How to weld the big tank use Welding manipulator

LHW5050 Welding manipulator

Technical Proposal

1.Outline

This machine used for tank/vessel/pipe welding, circular seam and longitudinal seam welding.

It can be formed a welding center working together with welding rotator or positioner etc; which is a ideal equipment for improving welding quality and efficiency.  

2.Work conditions

·Altitude height not more than 1000m

·Air temperature should not be out of the following range:

    a) Highest temperature 40℃

    b) Lowest temperature 0℃

·Air relative humidity: Maximum average relative humidity is 90% when day average temperature is not more than 25℃;

·The equipment should be used in environment of no serious explosive or corruptive gas、steam、salt-fog、chemical deposition, and be far away from vibrant shock.

·power supply electricity quality:

     Voltage fluctuation (for rated frequency): ≤±10%;

     Frequency fluctuation (for rated voltage): ≤±2%;

3.Drawing for reference (movable and revolve type)

1-trolley ,2-column revolve unit,3-column,4-flux feeding and recovery system ,5-guide saddle，6-elevating unit,7-boom,8-welding system

4. Main technical parameter

5.Structure and characteristic

The welding manipulator mainly consists of boom elevation unit, boom retraction unit, motorized cross slider, column, boom, trolley, flux feeding and recovery system, platform for loading people, ladder, guide device, rotation part, traveling device and control part.

·The structure adopt lumen column, counter-weight guiding safe and reliable

·The boom with strength ribs, boom and column adopt triangle type rail, with large loading capacity and stable running.

·Strict requirements on structures welding seam, for example welding seam height not less than welded plate thickness's 0.7 times, structure all adopt anneal stress relieved and sandblasting treatment.  

·All bearing adopt domestic best brand products, with lubrication hole at bearing, easy for maintenance.

lWith drop safe protect unit, and safety ladder. 

·Running of boom and column adopt drag chain for cable arrangement.

·With 100×100mm precise motorized cross slide unit, maximum loading 80kg;

·Adopt remote panel for operation, the cable for operate panel is imported from German.

·The trolley movement is driven by reducer through motor. The travelling speed is  2000mm/min. Four rollers will drive together, moving placidly, and there are anti- incline device at the end side of trolley, to ensure the safe and reliable during moving.

·Column top is the boom elevation unit, consist of AC brake motor, worm reducer and chain sprocket couple etc which can realize boom elevating to suitable position. The brake motor is not only ensuring pinpoint but also avoiding shocking. There is a rachet anti-dropping unit. If the chain break off which can prevent boom dropping, safe and reliable.

·The boom connects with column by guide holder, which realizes not only elevating in vertical but also retracting in horizontal. There is motorized cross slider at the end of boom together with welding unit, and wire spool is equipped at the other end of boom. The wire connects to welding gun via guide pipe along with boom.

6.Electric control system

·Operation control consists of electric control and remote control box two parts, which adopts traditional relay control and advance variable frequency speed control. Boom retraction motor speed system adopts inverter for speed adjustment, which has function of low frequency high torque, rotation difference compensation function, over loading, over current and short circuit protection, and with the function of alarm output, high start torque and control precision and stable performance.

·There are power indication light and E-stop button, inverter alarm/alarm reset button etc on the panel of electric control box.

·Equipment operation centralized on remote control box, which has E stop button, power indicator light, boom elevation switch, boom retraction switch, boom retraction speed adjust knob(with dial indicator), cross slider switch, etc.

·By remote control box, it can debug and operate some parts in far distance,easy in operation.

·With perfect self locking and each other locking protection function, ensure

the operator and equipment safety.

·All part of Electric system has reliable grounding protection, all grounding point no mixed connection.

·Main electric elements are Schneider.

·Inverter: T-verter or Schneider.

7.Flux recovery and transport (China brand LT-HS100E2)  

Flux capability：                                                  50kg

Max. Recovery and transport distance：   12m

Gas pressure：                                                      0.4-0.8MPa

Motor power：                                                      3KW

Equipment consists of dust filters, storage tanks, transfer tanks, vortex air pump, shock bodies, piping systems and electrical control system components, installed in  the manipulator arm of the back-end.

Working pressure≤-12KPa，recovering speed 6-12kg/min.

Imports of high efficiency filter material; with high start, low transmission, smooth transportation; PLC electrical control; produced by export standards.

8.Welding system :China ZD7-1250IGBT

9.Supply range

● LHW5050 welding column&boom main machine                   1set

(Inc. Movable trolley, Elevating device ,Guide holder, ladder etc )                                

● Flux feeding and recycle system                                                     1set

● welding power ZD7-1250igbt                                                           1set

● Working platform                                                                                  1set

● Electric system                                                                                       1set

● Technical documents (Inc manual book, certificate, delivery list,foundation dawing etc) 1copy            

10.Inspection standards

According to the technical agreement which signed by both parties.

11.Some pictures for your referenc