Double wire swing submerged arc roller automatic welding machine
一、Basic functions
● Single or double wire submerged arc welding；
● Swing or non swing weld overlay；
● It can be spiral or step welding, as well as single ring welding, axial straight welding, and spot welding to repair holes；
● The voltage for starting, ending, and su***cing can be set according to the welding process requirements, and the wire feeding speed and arc stopping time can be automatically adjusted to achieve stable welding specifications and complete the entire welding process；
● The combination of color touch screen and PLC program control enables human-machine dialogue and visual control of operations；
● Both the tire turning and welding trolley are servo systems with stepless speed regulation. By manually inputting parameters such as line speed and weld bead width, the suitable roller speed and weld bead overlap can be automatically adjusted according to the roller diameter and roller body length；
● Can achieve automatic transportation and recycling of solder flux and separation of solder flux and slag；
● High power and efficient water-cooled welding gun can achieve high deposition rate and welding efficiency。
● The crossbeam welding car and the rotating tire tailstock are both equipped with manual clutch devices, which can easily move the car and tailstock
二、Equipment Composition：
☆ Roll turning mechani**：
It is a high-speed adjustable mechanical tran**ission system composed of a sturdy spindle box, infinitely variable speed servo motor, high speed ratio reducer, and synchronous belt pulley. It is equipped with a machine tool tip and tailstock that can automatically expand and contract when heated, as well as a head tail welding power receiving system with good conductivity. According to user requirements, it is equipped with three or four jaw head tail dual chucks or a retractable tip. The tailstock can be easily moved after manual clutch disassembly；
☆ Welding electronic control system：
Including power supply control and PLC as the main control machine, it realizes communication with touch screen, human-machine dialogue, and is equipped with Lincoln NA-5 welding process control system. It can set, store and automatically control welding parameters according to welding process requirements。
☆ Front data button control station
The combination of button station and touch screen makes it easy for operators to control welding preparation (parameter input and calculation), welding start, parameter modification, welding stop and other operations. As long as the roller diameter, roller body length, and linear speed requirements are input, the rotation speed of the roller and the overlap size of the weld bead can be automatically calculated and controlled, avoiding waste and frequent defects such as weld bead missing meat and repair welding.
☆ Welding power system：
The Lincoln Electric DC-1000 welding power supply provides a 44V, 1000A DC welding power supply, while the positive pressure conveying system and negative pressure flux recovery machine provide the flux recovery gas source
☆ Welding Drive Execution System：
The high-power high-speed welding gun is installed on a heavy-duty trolley driven by a stepper motor, which can achieve precise XYZ three-axis linkage through sliding guide rails and ball screw mechani**s, ensuring **ooth operation of the welding gun with an accuracy of up to ± ≤ 1mm. The heavy-duty welding trolley also carries a 20kg electrically controlled flux hopper, wire conveyor, and wire straightener that can move synchronously
Synchronous dragging of welding wire guide and cable tray (compressed air pipe), and manual clutch of crossbeam heavy-duty trolley for easy lateral adjustment；
☆ Welding Swing Device：
The patented design consists of a heavy-duty rolling slider mechani** and an adjustable swing mechani**, which adjusts the swing frequency through an electronic speed control system, providing an adjustable and stable swing welding device that can withstand heavy loads；
☆ High power high-speed water-cooled welding gun：
The high-power, high-speed water-cooled welding gun with patented design not only has efficient water cooling, high power output, and high deposition rate welding efficiency, but also features uniquely designed single and double wire conductive nozzles that can be easily replaced and reused multiple times，
☆ Welding frame：
The sturdy steel structure frame that can meet the load capacity, the guide rails of the bed body ensure the concentricity of the head and tail of the bed, and the tailstock that can be manually and easily moved to roll on the guide rails. The welding flux and slag vibration conveying mechani** fixed on the rack runs **oothly and noiselessly, and can separate and screen the welding flux and slag；
☆ Flux conveying and recycling system
The recovered flux can be automatically transported to the mobile flux hopper of the welding cart through the pipeline by a positive pressure flux conveyor, achieving automatic flux transportation; The flux and slag from submerged arc welding that have not been slagging off are transported to the tail of the machine tool by a vibrating conveyor. The flux separated by screening is recovered and transported to the flux recovery tank by a negative pressure flux recovery machine, and then enters the next cycle of transportation。
☆ Welding power tran**ission system：
The welding cables, control cables, cooling water pipes, air pipes, and flux conveying high-pressure air pipes inside the loading bridge can be synchronously moved with the welding gun by a moving welding cart
☆ Welding cooling system：
The water cooling system available for dual welding heads can quickly reduce the temperature of the welding gun, ensuring high power output of the high-speed welding gun；
☆ electric control system
三、technical indicators
Rated output current：1000A max
Rated output voltage：44V max
Range of wire diameter：2.4、3.2、4.0（mm）Suitable for barrel welding wire
Wire feeding speed：15~300Inch/min
Metal deposition rate：8~10 Kg/h, 20Kg/h max
Adjustment range of welding line speed：100~500mm/min
Range of spindle speed for tire rotation：0.064~1.911r/min
Horizontal (X-axis) movement speed of welding gun：150~400mm/min, maximum stroke5000mm
Vertical (Y-axis) movement speed of welding gun：100mm/min, maximum stroke300mm
Radial (Z-axis) movement speed of welding gun：100mm/min,maximum stroke300mm
Swing stroke of the pendulum：0~80mm
Swing frequency range：20~50 Hz/min
Spiral welding angle：0~60º
Step speed：100~150mm/min
Weld bead overlap width：0~30mm
Thickness of each layer of weld metal：1~3.5mm
Minimum diameter of welded workpiece：Ф100mm
Maximum diameter of welded workpiece：Ф400mm
Minimum length of welded workpiece：300mm
Maximum length of welded workpiece：4000mm
maximum load：3000Kg
Beam length：6000mm
Height of crossbeam and column：2000mm