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1 Welding Column and Boom Welding Manipulator 7- IMAG1178

Wuxi JACK Welding Column and Boom, 

Wide Variety of Professional and Versatile Manipulator Welding Machine for Customers!

Provide Rich Assortment of Wuxi JACK Welding Console Manipulator

1. Usage: With “regular” and “simple” structure of cross shaped mechanical frame, this widely applied welding equipment has varied configurations in terms of sizes and welding units, which is essential machine tool in the field of pipe/ tank/ pressure vessel fabrication, especially internal and external longitudinal welding seam;

2. The Welding Mode Provided with Welding Column and Boom:

Can be:
1) Conventional single arc or tandem (Twin arc, or double filler) SAW (Submerged arc welding);
2) Niche built up welding (strip cladding)/ narrow width welding;
3) Minority CO2 welding/ GMAW/ TIG...;
4) Other process technology: Assembly/ Painting/ Test...
3. Model and Size: As engineering based supplier company, Wuxi JACK provides full scope of LHZ models Welding Console Manipulator machine size: From LHZ2020 (2,000mm Max. horizontal stroke by 2,000mm Max. vertical stroke), to LHZ8080 (8,000mm Max. horizontal stroke by 8,000mm Max. vertical stroke):

4. Welding Seams Finished from Wuxi JACK Manipulator Welding Machine:

SAW Single Arc Strip Cladding
SAW Single Arc Built Up Welding
Single Arc SAW Welding
Single Arc SAW Welding

5. Different Models of Wuxi JACK Welding Console Manipulator in Assembly or at Customer Facility:

LHZ4040
LHZ5050
Group of Large Models
LHZ6060
LHZ3030
LHZ3535
LHZ4055
LHZ3030
LHZ2525
LHZ5050
LHZ4040
LHZ6060
LHZ6060
LHZ4055
LHZ6050
LHZ4040

6. Running and Commissioning Moment of Wuxi JACK Manipulator Welding Machine:

At Wuxi JACK workshop, testing on SAW welding
At Indonesian customer facility, adjusting on welding process parameters
At Wuxi JACK workshop, trial on SAW built up welding
At Wuxi JACK workshop, try on SAW strap cladding

Operating Videos of Wuxi JACK Welding Column and Boom

Related product pages on videos and introduction on this cross slides tank welding equipment:
1. Manipulator Welding Machine;
2. Introduction on Wuxi JACK Welding Column and Boom

Technical Specifications of Wuxi JACK Manipulator Welding Machine

1 Welding Column and Boom 1 000_0055
2 Welding Console Manipulator 12
1. Models Implication: This LHZ series pipe longitudinal seam welding equipment gets its model from the max. stroke of welding torch along width and height direction;
1) For Example, LHZ3040 Model Refers to:
a) X Axis: The max. up and down moving stroke of welding mechanism is 3000mm, which corresponds with the max. diameter of workpiece tanks;
b) Y Axis: The max. horizontal moving stroke of welding mechanism is 4000mm, which corresponds with the max. length of workpiece tanks;

2. Supplementary Degree of Freedom with Welding Column and Boom:

1) Stationary or with Moving Trolley:
This means that, the entire set of welding machinery is:
a) Either stationary, which means working scope of the Welding Console Manipulator is confined to relative limited range, its original tolerance moving stroke;
b) Or, has motor drive trolley, which helps the welding equipment capable of moving within certain distance, usually several tens of meters, thus enlarging its operating zone;
2) Upright Column: Either fixed (No revolve), or can be revolved 0° ~360°; for 0° ~360° revolve type, either it is turned by manual job, or under motor drive.
 

3. Technical Parameters of LHZ Series Cross Slides Welding Console Manipulator:

 Model of Conventional LHZ Series
 Welding Column and Boom		  LHZ2020 / LHZ2030/ LHZ3030/
 LHZ4040/ LHZ4050 / LHZ5050 /
 LHZ6060 / LHZ7070/ LHZ8080
 Horizontal Boom Up and Down Stroke
 (mm)		  2,000/ 2,000/ 3,000 /
 4,000/ 4,000/ 5,000 /
 6,000 / 7,000/ 8,000
 Horizontal Boom Leftward and Rightward Stroke (mm)  2,000/ 3,000/ 3,000 /
 4,000/ 5,000/ 5,000 /
 6,000 / 7,000/ 8,000
 Horizontal Boom Up and Down Moving 
 Speed (mm/min.)		  1,000/ 1,500
 Horizontal Boom Leftward and   Rightward Moving Speed (Welding   Speed) (mm/min.)  120 ~ 1,200/ 80 ~ 1,000
 Max. Loading Capacity at Front End of
 Horizontal Boom (kg)		  80/ 80~ 120/ 200/ 500/ 400
 Welding Seam Tracing Range (mm)  100 ~ 200
 Welding Seam Tracing Speed
 (mm/min.)		  200 ~ 250
 Welding Seam Tracing Precision   ±0.25 mm
 Welding Seam Tracing Unit Applicable
 Welding Mode in Welding Console Manipulator		  Single Arc SAW/ Tandem SAW/
 Built Up SAW/ CO2/ TIG/ MIG

Welding Modes and Operation in Wuxi JACK Welding Console Manipulator

Wuxi JACK Cross Slides Welding Manipulator

1 Welding Column and Boom 9 1526585399_IMG_4356
2 Welding Console Manipulator 10 20150108_132648
3 Manipulator Welding Machine 6 100_9665
4 Welding Column and Boom 7 100_9666
5 Welding Console Manipulator 3 20150107_125251
6 Manipulator Welding Machine 1 20141230_135453
7 Welding Column and Boom 9 20150108_115505
8 Welding Console Manipulator 5 100_7291

Function and Broad Use of Cross Slides Manipulator Welding Machine

1. Working Principle: This welding equipment machine tool gets its name from overall structure and appearance: A set of solid and flexible mechanical erected cross frame, assembled from horizontal boom and upright column, joint with heavy duty and high precision cross roll (Saddle), for performing longitudinal and horizontal welding operations on cylindrical working parts: Vessels/ tanks/ pipes...;

2. Work Manner of Welding Column and Boom:

1) Structure Feature: This cross slides welding equipment operates as a type of Welding Console Manipulator for managing on welding operation, without welding fixtures for carrying on workpieces;
2) Working Way: This welding machine tool usually works together with other common seen Welding Equipment: Welding Rotator and or Welding Positioner, composing into general purpose Welding Center:
3) Design sketch on Wuxi JACK LHZ model Manipulator Welding Machine, work together with Welding Roller Support: (Fig.1)
Fig1 Welding Column and Boom
4) Large Welding Center: Wuxi JACK LHZ6060 model Welding Column and Boom implements on external longitudinal seam welding on oil pipelines at Russian customer site, working with groups of HLK80 hydraulic drive lifting Welding Roller Bed: (Fig.2)
Fig2 Welding Console Manipulator 8
3. Wide Application: In manufacturing industries, Welding Column and Boom is the most efficient welding equipment, for completing on common welding operations on various materials/ dimensions/ structures of workpieces. So, it has gained very extensive applications worldwide;

4. Major Welding Operations in Manipulator Welding Machine:

1) Longitudinal Seam Welding: By means of leftward and rightward movement of horizontal boom, the welding equipment carries out longitudinal seam welding on external and or internal wall of workpieces. The corresponding welding speed is managed and displayed with horizontal boom drive systems;
2) Circumferential Seam Welding: When horizontal boom and its front end assembled welding mechanism keeps motionless status, with revolve of workpiece on Welding Turning Roll, circumferential seam welding can be fulfilled on both internal and or external wall of workpieces. The corresponding welding speed is managed and displayed with welding turning roll drive systems;
3) Internal or External Welding: Working head (Horizontal boom) of Welding Column and Boom can either “crawl on” external wall of tanks, or extends into internal wall of tanks, acquiring on both positions of accurate welding on workpieces;
4) Flexible Welding Mode: Nearly all the common adopted welding units in tank fabrication: SAW/ GMAW/ Strip Cladding/ TIG... can be equipped to this Welding Column and Boom;

5. Put into Use on Welding Console Manipulator:

1) Working Hand: The horizontal boom acts as operating manipulator of the welding equipment. Correspondingly, welding system of the machinery: Welding torch/ Welding wire feeder/ Welding control console... are installed at front end of the horizontal boom:
2) Welding function system being installed at front end of horizontal boom: (Fig.3)
Fig3 Manipulator Welding Machine 5 IMG_9662

6. Cross Slides Role in Operation of Welding Column and Boom:

The movement of horizontal boom includes:
1) In X axis along horizontal direction --- This corresponds with adjustable welding velocity of longitudinal seam welding;
2) In Y axis along vertical direction --- This corresponds with varying diameters of workpieces;
Thus forms up the central working movement of Welding Console Manipulator, which is managed with delicate design sophisticated cross slides:
1) Cross slides of Wuxi JACK heavy duty large Welding Column and Boom: (Fig.4)
Fig4 Welding Column and Boom 3 IMG_4950
2) Cross slides being assembled into erected Wuxi JACK medium duty Manipulator Welding Machine: (Fig.5)
Fig5 Welding Column and Boom Welding Manipulator 2- 20130727_165246
 

7. Select Proper Model of Cross Slides Welding Column and Boom:

1) Taking LHZ5060 Model as Example:
a) “50”— Refers to the max. vertical up and down stroke of horizontal boom, which equals to the max. diameter of pipes/ tanks being welded;
b) “60” – Refers to the max. horizontal stroke of horizontal boom, which equals to the max. length of pipes/ tanks being welded;
c) In summary, the largest working parts to be welded in this LHZ5060 model is: Pipe/ tank diameter is Φ5000 mm, and pipe/ tank length is 6000 mm;

2) Main Optional Configurations of Welding Console Manipulator:

Besides, according to on site process technology design and requirement of customer facility, Manipulator Welding Machine can be in the form of:
a) Moving or Not: On stationary fixed mechanical base, or with motorized moving trolley. If with moving function, the moving distance of the welding equipment is usually designated by customers:
Moving type versus stationary Welding Column and Boom: (Fig.6)
Fig6 Welding Column and Boom Welding Manipulator 2- GMAW- 100_9145
b) Column Revolve or Not: The upright column can be non-revolving, or with manual / motor drive revolving function;
c) These optional configurations greatly extend working capability of the welding machine tool;
3) Summary on strong points and technical specialties of our Welding Console Manipulator is illustrated in product page of “Introduction on Wuxi JACK Welding Column and Boom”.

Strong and Durable Mechanical Property of Wuxi JACK Welding Console Manipulator

Prepare on delivery package on a set of Wuxi JACK exported LHZ4060 model heavy duty Welding Column and Boom: (Fig.7)

Fig7 Welding Column and Boom Welding Manipulator 5
 

 

Mechanical frames play key role on guaranteeing high standard and persistent operation of this welding manipulating equipment:
1) Horizontal boom and upright erected column;
2) Delicate and ingenious designed cross slides;
3) High power smooth drive and transmission system

A. Horizontal Boom and Erected Upright Column of Cross Slides Manipulator Welding Machine

1. Importance: Horizontal boom and upright column compose basic mechanical skeleton of the LHZ series welding machinery. Its intensity and strength directly determine on stability and reliability of welding operation;
2. Cross Section Design and Craftsmanship: The horizontal boom and upright column all have rectangular cross section, which are fabricated from high strength large thickness steel plates;
3. Superior and Consistent Quality: In Wuxi JACK heavy duty Welding Console Manipulator, the workmanship of process technology on manufacturing horizontal boom and upright column is the foremost factor, which determine on quality of the entire set of the welding equipment;

4. General Process Technology on Fabricating Welding Column and Boom Mechanical Frame:

1) 1st Operation Cut Off: First cut the steel plates into shape and size with CNC Plate Cutting Machine;
2) Bending into Structured Part: Then bend the cut out steel plates into shape by means of different tonnage Press Brake;
3) Fabrication: Next fabricate the cut and bent steel structure plates into final shape of rectangular column;
4) Heat Treatment: Finally, carry out advanced and strict heat treatment on fabricated assemblies, to acquire on stress relief and gaining tough mechanical strength of mechanical frame;
5. Guidance and Transmission: The heavy duty linear guide rail/ gear and rack/ pivot cross slides, are all assembled onto cross slides of Welding Console Manipulator.

B. Ingenious Design and High Strength Cross Slides in Welding Column and Boom:

1. Key Role of Cross Slides in Operation of Welding Console Manipulator:

1) Function: The movement of welding torch for welding operation is realized by means of its horizontal boom movement with respect to upright column, in the direction of horizontal X axis and vertical Y axis. Such both direction position management is guided and transmitted by way of cross slides, which is assembled at intersection point of horizontal boom and upright column:
2) Up and Down Movement: With elevation of horizontal boom, the welding torch height level can be managed, based on size and diameter of workpieces;
3) Leftward and Rightward Movement: By means of horizontal extending and retreating of horizontal boom, the operating reach of welding torch can be controlled;
4) Welding Speed: When performing on longitudinal seam welding, horizontal movement of boom equals to movement of welding torch. For this reason, horizontal boom leftward and rightward speed is working welding speed of Welding Column and Boom, which is controlled with A.C. inverter, and displayed in digital manner in real time on operating panel;

2. Different Structures of Cross Slides in Wuxi JACK Light / Medium / Heavy duty Manipulator Welding Machine:

1) Task and Working Force: As shown in the above 4 photos, movement of horizontal boom along X and Y axis are driven with rolling friction force, instead of gliding friction force. This means, contact surface between 2 moving surfaces is guided with rolling rollers in cross slides, instead of direct touch and sliding force;

2) Light Versus Medium and Heavy duty Welding Console Manipulator:

The cross slides structure in different loading capacity Welding Column and Boom are different:
a) The above 1st and 2nd photo shows the cross slides in light duty models welding equipment;
b) The above 3rd and 4th photos show the cross slides in medium and heavy duty welding equipment;
3) Cross slides of Wuxi JACK light duty Welding Column and Boom: (Fig.8)
Fig8 Welding Column and Boom Welding Manipulator 2- IMG_1392
In small to medium duty models, horizontal boom movement along X and Y axis are guided with 4 pieces of guiding rollers, which are installed at 4 corners of the cross slides respectively:
4) Cross slides of Wuxi JACK medium and heavy duty large Welding Console Manipulator：(Fig.9)
Fig9 Welding Column and Boom Welding Manipulator 4- IMG_0676
Horizontal boom movement along X and Y axis are guided with 4 groups of guiding rollers: Each group of guiding rollers has 3 pieces, assembled at the 4 corners of the cross slides, encircling the guiding rail.

C. Drive and Transmission Systems of Welding Console Manipulator:

It has strong points of: High Power, Smooth and Stable:

1. Drive and Transmission Mechanisms in LHZ Models Manipulator Welding Machine:

Working Mode:
1) High Power A.C. Motor: as shown in the above 1st photo, for driving the horizontal boom up and down movement. This driving motor is installed at top of the upright column;
2) Constraint on Large Models: Sometimes, to reduce total height of heavy duty Welding Column and Boom, especially those large models, this drive motor is installed at bottom of the upright column, inside its mechanical base bed. This also helps lowering down gravity center of the large Welding Console Manipulator;
3) Precise Worm Gear and Motor Reducer, as shown in the above 2nd photo, for driving and transmitting horizontal boom movement along X and Y axis;

4) Up and Down Transmission Mechanism in Welding Column and Boom:

Shown in the above 3rd photo:
a) Wuxi JACK light duty Welding Console Manipulator adopts with leadscrew as transmission mechanism for its horizontal boom up and down movement: (Fig.10)

Fig10 Welding Manipulator Welding Column and Boom 2- IMG_1392
 

b) Wuxi JACK medium and heavy duty Welding Column and Boom adopts with chain and sprocket, as transmission mechanism for guiding its horizontal boom up and down movement: (Fig.11)

Fig11 Welding Manipulator Welding Column and Boom 2- IMG_1392

2. Horizontal Boom Linear Movement and Upright Column Revolve in Welding Console Manipulator:

1) High Precision Cross Roll Bearing as shown in the above the 5th photo, for guiding and transmitting the upright column 0° ~360° revolve. This cross roll bearing is a piece of advanced machined and heat treated circular bearing, combined with circular rack;
2) Heavy duty High Precision Linear Guiderail and Racks: Guiding and transmitting units for fulfilling linear movement of horizontal boom, as shown in the above 6th photo: The movement is guided with precise heavy duty rectangular cross section linear guiderail, and transmitted with high precision rack;
3) The Assembled Cross Slides: The central guiding and transferring unit for guiding horizontal boom along X and Y axis movement.

Operation on Manipulator Welding Machine

1. Safety Assurance on During Operation on Manipulator Welding Machine:

1) Protecting Horizontal Boom from Sudden Falling Down:

Shown in the above 1st photo:
a) The biggest safety hidden risk during operation of Welding Column and Boom is sudden falling down of horizontal boom when it is at high level position, which may do great harm on personnel working on site, and prime condition of utility and facility;
b) To avoid this from happening, there is a row of rectangular holes being cut in the upright column. During work, if ever chains break off and lead to sudden falling of the horizontal boom, the rachet safety pins will be ejected out immediately, and plugged into rectangular holes, thus firmly locking the horizontal boom into that position. This is marked in yellow frame in the above 1st photo;
c) The climbing ladder alongside the upright column in Welding Console Manipulator is surrounded with protection rails, as shown in orange frame in the above 1st photo;
2) Brake Motor: The driving motor for horizontal boom elevation is braking type. This gives double assurance on protecting the horizontal boom from unexpected falling down;
3) More information on safety measures taken in Wuxi JACK LHZ series welding equipment is introduced in product section of “Industrial Use Welding Column and Boom”.
 

2. Convenient and User Friendly Operation of Wuxi JACK Welding Console Manipulator:

1) Operating Point Welding Heads of different configurations: The above 2nd and 3rd photos show welding heads of the welding equipment;
2) Welding Modes: It can be any common seen available welding modes. The control console of welding power supply/ Welding seam tracker/ Welding wire feeder are all installed on front end of the horizontal boom, so as to acquire on easy management and monitor on high standard running by operators;
3) Hand held Remote Operating Pendant: As shown in the above 4th photo. This operating pendant helps operator managing on operation of the Manipulator Welding Machine in further distance, so as to have flexible working positions according to practical working conditions.

Application and Related Equipment of Cross Slides Welding Column and Boom

1. Operation Manner:
Welding Console Manipulator works with other common seen Welding Equipment to deliver various sophisticated welding jobs on cylindrical working parts:
1) Welding Rotator (Welding Turning Roll, Welding Roller Bed) for circumferential seam welding;
2) Welding Fixture for longitudinal seam welding on complicated workpieces;
3) Welding Positioner for carrying out structure welding,
To be formed into wide variety of Welding Center;
2. Similar Function of Welding Equipment:
With respect to Manipulator Welding Machine includes:
1) Various types of Pipe Welding Machine, which is usually tailor made, of more flexible in structure/ configuration and functions;
2) Longitudinal seam and circumferential seam Welding Equipment, which can also implements on both types of welding seam, but with much smaller size;
3. Applicable Workpieces:
Besides cylindrical working parts such as pipes/ tanks, as shown in the above photo, Welding Column and Boom can also be used for fabricating on structure members: H Beam/ BOX Beam when working on longitudinal seam welding. This fulfils similar tasks as 3 in 1 H Beam Welding Machine.

Welding Console Manipulator
01

Welding Column and Boom
02

Manipulator Welding Machine
03

Wuxi JACK Other Valuable Welding Equipment and Machinery

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HB06 Model Two Axis Revolve and Tilt Welding Positioner of 600kg Loading Capacity
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Wuxi JACK Welding Console Manipulator Blogs

  • The Variation in Configuration of Welding Manipulator And Proper Selection

    The Variation in Configuration of Welding Manipulator And Proper Selection
    Variety and Optional Configurations of Welding Manipulator; How to Make Proper Choice on Specific Models of Welding Column and Boom Read More
  • Technical Features And Business Prospects of Welding Column And Boom

    Technical Features And Business Prospects of Welding Column And Boom
     Business Application of the Cross Slides Welding Column and Boom;  Technical Issues from Perspective of Designing on the Cross Slides Welding Manipulator;  Safety Issues when Putting into Use of the Cross Slides Automatic Pipe Welding Equipment;  Summary on Wuxi JACK Cross Slides Welding Column and Boom Read More
  • Application of Facing and Milling Center in Steel Structure Industry

    Application of Facing and Milling Center in Steel Structure Industry
    What is Steel Structure Milling and Facing Center? Why there is Demand on Steel Structure Milling and Facing Center? Constitutes and Technical Overview of Steel Structure Milling and Facing Center Application Case of Steel Structure Milling and Facing Center by Wuxi JACK Read More
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