Safety Assurance on Developing and Producing Wuxi JACK Welding Positioner

The Subject of This Blog on Welding Positioner:

1. Security is the foremost issue during operation of Welding Positioner: It should be paid great attention on by customers before put into use, and by suppliers during its development;

2. In this short blog, we will have a brief discussion on topics involving safety of Welding Positioner:

• Importance of Safety Assurance and Related Safety Risk during Operation of Welding Positioner;

• Safety Assurance in Wuxi JACK 2 Axis Standard Type Welding Positioner and its Rotary Welding Table;

• Safety Assurance in Wuxi JACK 3 Axis L Type Elevating Welding Positioner and its Welding Turning Table;

• Safety Assurance in Wuxi JACK 3 Axis Head and Tail Welding Positioner and its Rotary Welding Table

A. Importance of Safety Assurance and Related Safety Risk during Operation of Welding Positioner:

1. During application of Welding Positioner, especially those with large size and heavy weight Welding Turning Table, for example: L Type Elevating Welding Positioner, or Head and Tail Welding Positioner, there exist certain degree of safety risk, which should be taken great caution to eliminate ahead of time;

2.  Without proper measures, safety risks of Welding Positioner operation will bring along dangers of:

1) Serious working personnel harm;

2) Damage of workpiece and Welding Positioner, Rotary Welding Table;

3) Inferior welding quality delivered from Welding Turning Table;

3. The main potential safety risks during running of Welding Positioner can be attributed as:

1) Unreliable Stoppage of Rotary Welding Table in All Kinds of Welding Positioner;

2) Sudden Falling Down of Welding Turning Table and workpiece;

3) Out of Synchronization at both ends of workpiece elevation in Head and Tail Welding Positioner.

B. Safety Assurance in Wuxi JACK 2 Axis Standard Type Welding Positioner and its Rotary Welding Table:

1. HB series 2 Axis standard Welding Positioner has the biggest using volume. Shown as below: (Fig.1)

2. Working actions of 2 Axis Standard Welding Positioner are:

1) 0°~ 360° revolving in adjustable welding speed of Welding Turning Table;

2) 0°~ 120° tilting in constant velocity of Welding Turning Table;

3. The Safety Assurance Measures Taken in 2 Axis Standard Welding Positioner are:

1)  The motors for driving revolving and tilting of Rotary Welding Table are all braking type, guaranteeing its reliable stoppage when necessary;

2) Conductive rod is installed beneath Rotary Welding Table, forming a welding current circuit in the Welding Positioner, and avoiding the issue of electricity leakage: (Fig.2)

3) Calculate and validate torque and eccentricity distance sketch of Welding Turning Table, for every model of Welding Positioner: (Fig.3)

C. Safety Assurance in Wuxi JACK 3 Axis L Type Elevating Welding Positioner and its Welding Turning Table:

1. LBS Model 3 Axis L Type Elevating Welding Positioneris a kind of very important welding equipment, with working actions of:

1) Up and down elevating movement of its Rotary Welding Table within vertical stroke;

2) 0°~ 360° revolving in adjustable welding speed of Welding Turning Table;

3) 0°~ 360° rotating in fixed speed of Welding Turning Table, shown as below: (Fig.4)

2.  The Safety Assurance Measures Taken in Wuxi JACK 3 Axis L Type Elevating Welding Positioner are:

1) The motors for driving revolving and rotating of Welding Turning Table are all braking type, guaranteeing its reliable stoppage when necessary;

2) The elevation of Rotary Welding Table is driven with hydraulic oil cylinders, and guided with double pieces of precise linear guiderail, shown in below Wuxi JACK 2 Ton L Type Elevating Welding Positioner: (Fig.5)

3) Advantages of such design and configuration in L Type Elevating Welding Positioner is,

a) Compared with motor drive and leadscrew transmission in L Type Elevating Welding Positioner produced by some other suppliers,

b) Hydraulic oil cylinder drive for Welding Turning Table elevation in Wuxi JACK L Type Elevating Welding Positioner has heavy and strong driving force, as well as reliable working of elevation.

D. Safety Assurance in Wuxi JACK 3 Axis Head and Tail Welding Positioner and its Rotary Welding Table:

1. Head and Tail Welding Positioner is a kind of complicated and large welding equipment, for fabricating diversified long length and heavy weight structure members;

2. There are 2 types of Head and Tail Welding Positioner in Application:

1) The 2 sets of upright columns and Rotary Welding Table are connected by means of a horizontal beam: (Fig.6)

2) There is no direct connection between the 2 sets of upright columns and Rotary Welding Table in the installed Head and Tail Welding Positioner: (Fig.7)

3. The Main Working Actions of Welding Turning Table in Head and Tail Welding Positioner:

1) Vertical movement of Welding Turning Table within its stroke;

2) 0°~ 360° revolving in adjustable welding speed of Welding Turning Table;

3) 0°~ 360° rotating in fixed speed of Welding Turning Table;

4. The Safety Assurance Measures Taken in Wuxi JACK Head and Tail Welding Positioner:

1) Driving System of the Rotary Welding Table Elevation and Revolve in Head and Tail Welding Positioner:

a) The motors and reducers for driving Welding Turning Table elevation and revolve are all double stage style with self-lock function;

b) The first stage is gear reducer, guaranteeing delivering of heavy torque;

c) The second stage is worm reducer with self-lock function;  

d) The elevating servo motors at both sides of Rotary Welding Table and workpiece also have self-lock function;

e) The Rotary Welding Table revolve driving motor is braking type motor;

All of these fully guarantee reliable braking of both elevation and revolve for Welding Turning Table, in the process of Head and Tail Welding Positioner operation;

2) 1.5~2 Times Safety Margin on Theory Calculation for Model Selection and Mechanical System of Welding Turning Table Elevation and Revolve in the Head and Tail Welding Positioner:

The design and model selection on revolve motor reducer/ mechanical transmission components of the Head and Tail Welding Positioner all have ample safety margin:

a) Calculation is based on standard of 1.5 times safety margin;

b) The core element (Bearing/ Slewing support) has 2 times safety margin;

3) Transmission of Rotary Welding Table Revolve in Head and Tail Welding Positioner:

a) The revolve of welding turning table is realized with slewing support in Wuxi JACK Head and Tail Welding Positioner: (Fig.8)

b) Upon its revolve at target angular position, there are 8 pieces of air cylinders around the full circle of slewing support to lock the slewing support firmly;

4)  Mechanical Safety Measure for Rotary Welding Table Elevation in Head and Tail Welding Positioner:

a) Wuxi JACK designs row of safety holes at internal surfaces of the Welding Turning Table;

b) Upon Rotary Welding Table elevated to target level, there are safety pins to have double assurance on completely safety of the Head and Tail Welding Positioner: (Fig.9)

c) These safety pins will be plugged into the safety holes, to avoid the risk of accidental dropping down of Rotary Welding Table and workpiece;

d) The plug-in and pull-out of safety pins is implemented with manual job.

E. Summary on Safety Assurance of Welding Positioner:

1. The safety measures listed in this short blog are just examples for your reference;

2. As a kind of special design Welding Positioner, more safety measures are put into practice in every business case of Wuxi JACK L Type Elevating Welding Positioner, together with Head and Tail Welding Positioner;

3. If you have interest, please visit product family of Wuxi JACK Welding Positioner.