Technical Parameters of Adjustable Welding Rotator
| Model |
ZHGK-60 |
| Load Capacity |
(MT) |
Hydraulic Idler 1
Hydraulic Idler 2 |
30
30 |
| Rotation Capacity |
(MT) |
Power |
60 |
| Vessel Ø |
(mm) |
Min. (80°)
Max. (50°) |
2000
6000 |
| Roller Ø |
(mm) |
Hydraulic Idler 1
Hydraulic Idler 2 |
300
300 |
| Roller Width |
(mm) |
Hydraulic Idler 1
Hydraulic Idler 2 |
250
250 |
| Wheel type |
|
|
PU |
| Adjust mode |
|
|
hydraulic adjust |
| Moving wheel Ø |
(mm) |
|
500 |
| Hydraulic Stroke |
(mm) |
|
250 (-80 to 170) |
| Rail inside distance |
(mm) |
|
3500 |
| Power Supply |
(V) |
Determined according to customer needs |
Description of Fit Up Series Welding Rotator
Conventional Rotators are designed to aid in the welding of cylindrical vessels or columns.
The Fit Up Series Welding Rotator is designed to simplify the alignment and rotation of heavy cylindrical workpieces like pipes and tanks. It is ideal for industries such as oil and gas, shipbuilding, and pressure vessel manufacturing, where precision is critical. The rotator automates the fit-up process, reducing manual adjustments and increasing welding efficiency.
A key feature is its synchronized movement, allowing multiple rotators to work together for smooth rotation and precise alignment of mismatched joints. With its heavy load capacity, it easily handles large workpieces, ensuring stability during welding.
Parameter list of conventional ZHGK series welding rotator
Technology Function
This rotator enhances welding precision and boosts productivity for large-scale projects
- Trusted design
- Reliable Quality
- Renowned parts
- Inverter control
- Direct drive system
- Motorised travel option
- Build to order custom design
- OEM
· Summary
This rotator is mainly composed of one power rotator, one idler rotator and two idler hydraulic fit-up rotators. Vessel is welded on this rotator, till get to required length. First vessel lay on power rotator and idler rotator, second vessel lay on two idler hydraulic fit-up rotator. When spot welding two vessels, the rotator moving on rail, and then holding up two vessels. Manipulator finished inner and outer circumferential seam welding. And then add more vessels, till last vessel is welded, the whole vessel is finished welding.
Hydraulic fit-up rotator has hydraulic up-down device, it can moving on rail. Power rotator is controlled by inverter which control AC motor and speed reducer to drive roller turning.
· Welding technology flow
Step 1: Lay first vessel on power rotator side;
Step 2: Lay second vessel one idler rotator side, then can realize fit-up welding through adjust fit-up rotator;
Step 3: Manipulator finish inner and outer seam welding;
Step 4: Power rotator take finished vessel moving backward;
Step 5: Lay third vessel on idler rotator side;
Step 6: Adjust fit-up rotator to realize fit-up welding;
Step 7: Manipulator finished inner and outer seam welding;
Step 8: Power rotator take finished vessel moving backward;
Step 9: Lay fourth vessel on idler rotator side;
Step 10: Adjust fit-up rotator to realize fit-up welding;
Step 11: Manipulator finished inner and outer seam welding;
Following above step again and again till last vessel is welded.
· Device character
3.1. Suitable workpiece for machine
1) Max vessel weight: 80 T;
2) Vessel diameter: φ500mm - φ2280mm;
3.2. Machine character
1) On the base of idler rotator fixed moving wheels which can make the idler rotator moving along with rail.
2) The two rotator both have hydraulic cylinder,it can adjust through expansion of oil cylinder, so that will be convenient to fit-up.
3) Special type used for aligning two pcs workpiece, compensate workpiece elasticity deformation.
3.3. Hydraulic system
Hydraulic fit-up device and idler rotator all including hydraulic system. It's technical character as following:
(1)system pressure 21 MPa
(2)working pressure 16 MPa
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
-
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.
-
Ensure the speed reducer is filled with 30# engine oil before starting, especially when the temperature is below 0ºC.
-
Replace the oil in the speed reducer after the first month of use. Afterward, change the oil every six months.
-
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?
1.
Improved Welding Efficiency: Welding rotators allow continuous rotation of pipes and tanks, enabling faster welding with minimal repositioning.
2.
Enhanced Precision: Automatic speed and position adjustments provide greater accuracy, leading to high-quality welds.
3.
Increased Safety: Welding rotators reduce manual handling, minimizing the risk of accidents and operator fatigue.
4.
Versatility: They can handle a variety of workpiece sizes and materials, making them suitable for different industries.
5.
Cost Savings: By streamlining welding processes and reducing labor requirements, they contribute to overall cost reductions.
6.
Consistent Weld Quality: Uniform rotation ensures even heat distribution, preventing defects and ensuring consistent welds.
7.
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?
-
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.
-
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.
-
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.
-
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.
-
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?
-
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.
-
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.
-
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.
-
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.
-
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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