Pipe Elbow Welding Machine with Automatic Circumferential SAW Welding

A. Role of Pipe Welding Machine for Pipe Fabrication:

1. Work Station: In deployment of pipe assembly and welding machine, following:

1) Pipe edge beveling;

2) Pipe flange assembly and tack welding;

3) Pipe elbow assembly and tack welding;

2. The third step is for both pipe elbow and pipe flange circumferential welding, implemented with 2 different types of machines. Here we introduce both types as below;

3. Technical Features: The welding on pipe elbow and pipe flange are different: The former is SAW, and the latter is CO₂ gas shielded welding.

B. Pipe Elbow Welding Machine:

1. Function and Welding Mode:

Wuxi JACK machine on pipe elbow SAW welding: (Fig.1)

1) This machine performs closing step in pipe production --- pipe elbow welding;

2) The welding mode here is circumferential SAW submerged arc welding, in the position of vertical downward;

2. Structure and Working Way of Pipe Elbow Circumferential Seam Welding Machine:

1) Structure: The machine has similar structure and working principle as machines in “Welding Fixtures and Special Welding Machine”: A set of roller bed plays the role of workpiece supporting rack, as well as welding rotator, in the process of circumferential seam welding;

2) Work Table: The roller bed is in work table style --- It has the same height as operator, so as to provide convenient and comfortable observation by operator, during circumferential submerged arc welding operation;

3) Submerged Arc Welding System:

This includes:

a) SAW welding power supply;

b) Welding control console;

c) Welding torch mechanism;

d) Welding flux hopper;

These are put alongside workpiece turning roll, with welding torch be positioned right above pipe elbow welding seams;

4) Operating Manner: This machine works in the mode of welding torch stationary, while workpiece pipe elbow rotates in welding velocity, on its supporting roller bed;

3. Operating Steps in Pipe Elbow Circumferential Seam Welding Machine:

1) Load Workpiece: The assembled and tack welded pipe elbow onto table type turning roll, and make adjustment on its location, making sure welding seam right beneath the welding torch;

2) Welding Position Control: Have precise modulation on position of the welding torch by means of its cross slide, making it aiming at welding seam in precision;

3) Circumferential Welding Velocity: Start on roller bed of workpiece, adjusting its linear revolving speed on operating panel, which is the velocity of circumferential submerged arc welding in this Pipe Elbow Welding Machine;

4) SAW Circumferential Welding: Start on submerged arc welding power supply, and adjust its welding current on SAW control console, and initiate on the SAW circumferential seam welding operation;

5) Next Step: At the completion of welding, we go to the final stop on pipe assembly and welding: Pipe flange finished welding;

4. Technical Parameters of Pipe Elbow Welding Machine:

Max. Pipe Diameter	600 mm (Tailor made available)
Max. Pipe Length	10,000 mm (Tailor made available)
Pipe Thickness Range	10 ~ 20 mm
Pipe Elbow Welding mode	Automatic Submerged Arc Welding
Pipe Elbow SAW Welding Max. Current	1000 A
Pipe Elbow SAW Welding Linear Speed	240 ~ 2000 mm/min.

C. Pipe Flange Welding Machine:

1. Usage and Technical Feature of Pipe Flange Circumferential Seam Welding Machine:

1) Work Station: This machine is the last equipment in pipe elbow flange fabrication. Different from pipe elbow SAW welding, here the pipe flange finished welding is adopted with CO₂ Welding:

a) Wuxi JACK machine on pipe flange finished welding: (Fig.2)

b) Finished pipe flange welding parts from Wuxi JACK machine: (Fig.3, 4)

2) Function: This machine welds on the assembled pipe flange, with welding mode of circumferential CO₂ gas shielded welding, in position of flat fillet welding;

3) Technical Specialty:

a) This machine is different from conventional type, which tilts flange certain angle, to make welding performed in the position of vertical downward, because flange is short and light, which is easy to be tiled;

b) Here is this pipe fabrication process, pipe welded with elbow at one end and flange at the other end has long length and heavy weight, which is very difficult to be swinged. This is the reason this machine adopts welding position of flat fillet welding;

2. Structure and Main Units of Pipe Flange Circumferential Seam Welding Machine:

1) Structure:

a) As can be checked from its photo, this machine has body trunk of vertical standing and extension arm, like a set of lathe;

b) Welding torch and its control console is fit at the front end of extension arm, alongside the pressing rollers, just above welding seam;

c) Welding wire spool is at the rear end of extension arm;

d) The extension arm can be lifted up and down, based on diameter of workpiece pipe flange;

2) Working Principle:

a) Machine bed is a set of box frame, which integrated with electric control board inside;

b) On its top surface is a set of small turning roll, which serves as holding unit of workpiece, revolves in the process of circumferential seam welding, thus in turn drives workpiece into revolve;

c) The welding torch overhead keeps still during welding: With revolve of workpiece, the circumferential gas shielded welding is completed;

3. Pipe Flange Secure into Pipe Flange Welding Machine:

1) Due to the heavy weight and big size of workpiece pipe and flange, to make its stable running without issues like skidding happened,

2) Besides the roller bed beneath the pipe flange, there is another pair of rollers at the bottom face of extension arm,

3) Which press pipe flange tightly during its circumferential CO₂ welding, making sure the workpiece assembly is held tightly, with 4 pieces of turning rolls surrounding it;

4. Operation in Pipe Flange Circumferential Seam Welding Machine:

1) Precondition: To start on circumferential gas shielded welding operation, put pipe flange assembly onto its supporting roller beds. By this step, the workpiece should already have its elbow welded, in the previous step of pipe flange submerged arc welding;

2) Adjust position of pipe flange assembly, making sure its welding seam is right beneath welding torch; During adjustment, pay attention to balance of pipe flange assembly on this machine;

3) Precise Adjustment: Descends extension arm until tip of welding torch touches surface of pipe flange assembly, and adjust position of welding torch in inching way, by means of its cross slide, making its tip directly aiming at welding seam;

4) Welding Speed: Set up roller revolve speed, which is also velocity of circumferential seam welding, on operating panel of this Pipe Welding Machine;

5) Set up welding current of circumferential CO₂ welding, in control console of power supply, based on wall thickness of pipe flange assembly, and start on circumferential seam welding process accordingly;

6) Operator Protection: One of the matters needing attention which should be stressed here is, during circumferential gas shielded welding, there will be strong arc light generated, which will do great harm to people eyesight. So, be sure to put on welding helmet during the entire CO₂ welding;

5. Technical Parameters of Pipe Flange Welding Machine:

Max. Pipe Diameter	600 mm (Tailor made available)
Max. Pipe Length	10,000 mm (Tailor made available)
Pipe Thickness Range	10 ~ 20 mm
Pipe Flange Welding mode	Automatic CO2 Gas Shielded Welding
Pipe Flange CO2 Welding Max. Current	500 A
Pipe Flange CO2 Welding Linear Speed	400 ~ 3000 mm/min.