Lab Use Various Mode Stationary Gantry Welding Machine

A. Background and Usage of Special Made Gantry Welding Fixture:

1.  Business Case of Special Made Gantry Welding Equipment:

1) Customer: As a tailor made Special Made Welding Machine, this machine was designed and produced by Wuxi JACK, for a famous American welding company of Chinese branch based in Shanghai;

2) Application: The customer planned to use this special design Welding Fixture in their welding laboratory, for validating on common applied welding technique: SAW (Submerged Arc welding), GMAW CO₂, Strap Cladding. So, it is a special made welding equipment for special use:

3) The SAW welding head installed on this special Gantry Welding Fixture: (Fig.1)

2. Request from Customer on Gantry Fixture Special Made Welding Machine:

1) This special made Gantry Frame Welding Machine should be capable of carrying out independent running of welding head and its motorized moving carriage;

2) Welding mode is SAW (Submerged Arc welding), or other frequently selected welding technique. The replacement of welding head mechanism should be easy and convenient;

3) The entire set of welding fixture should have good stability, high rigidity, flexible and convenient operation;

4) The equipment can work steadily and reliably within the range of 150A~ 1300A within fluctuation tolerance of ±5%；

5) This special made welding fixture should be equipped with workpiece worktable. The worktable is designed and made based on workpiece type.

B. Main Units in Special Made Gantry Welding Machine:

1. The Complete Set of the Gantry Welding Equipment:

Is composed of:

1) Mechanical machine body of stationary gantry frame;

2) SAW or other welding mode power supply;

3) Welding control console;

4) Welding head mechanism, including welding wire feeder, operating pendant;

2. SAW Power Supply in Special Made Gantry Frame Welding Machine:

1) Main Parameters:

Rated Welding Current	1000 A
Rated Duty Cycle	100%
Input Electricity Specification	3P 380V ±10%，50Hz±1Hz
Output Current	150 ~ 1300 A
No Load Voltage	Up to 75V

2) Main Function and Features:

a) It is a kind of multi-function welding power supply. It can be used in both submerges arc welding, and open arc welding;

b) It can be used in various welding equipment, including general purpose and special welding machinery;

c) Constant voltage and constant current;

d) Average working life is 15 years in the working mode of 3 shifts;

e) Remote control available, and welding parameter adjustment with control console;

3. Welding Control Console in Special Made Gantry Welding Fixture:

1) Precise management of welding technology, arc striking characteristic, welding start and stop, welding seam dimension and appearance, reducing welding cost for both “ordinary” and Special Made Welding Machine;

2) Productivity is raised thanks to its high deposition rate, high welding speed and eliminating bottleneck;

3) Welding program, welding wire feeding speed, welding wire size, welding parameters, and welding mode can be modulated very easily within extensive range. This is especially beneficial for specialized welding equipment;

4. Welding Wire feeder in Gantry Fixture Special Made Welding Machine:

1) Welding wire feeding range is 0.4~ 7.4m/min., welding wire diameter range is ф2.4- ф5.6mm；

2) Welding wire feeding box reduction ratio is 142:1, and optional 95:1 is available for this Special Made Welding Machine;

3) Welding wire feeding is powered with D.C. motor, managing wire feeding speed precisely;

4) Best pressure fitting by means of adjustable spring for clamping welding wire, avoiding wire deformation;

5) Welding wire feeding head can be revolved in full position, equipped with welding wire straightener, meeting high demand on all kinds of welding application, including SAW in this Special Made Gantry Welding Machine;

C. Supply Range of Gantry Fixture Special Made Welding Machine:

No.	Components	Qty
1	Welding Carriage and its Motor	2 sets
2	Horizontal Adjusting unit, stroke 200mm	2 pieces
3	Vertical Adjusting unit, stroke 200mm	2   pieces
4	4m Length Beam + 2 pieces of Precise Ball Bearing Linear Guideway+1 piece of Precise Rack	2 sets
5	Wire Spool Fitting Rack	2 pieces
6	Control Board Fitting Rack	2 sets
7	Welding Current/ Voltage Display unit Fitting Rack	2 pieces
8	Welding Torch Fitting Rack and its Adjusting unit	2 pieces
9	Control cable + Drag Chain	2 sets
10	Welding Power Supply	2   sets
11	Welding Control Console and Cable	2   sets

D. Performance and Characteristic of Special Made Gantry Frame Welding Machine:

1.  Structure of Special Made Welding Machine:

1) Gantry frame is one of the most often adopted structure in both universal and tailor made welding machinery;

2) Gantry frame has merits of both transverse and vertical movement of welding torch, making sure more degree of freedom, and open structure for workpiece loading and unloading. We have introduced many gantry welding machines produced by our company;

3) During testing, workpiece can pass through the gantry beneath its overhead horizontal beam and between the upright columns. In this way, the gantry frame can also be taken as view of door style:

4) Overall structure of the Gantry Welding Fixture: (Fig.2)

2. Degree of Freedom in This special Gantry Welding Fixture:

1) The gantry frame is fixed type. So, its welding torch performs welding operation along the transverse direction of gantry beam;

2) The entire welding equipment is secured into working site floor with anchor bolts;

3) If necessary, the gantry frame can also be made into moving type. In that case, welding torch can move both along leftward and rightward direction, and forward and backward direction;

4) There is one set of manual control cross slide on the welding carriage, for adjusting on position of the welding gun in both X and Y axis, to make it direct at welding seam;

5) Angle of the welding torch can be adjusted by means of its revolving head.

E. Put into Use on Special Made Gantry Welding Equipment:

1.  Operating Motions in Special Made Gantry Welding Machine:

1) Main Units: The gantry frame consists of both sides columns, transverse beam, motor drive welding carriage, manual cross slide for adjusting on vertical and horizontal position of welding torch, and electric control system;

2) Guide on Welding Torch: For maintaining on precise positioning of welding torch in this fixture, its transverse movement along gantry beam is guided with precision rectangular linear ball bearing guideway;

3) Hard Stops: There are mechanical stops at both ends of the beam for safety precaution;

2. Welding Quality Assurance in Special Made Gantry Frame Welding Machine:

1) Delicate Design: The design of double guideways and rack for welding carriage movement makes sure its high standard of stability: Front surface of the beam is assembled with two pieces of the abovementioned precise ball bearing linear guideway, as well as one piece of integral rack for transmission. In this way, transverse movement of the welding torch and its carriage can be fully guaranteed;

2) Element Machining: The transverse beam is made of rectangular steel pipes. It is heat treated after welded into shape, of durable structure without deformation. For this, all of its surfaces are finely machined after fabrication;

3. Put into Use on Gantry Fixture Special Made Welding Machine:

1)  Daily Service: In its daily usage, strict cleaning and lubrication on this transmission unit of guideway and rack is very beneficial on maintaining its superior service quality and long life;

2) During work, welding torch and its carriage moves along the beam guided with linear guideway for welding process, and driven with A.C. motor reducer;

3) Moving speed of welding head, which is also the welding speed, is adjustable with A.C. inverter and displayed in a display meter;

4) Mechanical beam height is calculated on the basis of worktable height and operator height;

5) Besides SAW, other welding power supplies and console can be equipped with this special Gantry Welding Fixture, making it a multi-function machinery.