PFW1020 Four Torch Station GMAW Pipe Flange Welding Machine

A. Usage and Function of PFW1020 Circumferential Seam Pipe Flange Welding Machine:

1. Function: PFW1020 model machine fabricates on pipe and end flanges into finished working parts, in the welding mode of MAG or MIG;

2. Working Capabilities:

1) Summary: This Special Made Welding Machine is designed for performing welding two pieces of flange onto both ends of pipe with one time operation, by means of 2 pieces of welding torch operating simultaneously:

2) Pipe flange circumferential MAG welding in Wuxi JACK PFW1020 machine: (Fig.1)

3) Welding Operation: Pipe and 2 pieces of flange are laid on to 2 sets of motor drive moving Welding Rotator. By means of rotation of its welding turning rolls, GMAW welding can be implemented on pipe and flange;

3.  Major Working Steps in PFW1020 Pipe Flange Circumferential Welding Machine:

1) Based on actual length of pipe, the four sets of GMAW welding torch can be adjusted its position, along the entire longitudinal body of pipe;

2) The motorized moving Welding Rotator, serving as pipe holding unit, in Wuxi JACK PFW1020 model machine: (Fig.2)

3) The two sets of Welding Rotator:

a) Support pipe;

b) Rotate in A.C. inverter adjusted welding speed;

c) Adjust longitudinal position, based on different length of pipes;

4. Quantity of Welding Torches and Welding Seams:

1) This welding equipment fixture utilizes four sets of MAG welding torches, for fulfilling both ends flange welding onto pipe. Accordingly, it has 4 sets of welding oscillator units;

2) Each of the welding torch is equipped with 3 dimensional adjusting unit;

3) In this way, during operation, each of the welding torch can adjust its angular position, along horizontal X and vertical Y axis two dimensional position easily.

B. Workpieces Applicable for PFW1020 Pipe Flange Circumferential Welding Machine:

1. Specifications of Workpieces Designed for PFW1020 Pipe Flange Welding Equipment:

Design drawing on pipe flange workpiece, intended for Wuxi JACK PFW1020 Special Made Welding Equipment: (Fig.3)

As shown in the above sketch:

1) The Max. external diameter of pipe is Φ1020mm;

2) The Max. internal diameter of flanges for mating is Φ1360mm;

3) The Max. length of finished pipe flange can be 5500mm;

2. Welding Seams Completed:

1) Welding seams confirmed by Wuxi JACK engineer with hand writing sketch, on workpiece pipe flange: (Fig.4)

2) As shown in the above sketch, totally 4 pieces of circumferential seams at both ends of pipe flange mating can be acquired, in the form of flat fillet GMAW welding (MIG or MAG);

3) Based on wall thickness of pipe and flange, welding current can be modulated conveniently for getting satisfactory performance.

C. Main Configurations and Technical Performance of PFW1020 Circumferential Seam Pipe Flange Welding Equipment:

1. Welding Torches:

1) There are totally 4 pieces of welding torches in this machine, and this is the name “PFW1020 Four Torch GMAW” got from;

2) Each of the welding torch can be manually adjusted in 3 dimensional direction, for perfectly aiming on welding seam, which involves totally 4 sets of manipulating systems;

3) Welding torch mechanism in Wuxi JACK PFW1020 model machine: (Fig.5)

2. GMAW Welding Power Supply in PFW1020 Circumferential Seam Pipe Flange Welding Machine:

1) Recommended Brand: MAG or MIG is Chinese HUAYUAN made NB-500HD model;

2) Specification: Welding current of the MIG/ MAW machines is in the range of 80~ 500A, totally 4 sets;

3) Arrangement: The 4 sets of MIG/ MAG welding machines are positioned at pipe both ends respectively: Each end 2 sets;

3. Detailed parameter of MAG welder for PFW1020 Circumferential Seam Pipe Flange Welding Equipment: (Fig.6)

4. Workpiece Holding and Rotating Units in PFW1020 Special Made Pipe Flange Welding Machine:

1) Role: There are two sets of motor drive moving Welding Rotator machine, supporting and rotating pipe simultaneously;

2) Working Speed: Rotating speed of welding turning rolls is adjusted with A.C. inverter, which equals to actual MIG/ MAG welding velocity, and is displayed in real time manner;

3) Longitudinal Adjustment: This supporting unit can adjust its longitudinal position according to pipe length, with railway fixed into workshop ground:

4) Pipe flange rotating units in Wuxi JACK PFW1020 model welding equipment: (Fig.7)

5) Modulation: Each set of Welding Rotator has two pieces of turning rollers, which have handwheel to adjust on roller distance according to pipe diameter. There are totally 2 sets of supporting units in this machine;

5. Welding Function Supplementary Units:

1) This welding equipment is equipped with four sets of ED-WLS40 model oscillator, a very valuable and convenient device;

2) This control device is directly connected to swing line accessing control box;

3) The swing unit is mounted onto running device, adjusting buttons being installed in control box:

4) Oscillator closed loop control circuit equipped with Wuxi JACK PFW1020 model machine: (Fig.8)

D. Welding Seam Tracing Unit in PFW1020 Pipe Flange Special Made Welding Machine:

1.  Strong Points of ED-WLS40 Oscillator:

1)  This is a special device for performing linear swing along workpieces, during welding operation in the machine;

2) It is a small and light contrivance, easy to operate, having no operation place restrictions;

3) Welding oscillator being applied in pipe flange Welding operation: (Fig.9)

2.  Technical Performance of Welding Oscillator in Pipe Flange Welding Machine:

1) Critical Indexes: Swings under digitally control/ Moving to center / Left and Right limit/ Swing speed management;

2) Action: Welding torch automatically returns to original center when stopping welding;

3) Characteristic: Extensive welding voltage range controlled with switch, not affected with input voltage;

3. General Operation on Oscillator in Pipe Flange Circumferential Welding Machine:

1) Switch on power, its indicator light on;

2) Turn adjustment knob on panel of the oscillator;

3) For four swing modes, modulate two points stop time;

4) Adjust swing width and speed by turning knob;

5) During swing, check on actual torch swing amplitude;

6) During operation, turn knob based on performance requirements if necessary;

7) At completion of welding, turn the oscillator to OFF position;

8) Welding torch automatically return to its original center position, thus completing task of oscillator for pipe flange circumferential welding operation.

E. Technical Specifications of PFW1020 Pipe Flange Special Made Welding Equipment:

No.	Parameter	Specification	Note
1	Diameter Scope of Pipe	Φ200 mm ~ Φ1000 mm
2	Diameter Scope of Flange	Φ300 mm ~Φ1360 mm
3	Applicable Pipe Length	3000 mm ~5500 mm
4	Welding Speed (Rotating Linear Speed)	100-1000 mm/min.	A.C. Inverter control, continuous stepless adjustment
5	Welding System Quantity	4 Sets	Including: Welding torch/ Welding Power Supply/ Welding Supporting Unit
6	GMAW Welding System	HUAYUAN made NB-500HD (MAG or MIG)
7	Max. Welding Current	500 A
8	Welding Oscillator	4 Sets	Model ED-WLS40
9	Welding Torch Adjust Unit	4 Sets	3 dimensional
10	Support Travelling Car	2 Sets	Motor drive, along rail
11	Power Electricity	AC380V, 50Hz， 3 Phase	Special Made available