2、 Equipment List

Introduction to Welding Process

Manually push the workpiece into and place it on the core shaft, and lower the core shaft hook → manually center the weld position of the workpiece, and the pneumatic key pressure plate will press the workpiece side by side → move the electric welding gun to the starting point of the weld, electrically lower the welding gun, and fine tune the welding gun to align with the weld → press the "welding" button, the welding power supply will automatically start the arc, and after the arc stabilizes, the welding gun will automatically walk and start the normal welding process → automatically stop welding and raise the welding gun after reaching the set welding length → the welding gun will automatically reset at high speed → release the pressure plate by pneumatic means, open the core shaft hook by hydraulic means, and unload the workpiece, completing automatic welding.

This equipment adopts a cantilever single column structure, mainly composed of a bed body, piano key pressing plate mechanism, welding pulley and sliding beam mechanism, core shaft, hook, centering mechanism, control system, etc.

²The host body adopts a welded structure with sufficient rigidity to ensure long-term use without deformation.

²The crossbeam guide rail mechanism is used for the movement and walking of the welding gun, and a linear guide rail is installed on it for sliding; The welding gun is driven by a motor and driven by gears and racks to move in a straight line. The walking speed of the welding gun is infinitely adjustable and displayed on the control screen.

²There are two sets of pneumatic piano key fixtures used to press the workpieces on both sides of the longitudinal seam. The maximum pressing force of the piano key is 7-30Kg/cm, which can effectively prevent workpiece displacement and welding wave thermal deformation.

The fixture consists of components such as airbags, pressure plates, pressure fingers, and adjusting bolts. The airbag pressurization method ensures that the workpiece is uniformly compressed and stressed.

The material of the piano keys is aluminum alloy, equipped with copper alloy fingertips that can be used on both sides to ensure optimal weld cooling performance. The width of the pressure finger is 75 millimeters, and the distance between the left and right pressure fingers (10-30mm) and the stroke can be adjusted.

The airbag adopts an inner and outer double-layer structure design.

The piano key movements are controlled by two foot switches with protective covers.

²The core shaft is a steel structure that is integrated with the base of the longitudinal seam welding system. There is a groove at the top of the core shaft for clamping the formed liner on the back of the weld seam, and the liner is processed with a formed groove. In the case of using high current or high load welding, in order to prevent the temperature rise of the back support core shaft, it is necessary to perform water cooling circulation on the core shaft to ensure uniform heat dissipation of the workpiece and good formation of the back of the weld seam. The back forming pad of the weld seam is made of stainless steel (welded aluminum alloy), and the surface is processed with forming grooves,; The surface of the forming pad is processed into a flat plane, and the chamfers on both sides ensure more reliable compression of the workpiece. The pad is equipped with a water-cooled channel to cool the workpiece, reduce the heat affected zone of the weld, minimize workpiece deformation, ensure uniform heat dissipation of the workpiece, and form the back of the weld.

²Pneumatic locking device, driven by a cylinder to rotate the hook, tightens the core shaft and integrates it with the clamping beam, ensuring the rigid connection of the entire mechanism. Installed at the end of the clamping platform away from the main support. It includes a set of safety switches to ensure that the piano key mechanism does not malfunction when the hook is not in place.

²The pneumatic system consists of three components: solenoid valve, cylinder, air source processing unit, and connecting air pipe. The intermediate adjustment handle of the rotating air source processing triple piece can adjust the output air pressure, and the pressure gauge displays the output air pressure of the air source processing triple piece.²Cables, control cables, water pipes, and air pipes are arranged using tank chains.

²Welding gun fine-tuning mechanism, used for aligning and micro adjusting the initial position of the welding gun. The system is equipped with a mechanism for setting the forward tilt angle of the welding gun, which facilitates the operator to set the position and angle of the welding gun.

²In order to adapt to the diameter changes of different workpieces, a lifting and loading trolley is equipped, which adopts a scissor type hydraulic lifting method and is powered by hydraulic cylinders; A set of standard adjustable roller frames is placed on the lifting trolley to carry the workpiece and provide the necessary rotation for workpiece centering. The distance between the master and slave roller frames can be adjusted and positioned using fixed bolts on the platform. The entire organization is equipped with an electric trolley at the bottom, which facilitates the feeding and sending of workpieces.

²The welding operation platform is beneficial for operators to observe the weld seam.