Roller exert proper pressure on the workpiece, which can avoid cold work hardening on working surface.

D.      Maintenance on the Pipe Welding Roller Rotator:

In the sequence of time axis:

1.       Producer Duty: It is responsibility of manufacturer to produce Pipe Welding Rotator, that meets national and industrial standards, to ensure safety and health of operator;

2.       Customer Duty on Running the Pipe Welding Turning Rotator:

1)       TPM: Set up proper maintenance plan on Welding Rotating Roller Table, based on suggestion from Wuxi JACK;

2)       Working Staff: Only qualified operator can operate on Pipe Welding Rotator;

3)       Protection: Check and remove obstacles on surface of Welding Rotating Turning Roller before welding; Foreign matter is strictly prohibited from falling into gear of Welding Roller Rotator;

4)       Safety Precaution: Do not touch Welding Rotating Turning Roller, when Pipe Welding Rotator is in working;

5)       Lubrication: Welding Rotating Roller Table should be lubricated through oil cap on the bearing cover. When working on Pipe Welding Rotator for the first time, remove gear guard and apply proper amount of grease onto gear. Sodium based grease is recommended for the Welding Turning Rotator.

E.       Summary on Product Family of Pipe Welding Turning Rotator:

1)       Wuxi JACK has set up and implemented complete strict quality assurance system on all our products, including HGZ&HGK&HLK series Pipe Welding Rotator;

2)       For customers having demand on pipe fabrication, you may consider our superior quality and cost effective products.