Plasma + argon arc (TIG) + submerged arc welding (SAW) welding tank head circumferential seam and straight longitudinal seam

Equipment performance of P+T/submerged arc welding longitudinal and circumferential seam welding system solutions

According to the welding technical requirements of your company’s products and the status of the workpieces that have been communicated and understood in the early stage of the product, we are very honored to provide this special machine system solution for the welding of this product to meet the current and future requirements of your company for this series of products. Welding required. This system is an efficient and flexible welding system designed and manufactured by UCRT (professional automated welding design and manufacturing company) based on more than ten years of design experience, combined with our company’s welding technology, equipment and process concepts.   

      Project configuration and characteristics of P+T/ submerged arc welding longitudinal and circumferential seam welding system solutions

one. Workpiece situation

1.        Workpiece diameter: Φ500mm～Φ3600mm

2.       Length of workpiece: length of single section <2000mm. Total length of workpiece ≤10000mm

3.       Material: stainless steel, carbon steel

4.       Wall thickness: 6～10mm (plasma + argon arc welding) 12-20mm (submerged arc welding)

two. Welding process introduction

2.1  Welding process

The thickness of the cylinder body is 6-8mm, and the single-gun plasma filling wire welding process is adopted, which can realize single-sided welding and double-sided forming without groove opening;

The thickness of the cylinder is 12-20mm, and the submerged arc welding process is adopted.

2.2  Workpiece assembly requirements

    1 ) Butt-joint and gap ≤0.5mm; 1.5～3mm, butt-joint and gap ≤8% of plate thickness.

    2 ) There is no oil and water at the butt joint.

    3 ) The spot welding distance is about 150mm, the spot welding point should be small, and the roundness of the cylinder should be ensured after the ring seam is assembled.

2.3  Welding wire

    The material of the welding wire is selected to match the material of the workpiece. The diameter of the welding wire can be selected from 1.0 or 1.2mm disc-shaped welding wire, and the weight of each coil of welding wire is about 15KG. The welding wire should be properly stored and protected to avoid moisture and bending, which will affect the quality of the welding seam and the stability of the wire feeding.

2.4  Protective gas

For plasma welding, there are multiple welding shielding gases. Plasma gas is generally 99.99% pure argon, stainless steel plasma and tig welding torch shielding gas is 95% argon + 5% hydrogen, and high-quality weld formation and protection color can be obtained. 99.99% pure argon is used for the hood gas and the back shielding gas.

2.5 Characteristics of plasma welding system

1)        The penetration ability is strong, and the plate thickness below 8mm does not need to be grooved, which greatly reduces the preparation time before welding.

2)       The arc energy is concentrated, the welding heat affected zone is small, and the welding deformation is small.

3)       The welding speed is fast, and the plasma time is 4-5 times shorter than that of manual argon arc welding.

4)       Excellent repeatability.

5)       The rigidity of the arc column is large, and the small hole effect is adopted, which can realize stable single-sided welding and double-sided forming.

6)       The electrode is shrunk in the nozzle, which is not easy to be polluted and burned, and the electrode has a long life and few weld defects.

7)       The welding quality is good, and there are many weldable materials.

8)       The plasma arc has good controllability and regulation.

three. Equipment configuration and features

 Circumferential seam system: the combination of 4000 manipulator and 20T adjustable roller frame is adopted.

The power distribution cabinet of the system requires: the air switch is 100A, the power is 60KW, and a 3-phase five-wire main incoming cable is connected to the equipment electrical cabinet, which is prepared by the customer before the equipment enters the factory.

Equipment introduction:

4.1   CJ4000*4000 operating machine

CJ type column beam welding manipulator is the main process equipment for automatic welding of boilers, pressure vessels, pipes and metal structural parts. It is matched with roller frames, positioners and/or turning machines to form an automatic welding system, which can be used for various pressure vessel barrels . Internal and external longitudinal circumferential seams of large diameter pipes, welding of spherical and elliptical head seams, surfacing welding of the inner wall of the cylinder body and the head, and surfacing welding of the reinforced area of ​​the head opening, etc. Welding methods such as TIG, MIG/MAG, PLASMA, submerged arc welding can be used.

Introduction to Mechanical Structure

The manipulator is mainly composed of the following components.

chassis

The chassis is used to support the entire manipulator.

column

The column is installed on the chassis, the sliding plate is installed on the front, and the lifting drive mechanism is installed on the top surface.

 Beam, slide box

The four groups of rollers on the inner side of the sliding plate of the manipulator are matched with the guide rail of the column. The roller shaft is an eccentric shaft. Rotating the eccentric shaft of the roller at a certain angle can adjust the level of the beam and change the gap between the roller and the guide rail. It is installed on the side of the sliding plate. There are motors and reducers. The output gear of the reducer meshes with the rack on the beam to move the beam.

technical parameter

4.2 GTGJ20-C adjustable roller frame

The welding roller frame is the main supporting equipment for the welding of pressure vessel boilers, and it is the necessary process equipment for the circumferential seam welding of the cylinder and the adjustment of the workpiece support. The general welding roller frame is divided into two types: self-adjusting and adjustable. The adjustable roller frame is mainly suitable for use when the workpiece is light. Generally, the welding roller frame is used in groups. If the length of the workpiece is very long, multiple passive roller frames and one active roller frame are also used in groups.

Introduction to Mechanical Structure

The equipment consists of a set of active roller frames and two sets of driven roller frames. The master-slave roller frame is equipped with a base guide rail. The distance between the active roller frame and the driven roller frame can be freely placed by the user according to the length of the workpiece and can be locked and fixed. ..

§    Active roller rack

The active roller frame consists of a drive motor and a worm gear reducer to form a transmission system, which drives the iron core rubber wheel to make the workpiece move smoothly. The speed adjustment of the roller frame adopts the method of frequency conversion speed regulation. The components are composed of frame, roller, roller bracket, etc. The distance between the two rollers can be adjusted manually by the screw. Causes scratches on the workpiece and large axial movement of the workpiece during rotation.

§    Driven Roller Rack

The driven roller frame has no transmission system and is composed of a frame, rollers, roller brackets, etc. The distance between the two rollers can be adjusted manually by the screw.

4.3 EWM452 plasma welding power source

This series of plasma welding power sources are products with the latest inverter technology advantages, which are widely used in welding in electronic and precision machinery, measurement and control technology, aircraft and aerospace, food, medicine and other industrial fields. Such as welding of high alloy steel, nickel, copper, titanium and other special alloys of plates, wires, gaskets, filters.

Features:

uCompared   with TIG, the welding speed is significantly increased, and the penetration depth is deepened               

uUsing   the latest inverter technology, high reliability and stability

u   Precise plasma arc makes the heat precisely concentrated, and the material is not easily deformed

uThe   plasma arc shrinks, keeping the arc diameter constant even when the workpiece distance increases

u   welding gun is suitable for automatic welding, with high duty cycle and equipped with interface

u   Modular design for easy maintenance and maintenance

u   With current and voltage output control, it can communicate with PLC system to realize centralized control of welding parameters.

Application areas:

• Plasma DC welding method (to negative pole): unalloyed steels, low alloyed steels, high alloyed steels, nickel, copper, titanium zirconium and corresponding alloys, special metals
Aerospace, chemical and food industry, shipbuilding, vehicle construction, piping , containers, high-pressure airtight containers, plant construction, etc.

technical parameter

4.4 Welding power source

product description

1. Digital display of current and voltage, accurate and convenient preset parameters

2. Three functions of DC TIG welding/DC pulse TIG welding/DC manual welding, which are widely used

3. There are two pulse functions of low frequency (0.5~30Hz) and medium frequency (10~500Hz). The low-frequency pulse is suitable for all-position welding of medium, thick and tubular materials of various materials; the medium-frequency pulse arc has high stiffness and good concentration, and is more suitable for the welding of various heat-sensitive materials, heat-strength materials, and thin plates.

4. The pulse current, base value current, pulse frequency and pulse width can be adjusted steplessly, which is suitable for welding under various specifications.

5. During electrode arc welding, the thrust current can be adjusted steplessly to avoid sticking

6. Built-in anti-shock device to improve operational safety

7. Three-layer four-chamber dustproof structure, enclosure protection grade IP23, suitable for use in harsh environments

4.5 Submerged arc welding power source

Product name: MZ – 1000

Except for the grating motor, the other configuration is the same as that of the IV series welding machine;

With constant current and constant voltage characteristics, it can realize the welding process of thick wire, thin wire, flux core, strip pole, double wire and single arc, etc.

Digital communication interface, easy to form PLC and other special welding machines

The main control board of the welding machine is upgraded, the response speed is improved, the welding arc is more stable, and the phenomenon of arc breakage is reduced.

Using the grating feedback motor, the wire feeding speed can be controlled accurately and quickly, and the control parameters of different welding wires can be refined to ensure stable welding and neat welding edges.

Add the functions of scratching and reverse arcing, improve the control method of arcing, and ensure the success rate of arcing under the specifications of various welding wires

Add the adjustable functions of arc starting parameters, arc extinguishing parameters, and burn-back parameters to improve the applicability of different processes and facilitate customer operation

4.6 Plasma/argon arc welding control system

In the actual production welding process, in order to complete the complex welding tasks of different products, the relevant welding parameters and motion parameters should be matched and implemented through a centralized controller. The control system is the center for completing multi-task longitudinal/circumferential seam welding. The system adopts German Siemens PLC as the main control unit; adopts multi-module centralized control mode, and coordinates and communicates related welding parameters and motion parameters through programming; and selects a larger engineering control cabinet, which is equipped with ventilation, dust-proof, heat-dissipating, Anti-interference and other functions; reasonable installation of various functional modules and switching elements through the wire trough; dust-proof spacers on the edge of the cabinet can effectively isolate the dust at the work site, and prevent dust from entering the control system and depositing on components and causing device failure. .

The control system has the characteristics of stable operation, simple programming, intuitive interface, convenient maintenance, and strong anti-interference ability. The input voltage of the control system is three-phase 380V/50Hz or single-phase 220V/50Hz, and the voltage fluctuation is within ±10%. If it exceeds the range, it is recommended to add a regulated power supply.

The system

  Good quality assurance, super anti-interference ability;

 Simple to use, easy to maintain and easy to transform;

 Good human-machine communication environment.

Welding torch/workpiece welding speed adjustment and display

 Welding current and voltage display

Welding start/stop control

 Welding torch/workpiece position adjustment jog control

 Welding/simulation function

Control of other tasks (such as video surveillance, plasma flow control, etc.)

Parameter programming and storage, can store 30 groups of parameters

Program lock function

Selection of welding process such as DC/pulse

 walking speed control

 Wire feeding motion control (wire feeding speed, wire feeding delay time, retraction time, increments can be set)

Yaw control (switch, swing width, swing speed, left and right dwell time, yaw offset, etc.)

 Arc length control (switch, auto tracking delay time, tracking arc voltage, arc voltage increment, sensitivity, etc.)

 4.7 Plasma temperature controlled cold water tank

The temperature-controlled cold water tank is composed of high-efficiency condenser, compressor, fan motor, thermostat and water detection sensor. It is a necessary supporting equipment for cooling the welding torch in the process of automatic welding (such as plasma) and welding under high load continuous state.

The main technical parameters

Power supply rated voltage: 1×220V/50Hz (fluctuation range: 208V～220V)

Compressor load: 2 P

 Cooling capacity: 5332 (under 15°C)

Water tank capacity: 20 liters

 Temperature adjustment range: -5℃～+40℃

The main function

Control temperature range, with electronic thermostat, digital display set temperature and actual temperature

With water temperature overload protection, water shortage flow sensing protection, water level indicator display

Adopt Kemby joint, the flow of water in and out is large

Adopt large-capacity water tank, 25-meter head pump and large-diameter water pipeline, which can be applied to the structure of long-distance pipeline arrangement

4.8 GTP450A plasma torch

    Plasma torches are mainly used for welding materials such as stainless steel, carbon steel, titanium, zirconium and their alloys. The welding torch has the characteristics of good cooling effect, good arc compression effect and stable arc, and is one of the important accessories for obtaining good plasma welding quality.

  The main technical parameters

 Rated current: 450A;

At 450A, the load duration is 60%; at 400A, the load duration is 100%

Weight: 3.7KG;

Suitable for tungsten electrode diameter: ￠3.2, 4.0mm, length 150mm;

According to the thickness of the workpiece, the plasma nozzle can be selected: ￠2.5, 2.8, 3.2.

4.9 Plasma tray

The drag cover is used together with the HPT-500A plasma welding torch, and has a good protective effect on the welding of stainless steel, titanium alloy, zirconium alloy and other materials.

Mainly have the following characteristics:

 Compact structure and easy installation;

 Water-cooled structure, suitable for long-term, high-current welding process;

Good protection effect;

Adopt stainless steel structure, no pollution to cooling water.

4.10 TIG torch cover

    The drag cover is used in conjunction with TIG welding torches and is suitable for welding stainless steel, titanium alloys and other materials. It has the following characteristics:

Compact structure and beautiful appearance

Good protection effect;

It is made of aluminum alloy as a whole and cooperates with the welding torch as a whole.

4.11 High frequency arc pilot

High-frequency arc starter is a supporting device for welding equipment used to improve the success rate of arc ignition. It is mainly suitable for occasions where the welding cable is long, the peripheral equipment has more interference, the frequency loss is serious, and the arc striking effect is not good. The device has a built-in cooling fan (24V/6W), which can work with high current for a long time; the built-in arc-striking plate of the device outputs high-frequency high-voltage pulses of T=2us, V=750V, and the arc-striking voltage is up to 8000V after being boosted by a high-voltage transformer , so as to improve the success rate of arc ignition, reaching 100% success.

4.12 TIG/PAW wire feeder

The wire feeder is driven by a DC motor and is decelerated by a micro reducer. The gear on the output shaft meshes with the gears with wire feed wheels on both sides. There is a pressing wheel above the wire feed wheel, which is pressed by a spring lever and can be changed by rotating the eccentric wheel. The size of the pressing force between the pinch roller and the wire feed roller. It is suitable for the low-speed wire feeding requirements of TIG and PAW welding processes. According to the diameter of the welding wire, the corresponding wire feeding wheel is installed. The wire feeding speed is 200-2000mm/min, and the standard distribution wire wheel is Φ1.0mm. The wire feeding mechanism is integrated with the system, and the speed adjustment is completed by the centralized controller.

4.13 Precision 3D wire feed bracket

The device is a functional accessory that supports the welding wire, so that the welding wire can be introduced at a given angle, and the position of the welding wire can be adjusted through the three axes of the handle to realize the optimal angle of the wire feeding during welding. It has the functions of accurate and convenient angle adjustment and simple connection with the welding torch.

4.14 Electric cross carriage

This component is an important part in automatic welding. It can realize arc height jog control (arc length control in TIG/plasma state) and swing control of welding torch when matched with power supply and controller. The sliding frame is composed of two sliding plates connected in a cross. The adjustment movement of the sliding frame is driven by the stepper motor to drive the lead screw to rotate, and then the nut drives the sliding plate to move, and the support plate, welding gun seat, Parts such as welding torches and multi-dimensional wire feed brackets. The arc height adjustment carriage and the swing carriage can be installed and applied separately, and the horizontal and vertical positions of the welding torch can be adjusted by jogging the control button during the welding process.

The basic technical parameters are as follows:

4.15 Monitoring system

The system has a clear and accurate monitoring position, and it is convenient to adjust the position of the welding torch flexibly. It is suitable for observing the position of the weld seam and the molten pool before welding and during the welding process. It can be used for TIG/PAW open arc state by selecting the corresponding filter. Characteristics of the next welding work. The device consists of industrial monitor, five times magnification CCD camera, filter device and lens switch control, cooling air circuit and anti-interference module and other components. The camera is installed on the bracket connected to the welding torch, and is generally installed in front of the welding travel direction, so as to observe the position of the welding torch and the situation of the molten pool.

Before the welding starts, the relative position of the welding torch and the welding seam can be easily observed through this system, which is convenient for the welding torch to be centered. After the welding arc is formed, the filter is automatically opened to filter the arc light. At this time, the camera will monitor the welding situation at the welding position. The operator observes the actual welding seam through the monitor to adjust the position of the welding torch, so that the welding arc is relatively in the center of the welding seam, so as to monitor the position of the welding torch and adjust it.

4. 16 Cable assembly

The imported control wire from Germany is installed in the tank chain, and it moves harmoniously with the operation of the welding trolley. The wiring is beautiful and stable, which can well protect the cable and prolong the life of the cable.

parties sign or seal it and it will take effect when the contract takes effect.