1 Welding Center Welding Manipulator Welding Rotator 86- LHZ5050 ESAB WC0505

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Application of Welding Center and its Significance

 

1. The Definition on Welding Center:

1) Welding Center is a group of integrated Welding Equipment, which can fulfil the task that can not be realized with single set or type of Welding Equipment;

2) For example, below is a system of Wuxi JACK medium duty Welding Center, that is composed of LHZ3030 stationary Column and Boom Automatic Welding Equipment, and HGK20 leadscrew adjusting Welding Rotator:

Fig1 Welding Center Welding Manipulator Welding Rotator 43- LHZ3030- GMAW- 100_9365
 
 
 

2. Welding Equipment and Function Units in Welding Center:

The possible working cells that may be composed into Welding Center:
1) Column and Boom Automatic Welding Equipment: Stationary/ Moving type Column and Boom Automatic Welding Equipment, with various specifications of boom and column stroke;
2) Welding Rotator: Self Adjusting/ Bolt Adjusting/ Leadscrew Adjusting Welding Rotator, of different loading capacities;
3) Welding Positioner: Standard Single Working Table/ Head and Tail/ L type Welding Positioner, with changed loading weight;
4) Welding Fixture and Special Welding Equipment: Wide variety changing in structure and specifications of Welding Fixture, and Welding Equipment, and Pipe Welding Equipment;
5) Welding Robot;
6) All types of welding modes Welding Power Supply, together with supplementary units, such as Seam Tracker, Video Camera, Special Welding Head, etc.
 

3. Characteristic and Significance of Welding Center:
 

1) Welding Center is always special made, and differs case by case: It is a personalized integrated Welding Equipment, catering for personalized demand from customers;
2) Welding Center embodies the comprehensive capability of the nation, region and industries;
3) With time going and development of Technique/ Technology/ Technical Standard in Industries, more and more Welding Center are applied at customers site across Manufacturing Industries;
4) For quick understanding on Welding Center and its Welding Equipment, please check product page of “Introduction on Wuxi JACK Column and Boom Automatic Welding Equipment”.
 
 

In this thematic page, we list 4 applicating cases of Wuxi JACK Welding Center, which are composed from different species and specifications of Welding Equipment:
 

1. Large Size Heavy duty SAW Finished Welding and Strip Cladding Welding Center LHZ5050 Column and Boom Automatic Welding Equipment+ HLK80 Welding Rotator+ HB30 Welding Positioner for Tank Production;
2. Middle Size Medium duty CO2 GMAW Welding Center LHZ3030 Column and Boom Automatic Welding Equipment+ HGK10 Welding Rotator for Stainless Steel Pipe Making;
3. Large Size Heavy duty SAW Welding Center LHZ6050 Column and Boom Automatic Welding Equipment+ HGZ200 Welding Rotator for Oil Gas Pipeline Fabrication;
4. Compact Size Light duty Welding Center for Pipe Flange Welding

Order to Delivery Value Chain of Wuxi JACK Welding Center

Working Video of Wuxi JACK Welding Center and Welding Equipment

Trying on Built Up Welding in Wuxi JACK LHZ5050 Column and Boom Automatic Welding Equipment;

Close distance observance on Strip Cladding on Wuxi JACK Welding Center (HLK80 Anti-Drifting Welding Rotator with LHZ5050 Column and Boom Automatic Welding Equipment)

Submerged Arc Welding in Wuxi JACK LHZ5050 Welding Center (HLK80 Anti-Drifting Welding Rotator with LHZ5050 Column and Boom Automatic Welding Equipment)

Large Size Heavy duty SAW Finished Welding and Strip Cladding Welding Center LHZ5050 Column and Boom Automatic Welding Equipment + HLK80 Welding Rotator + HB30 Welding Positioner for Tank Production

A. Background of SAW Finished Welding and Strip Cladding Welding Center:

1. This SAW Welding Center was developed for a Russian customer in Oil and Gas Industry by Wuxi JACK, for fabricating large size tanks with diameters up to 4500mm;

2. The fabrication on tanks in this Welding Center involves 3 basic operations in Welding Equipment of:

1) The longitudinal welding for completing production on each segment of tanks, which need to be completed with the LHZ5050 Column and Boom Automatic Welding Equipment;
2) The circumferential welding for joint 2 segments of tanks, by means of the HLK80 Welding Rotator and LHZ5050 Column and Boom Automatic Welding Equipment;
3) The Strip Cladding on external surface of tanks, by means of the HLK80 Welding Rotator and LHZ5050 Column and Boom Automatic Welding Equipment.

B. Welding Equipment and Function Cells in SAW Finished Welding and Strip Cladding Welding Center:

1. Welding Equipment in the Welding Center:

1) One set of LHZ5050 heavy duty column manual revolve moving Column and Boom Automatic Welding Equipment;
2) Six sets of HLK80 (80Ton loading capacity) Bolt adjusting Welding Rotator;
3) One set of HB30 Two Axis Welding Positioner;

2. Welding System in Welding Equipment of the SAW Welding Center:

1) One set of Sweden ESAB LAF1601 SAW power supply, equipped with 15m long cables;
2) Welding head A6S ARCMASTER (SAW twin wire, 3mm diameter, ratio 156:1), for carrying out SAW finished welding in the Welding Center;
3) Welding head 30-100mm A6 for doing Strip cladding in the Welding Center, installed on the front end boom of Column and Boom Automatic Welding Equipment;
 

3. Welding Supplementary Units in Column and Boom Automatic Welding Equipment and Welding Rotator of the Welding Center:

1) Control panel PEK with motorized support 300x300mm; A6 cable and PEK 5m of the Welding Center;
2) Flux nozzle for A6 strip head on the Column and Boom Automatic Welding Equipment;
3) GMH automatic welding seam tracker on the front end boom of Column and Boom Automatic Welding Equipment;
4) 2 sets of 30kg SAW welding wire spool installed on the Column and Boom Automatic Welding Equipment;
5) A6 welding wire straightening unit installed on the Column and Boom Automatic Welding Equipment;
6) Complect TWIN 2x3mm installed on the Column and Boom Automatic Welding Equipment;
7) 10L capacity welding flux hopper installed on the Column and Boom Automatic Welding Equipment;
8) SAW twin arc welding torch installed on the Column and Boom Automatic Welding Equipment;
9) 2*3.0mm twin welding wire feeding system of the Welding Center;
10) Laser generator point and lamp for tracing welding seam during running of the Column and Boom Automatic Welding Equipment;
11) Strip belt reel, for stripping cladding in the Column and Boom Automatic Welding Equipment.
 

4. Commissioning on SAW Twin Arc and Strip Cladding Heads on the LHZ5050 Column and Boom Automatic Welding Equipment of the Welding Center at Wuxi JACK Facility:

C. Technical Features of SAW Finished Welding and Strip Cladding Welding Center:

1) The welding mode in this Welding Center is SAW (Submerged arc welding). Such welding mode is applicable for fabricating workpieces made of medium level thickness carbon steel;
2) Specific in Welding Equipment of this Welding Center, the welding heads installed in the LHZ5050 Column and Boom Automatic Welding Equipment can deliver 2 kinds of SAW welding: The conventional finished welding, as well as Strip Cladding. The welding heads for the 2 kinds of SAW modes are different;
3) The SAW Strip cladding in Column and Boom Automatic Welding Equipment of the Welding Center has high deposition rate, high welding quality, and low penetration. It will produce a layer of 60mm width x 0.5mm thickness on surface of workpieces on the Welding Center:

4) The built up welding seam produced from strip cladding head in the LHZ5050 Column and Boom Automatic Welding Equipment of the Welding Center:

Fig1 Welding Center Welding Manipulator Welding Rotator 99- LHZ5050 ESAB- 20150109_081553

5) Strip Cladding heads in the LHZ5050 Column and Boom Automatic Welding Equipment of the SAW Welding Center:

Fig2 Welding Center Welding Manipulator Welding Rotator 98- LHZ5050 ESAB- 20150108_132648
6) The HGK80 leadscrew adjusting Welding Rotator in this SAW Welding Center is hydraulic drive anti-drifting type;

D. Technical Parameters of SAW Finished Welding and Strip Cladding Welding Center, LHZ5050 Column and Boom Automatic Welding Equipment and HLK80 Welding Rotator and HB30 Welding Positioner:

 Boom vertical stroke  4000 mm
 Boom horizontal stroke  5000 mm
 Welding the work piece diameter  1000 ~ 4500 mm
 Boom horizontal speed  120 ~1200 mm/min.
 Adjustment of boom horizontal speed  VFD
 Boom horizontal speed  1000 mm/min., Constant
 Boom horizontal travel transmission  Gear and rack
 Boom vertical travel transmission  Chain and sprocket
 Cross-slides stroke  Vertical & horizontal 300mm, ESAB
 Welding power  LAF1601, ESAB
 Welding feeder  A6S twin wire ratio 156:1, ESAB
 Welding control panel  PEH type, ESAB
 Welding seam auto tracking device  GMH type, ESAB
 saddle for worker  One set
 video camera  One set
 Flux recovery unit  One set
 Column and Boom Automatic Welding Equipment type  Trolley and turning column

Middle Size Medium duty CO2 GMAW Welding Center LHZ3030 Column and Boom Automatic Welding Equipment + HGK10 Welding Rotator for Stainless Steel Pipe Making

1. Background of Middle Size Medium duty CO2 GMAW Welding Center LHZ3030 Column and Boom Automatic Welding Equipment + HGK10 Welding Rotator for Stainless Steel Pipe Making:

1) The CO2 GMAW Welding Center developed by Wuxi JACK in this applicating case is for a customer at Pharmaceutical Industry, for producing thin wall small to medium size pipes made of stainless steel material;
2) The required welding operations in this Welding Center are external longitudinal welding and circumferential welding;
3) The workpieces in this Welding Center have thickness range from 1mm to 5mm, which should be adopted with CO2 GMAW Welding.

2. Design Sketch on the CO2 GMAW Welding Center LHZ3030 Column and Boom Automatic Welding Equipment + HGK20 Welding Rotator:

3. The Welding Equipment of Column and Boom Automatic Welding Equipment and Welding Rotator in CO2 GMAW Welding Center:

1) One set of LHZ3030 Medium duty Column Manual Revolve Stationary Column and Boom Automatic Welding Equipment;
2) One set of HGK10 Leadscrew Adjusting Welding Rotator;
3) One set of Panasonic GL series 500A MIG/MAG Welding Power Supply and Control Kit

4. Technical Brief on CO2 GMAW Welding Center:

1) As shown in the 1st photo, welding torch on the front end boom of Column and Boom Automatic Welding Equipment has welding swing unit. This is for the purpose of getting sufficient width of welding seam from the CO2 MIG welding. Another Welding Equipment using this swing mechanism is LHD150 Pipe Back Welding Equipment;
2) As shown in the 2nd photo, to help operator of the Welding Center having a comfortable working level, the HGK10 leadscrew adjusting Welding Rotator is laid on a working table;
3) Also shown in the 2nd photo, there is a piece of small diameter tube inside the workpiece stainless steel pipe on the Welding Rotator. This is because considering the light weight of workpiece, there needs to have a ballast inside the workpiece, so that welding performance of the Welding Rotator/ Column and Boom Automatic Welding Equipment and hence Welding Center can be guaranteed;
4) As shown in the 3rd photo, the delicate cored flux welding wire feeder of the Column and Boom Automatic Welding Equipment is installed at middle point of horizontal boom. It is part of complete kit from Panasonic GL5 series MIG/MAG welding power supply.

5. Technical Parameters of Middle Size Medium duty CO2 GMAW Welding Center LHZ3030 Column and Boom Automatic Welding Equipment + HGK20 Welding Rotator for Stainless Steel Pipe Making

Large Size Heavy duty SAW Welding Center LHZ6050 Column and Boom Automatic Welding Equipment + HHZ200 Welding Rotator for Oil Gas Pipeline

1. Background of Large Size Heavy duty SAW Welding Center LHZ6050 Column and Boom Automatic Welding Equipment + HLK200 Welding Rotator for Oil Gas Pipeline Fabrication:

1) You can check the busy working applicating site of this Wuxi JACK large size heavy duty SAW Welding Center:

2) This large size heavy duty SAW Welding Center was designed and produced for an Indonesia customer of Petrochemical Plant by Wuxi JACK;
3) As shown in the above photos, this SAW Welding Center has the task of producing large size pipelines. The corresponding welding operations necessary performed in the SAW Welding Center are external and internal longitudinal and circumferential welding;
4) When Welding Equipment makes internal welding inside the pipes, as shown in the above photos, there should be cross arranged stiffening bars inside the pipes, to prevent it from deformation.

 

2. The Welding Equipment, Column and Boom Automatic Welding Equipment and Welding Rotator Arranged in the SAW Welding Center:

1) One set of LHZ6050 Heavy duty Column Manual Revolve Stationary Column and Boom Automatic Welding Equipment;
2) Six sets of HGZ200 Self Adjusting Welding Rotator;
3) Several sets of 1000A SAW welding power supply and control kits
 

3. Technical Features of SAW Welding Center:

1) During working of the SAW Welding Center, the workpiece large diameter pipes are put onto the HGZ200 self adjusting Welding Rotator;
2) For making circumferential welding in the Welding Center, the Welding Rotator rotates, leading workpiece into revolve. Meanwhile, welding torch on the boom front end of the Column and Boom Automatic Welding Equipment performs welding;
3) When making longitudinal welding, the Welding Rotator serves as support for workpieces. The horizontal boom of Column and Boom Automatic Welding Equipment travels forward and backward, completing welding;

4) There are seam tracker, precision cross slides, control consoles installed at front end of boom in the Column and Boom Automatic Welding Equipment of the Welding Center:

4. Technical Parameters of Large Size Heavy duty SAW Welding Center LHZ6050 Column and Boom Automatic Welding Equipment + HLK200 Welding Rotator

Compact Size Light duty Welding Center for Pipe Flange Welding

1. Compared with the previous 3 cases of Welding Center, the MIG Welding Center here has light weight and compact size;
2. This MIG Welding Center is used for welding various specifications of pipe flange parts in the optimum welding position, with welding mode of MIG;
3. As can be observed from the above photos, such MIG Welding Center is composed of special made Welding Positioner, special made tilting type leadscrew adjusting Welding Rotator, and tailor made Welding Fixture;
4. 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.

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01

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02

Ribbed Plate Straightening Machine
03

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