What is a welding rotor ( Turning Roll )?
The welding rotator is an automatic tool that can weld pipes, tanks, piles and other round objects more easily. They can handle sizes from small to large, and save time by joining two moving metal sheets together, freeing up hands for welding.
They can manually load light and heavy workpieces remotely.
What is a Welding Positioner ?
Welding positioner is a variety of mechanical devices that change the position of the weldment or welding machine to complete mechanization and automatic welding.
Welding positioners are divided into three categories:
(1) Welded parts displacement machinery: including welding positioner, welding rotator, welding turning table and welding turning machine.
(2) Welding machine positioner: including welding operators and electroslag welding station.
(3) Welder positioner: including welder lift, etc.
The welding positioner is a machine that can rotate and tilt the workpiece, and it can make the welding seam on the workpiece in a favorable welding position. Mainly used for rotating and tilting welding frames, flanges and heads, but also for assembly, cutting and inspection.
The welding turntable is a simplified positioner. It rotates the workpiece around a vertical axis or at a fixed angle. Mainly used for welding, surfacing and cutting of rotating workpieces.
How to choose a welding rotor （ Turning Roll ）?
Self-aligning Welding Rotator : The self-aligning welding rotator consists of two parts, including a drive roller and an idler roller. Each active and passive frame of the self-aligning welding rotator series consists of four rollers. The roller is made of inner iron core and outer polyurethane. The operation of the driving roller is synchronously driven by a speed-regulating motor through two worm gear reducers, and a speed governor is used to achieve no speed change. The noise of mechanical transmission is low, and the workpiece rotates smoothly. The linear speed of rotation of the workpiece is 100-1000mm/min. Each fixture bracket can be automatically adjusted within the diameter of the workpiece. When the diameter is small, the lower wheels of each clamping frame are on the same horizontal line.
Conventional Welding Rotator: The conventional welding rotator is also equipped with a drive roller and an idler, and the control cabinet has a manual remote control. Each unit has only two rollers. The rollers are made of inner metal and coated with polyurethane. The friction between the active roller and the pipe drives the pipe to rotate. The drive device adopts a variable frequency speed regulating motor, and the welding part is driven to rotate through the reducer. The spacing adjustment of the roller components in each roller rack is completed by manual operation and positioning bolts according to the weldment conditions.
Design of welding fixture for welding positioning equipment：
The welding fixture should have the characteristics of fast and easy operation. The operating location should be in a location that is easy for workers to access and most suitable for operation. Especially the operating force of manual clamps should not be too large, and the operating frequency should not be too high. The working height should be set at the position where workers are most likely to exert force. When the clamp is in the clamped state, it should be able to lock itself.
The welding fixture should have enough space for assembly and welding, which does not affect the welding operation and welder’s observation, and does not hinder the loading and unloading of the weldment. All positioning components and clamping mechanisms should be kept at an appropriate distance from the weld bead, or arranged under or on the side of the weldment. The actuator of the clamping mechanism should be able to retract or index.
Reliable clamping and suitable rigidity. When clamping, it will not damage the position and geometry of the weldment. After clamping, the weldment will not loosen and slip, and the restraint on the weldment will not be too large and cause greater stress.
Set up necessary safety interlock protection devices to ensure safe use.
When clamping thin parts and soft material weldments, the clamping force should be limited, or measures should be taken to limit the stroke of the indenter, increase the contact of the indenter, and add copper and aluminum backing. Do not damage the surface quality of the weldment during clamping.
The jig near the welding part should consider the heat insulation of the handle, and the damage of welding spatter on the surface of the clamping mechanism and the positioner.
In order to prevent the coupling between the support reaction force and the clamping force, and the support reaction force and gravity, the force application point of the fixture should be located at or near the support of the weldment.
Various welding methods also need to pay attention to the special requirements of the fixture in terms of heat conduction, conduction, magnetic separation and insulation. For example, in projection welding and flash welding, the fixture is also used as a conductor. In brazing, the fixture is also used as a heat sink, so the fixture itself is required to have good electrical conductivity and thermal conductivity. In addition, for the fixture used in vacuum electron beam welding, the part of the fixture close to the gun head must not be made of magnetic materials, and the fixture must not have residual magnetism, to ensure that it does not affect the focus of the electron beam.
For the specific rigidity of the fixture, because it has a great influence on the shape accuracy and dimensional accuracy of the structure, a larger redundancy should be reserved in the design. It can be seen that the fixture used for large-scale plate welding structure should have sufficient strength and rigidity.
Only one power source and clamping device cannot be used in the same structure.
Good manufacturing process and high mechanical efficiency are what the fixture itself should have.
Use universal and standardized clamping mechanisms and standard parts as much as possible for welding fixtures.
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Post time: Oct-12-2021