Description of Standard Welding Rotator:
Our standard welding rotator is mainly used for handling and automatic welding circular metal containers, and can be widely applied to oil industry, press vessel field, wind power production line, pipe line production sector, and many other round workpieces.
Our HGZ-type standard welding rotator is designed and produced to better satisfy the growing demands for the pressure vessel manufacturers both domestically and internationally. It can deal with a wide range of diameters, and it adopts frequency conversion setting and stepless speed regulation mode.
So it enjoys more outstanding advantages over similar products. This rotator features stable and reliable performance, low noise, easy operation, and more. It has passed the CE certification, and has been exported to many countries such as Brazil, India, Jordan, South Africa, UK, Poland, Spain, etc.
Parameter list of conventional HGZ series welding rotator
Technology Function
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The driven and idler roller frames feature a box-shaped base structure designed for optimal force distribution, minimizing deformation. They can easily move along the track, allowing precise adjustment of the roller distance, and can be securely fixed for high positioning accuracy and effortless adjustment.
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The rollers are made from high-strength ZG45 steel castings, ensuring exceptional durability, wear resistance, and a long service life, ideal for handling large and heavy workpieces.
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The system uses a dual-drive mechanism where both rollers are powered by two motor sets through a reducer. The speed is continuously adjustable via a frequency converter, providing smooth, stepless control.
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The anti-creep function is achieved through an elevating design, adjusting the center distance of the workpiece by moving one roller up or down to align with the rotator's centerline, effectively preventing creeping.
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A high-precision displacement sensor from Germany's NOVO Company is utilized, offering excellent precision, long service life, and superior linearity for accurate performance.
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The electrical control system is equipped with Siemens or ABB low-voltage components, ensuring high stability and strong anti-interference capabilities.
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The system includes a professional axial movement detector that calculates the creeping amount based on detection signals, enabling accurate control. This detector is easy to install and adjust, ensuring operational convenience.
Maintenance of Welding Rotator
1. This welding rotator needs cleaning before putting into use. And to avoid aging, the rubber rollers should stay away from oils and high temperature. If possible, there should be a specific person to operate and maintain this device.
2. Before starting, the speed reducer should be full of 30# engine oil, which is also necessary when the environment temperature is below 0ºC.
3. The oil inside the speed reducer should be completely replaced after the use of first month, and later, the engine oil can be changed every six months.
4. The roller bed can not be used as the welding ground so that bearings can be prevented from damaging.
Features of Welding Rotator
1.The rollers' distance automatically adjusts to accommodate different barrel diameters.
2.Speed is adjustable via a frequency control system, enhancing operational reliability.
3.Easy operation is ensured with a manual control box.
4.Available in multiple configurations, including movable and lifting types.
5.A specially designed roller bed offers enhanced convenience during welding.
6.Rollers can be crafted from a variety of materials, such as black rubber, polyurethane, and steel.
Product details
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- Build to order custom design
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Wheel introduction
Polyurethane wheels offer exceptional abrasion resistance, versatile processing, wide applicability, and superior resistance to oil, ozone, aging, radiation, and low temperatures. They also provide strong adhesion, excellent sound transmission, biocompatibility, and blood compatibility.
Motor introduction
Welding Rotator Maintenance Guidelines
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Clean the welding rotator before use. Keep the rubber rollers away from oils and high temperatures to prevent aging. It's recommended that a designated person operates and maintains the equipment.
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Ensure the speed reducer is filled with 30# engine oil before starting, especially when the temperature is below 0ºC.
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Replace the oil in the speed reducer after the first month of use. Afterward, change the oil every six months.
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Do not use the roller bed as a welding ground to avoid damaging the bearings.
Top quality rotator manufacturer
1.With over 20 years of specialized experience in manufacturing self-aligning rotators.
2.Our products feature a bearing capacity that ranges from 5 tons to 400 tons.
3.We provide CE and ISO certifications, ensuring compliance with stringent sub-regulations. Additionally.
4.We offer a one-year warranty and free wearing parts.
5.Our highly skilled technical team is dedicated to supporting you and your large-scale projects, such as wind turbine welding.
Product certification
Step into the future of welding technology with our cutting-edge solutions.
From automated processes to intuitive controls, our products are at the forefront of innovation, providing you with the tools you need to stay ahead in today's competitive market!
Wuxi ABK Machinery Co.Ltd is a professional manufacturer of welding rotator in China. And our welding rotator mainly includes standard welding rotator, adjustable welding rotator, and special welding rotator. We can also provide our clients around the world with many other products including welding turntable, pile welding machine, wind tower production line, H beam welding line, pipe welding equipment, CNC cutting machine, grinding machine, roll forming machine, plate bending machine, etc. We have obtained ISO and CE certification, and we also offer OEM service.
Welding Rotator - The Ultimate FAQ Guide
As the demand for welding turning rolls rises in large-scale industrial manufacturing, many industries now rely on these tools to enhance welding efficiency.
If you have questions about welding turning rolls, we've compiled essential information to help you understand their usage better.
What is a Welding Turning Roll?
A welding turning roll is a specialized device designed to simplify and improve the welding process, ensuring precision and ease in handling cylindrical workpieces during production.
What are the key benefits of using a welding rotator in industrial applications?
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Improved Welding Efficiency: Welding rotators allow continuous rotation of pipes and tanks, enabling faster welding with minimal repositioning.
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Enhanced Precision: Automatic speed and position adjustments provide greater accuracy, leading to high-quality welds.
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Increased Safety: Welding rotators reduce manual handling, minimizing the risk of accidents and operator fatigue.
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Versatility: They can handle a variety of workpiece sizes and materials, making them suitable for different industries.
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Cost Savings: By streamlining welding processes and reducing labor requirements, they contribute to overall cost reductions.
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Consistent Weld Quality: Uniform rotation ensures even heat distribution, preventing defects and ensuring consistent welds.
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Adaptability: With adjustable rollers and speed controls, welding rotators can accommodate a range of diameters and shapes, offering flexibility in various projects.
How does the automatic adjustment feature of the rollers accommodate different pipe diameters?
- Sensor Technology: Sensors detect the diameter of the pipe and automatically adjust the distance between the rollers to ensure a snug fit.
- Hydraulic or Pneumatic Systems: These systems adjust the position of the rollers in response to the detected diameter, allowing for smooth and precise accommodation of varying sizes.
- Motorized Controls: Electric motors drive the adjustment mechanism, which can be controlled automatically to align the rollers based on the pipe diameter.
- Programmable Settings: Advanced systems allow for pre-set adjustments based on specific pipe diameters, facilitating quick and accurate changes without manual intervention.
- Real-Time Feedback: Continuous monitoring of the pipe's position and size ensures that the rollers are adjusted dynamically, maintaining proper alignment and support throughout the welding process.
What types of materials can the rollers on a welding rotator be made from, and how do they impact performance?
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Black Rubber:
- Impact: Provides excellent grip and cushioning, reducing the risk of slippage and damage to the workpiece. Ideal for handling delicate or coated surfaces.
- Performance: Offers good traction and flexibility, suitable for smaller to medium-sized pipes and tanks.
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Polyurethane:
- Impact: Combines the benefits of rubber with greater durability and resistance to wear, chemicals, and temperature fluctuations.
- Performance: Offers a balance of grip and longevity, making it suitable for a wide range of applications and providing consistent performance over time.
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Steel:
- Impact: Provides high strength and load-bearing capacity, making it suitable for heavy-duty applications and larger workpieces.
- Performance: Offers durability and rigidity, but may require additional surface treatments or coatings to prevent damage to workpieces and to reduce friction.
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Stainless Steel:
- Impact: Offers excellent corrosion resistance and durability, making it suitable for harsh environments and high-temperature applications.
- Performance: Ensures long-lasting performance with minimal maintenance, ideal for industries with rigorous operational conditions.
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Rubber-Coated Steel:
- Impact: Combines the strength of steel with the grip and cushioning of rubber, providing both durability and protection for the workpiece.
- Performance: Provides a versatile solution that supports heavy loads while minimizing surface damage.
Choosing the appropriate roller material depends on the specific requirements of the welding application, including the type of material being welded, the environmental conditions, and the desired balance between durability and surface protection.
How does the frequency control system improve the precision and speed of welding rotators?
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Adjustable Speed Control:
- Precision: Allows operators to finely tune the rotational speed of the welding rotator, ensuring optimal welding conditions for different materials and processes. This control helps achieve consistent welds and prevents issues related to speed variations.
- Speed: Enables operators to increase or decrease the rotation speed as needed, improving efficiency and adapting to various welding requirements.
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Smooth and Consistent Rotation:
- Precision: Provides smooth and steady rotation without jerks or fluctuations, which is crucial for maintaining alignment and achieving high-quality welds.
- Speed: Reduces the likelihood of speed inconsistencies that can affect weld quality and production rates.
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Enhanced Automation:
- Precision: Integrates with automated systems to synchronize the rotator's speed with other welding parameters, improving overall process control and precision.
- Speed: Facilitates automated adjustments to rotation speed based on real-time feedback, optimizing welding performance and reducing manual intervention.
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Reduced Mechanical Wear:
- Precision: Minimizes mechanical stress and wear on the rotator's components by maintaining optimal speed settings, leading to more accurate and reliable operation.
- Speed: Extends the lifespan of the equipment by avoiding excessive or inadequate speeds that could cause damage.
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Versatility:
- Precision: Allows for easy adjustment to accommodate various welding tasks and pipe diameters, ensuring the rotator performs optimally across different applications.
- Speed: Enables quick adjustments to match specific welding needs, improving overall productivity and flexibility.
Overall, the frequency control system enhances both the precision and speed of welding rotators, contributing to higher quality welds, increased efficiency, and more effective process management.
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