KELITE WELD TECH (CHINA) LIMITED

Custom machine requirements

1. Workpiece data

This machine (KLTHG-1500PTA) is mainly used for automatic circumferential seam welding of plasma surfacing welding on the surface of flat plates. Diameter range: 0-1400mm, weight is less than 500kg.

Machine main function description

1.1 Workpiece loading and unloading method: First, the operator hoisted the product on the platform of the dual-axis servo positioner, clamped the workpiece with a manual fixed fixture, and manually operated the operating machine to aim the plasma torch on the product surface. Press the power button, the plasma welding gun will automatically carry out plasma spraying and surfacing on the surface of the plate (the width of the swing and the distance of movement after one circle of welding can be set in advance). After the welding is completed, retract the welding torch and remove the product.

1.2 Welding method: This machine adopts plasma spraying (PTA) welding process.

2. Workpiece precision requirement：

（1）The surface of the work shall not affect the quality of welding oil, rust, moisture；

（2）Must not affect the positioning of burrs, etc.；

（3）The clearance shall be no more than 1mm；

（4）The consistency error of the same weld group is less than 0.5m。

1、Double-axis servo positioner; 2、KLTHJ precision welding manipulator；3、Combination slide；4、Walking track；5、Electric walking slide；6、Cantilever control box；7、Walking drag chain；8、Plasma powder surfacing machine；9、Powder feeder；10、Plasma welding gun；

2. PTA welding system KLTHG-1500PTA layout: (picture is for reference only)

3. KLTHP500   Double-axis servo positioner

Welding positioner is a process equipment that places the workpiece in a convenient position for welding by tilting and rotating. The welding positioner and welding manipulator or other mechanisms can form an automatic welding central station. Mainly used for TIG, MIG/MAG manual or other automatic welding requirements of the circumferential seam of the workpiece and the flange fillet weld.

The main structure:

     The positioner is composed of a working turntable, a turning mechanism (double half teeth), a reduction box, a frame, etc. According to the welding speed needs to set different speeds for welding. There are multiple notches on the turntable of the positioner, which can be connected by bolts to fix the three-jaw chuck or the fixture of the workpiece. This series of positioners are designed to be light, flexible, high in rotation accuracy, stable, and high in centering accuracy.

4. KLTHJ type (KLTHJ1500)precision welding manipulator

The HJ type precision welding manipulator is the main process equipment for automatic surfacing welding of pipelines and metal structural parts. It is matched with the positioner to form an automatic welding system. It can use TIG/MIG/MAG, plasma, submerged arc welding and other welding process methods .

Mechanical structure introduction

The manipulator mainly consists of beams, columns, bases, slides, and rotating parts.

4.1 Chassis

The chassis is used to support the entire manipulator.

4.2 Column

The column is installed on the revolving part, the front is equipped with linear guide rails, the slide plate is installed on the two guide rails, the top surface is equipped with a lifting drive mechanism, which is driven by a motor and decelerated by a gear box to realize lifting through a sprocket and a chain.

4.3 Beams and slide boxes

The four sets of sliders on the inner side of the slide of the operating machine are matched with the column guide rails, and the side of the slide is equipped with a motor and a reducer. The output gear of the reducer meshes with the rack on the beam to move the beam. Another set of sliding blocks on the slide box cooperate with the uprights to realize the stable ascent of the crossbeam. The horizontal movement speed of the crossbeam is controlled by an AC servo motor, and the vertical lifting speed of the crossbeam is a fixed speed.

5. Plasma powder surfacing machine

Plasma powder surfacing uses plasma arc as the heat source. The high temperature generated by the plasma arc is used to rapidly heat the alloy powder and the surface of the substrate and melt, mix, diffuse, and solidify together. After the plasma beam leaves, it is self-excited and cooled to form a high-performance alloy. Layer, so as to realize the strengthening and hardening of the surface of the part.

6. WL-20   temperature control cold water tank

Temperature control of the water tank by the efficient condenser, EBM fan motor, imported thermostat and water detection sensors and water tanks and other components.

Is the TIG/plasma welding process and high load continuous welding torch cooling an important ancillary equipment.

Technical Parameters
Power supply rated voltage: 1 × 220V 50Hz
Rated load: 205 W
Effective head：20m

Size:540*340*500mm

Weight: ~19kg

7. Electronically controlled sliding table (swing device)

This part is an important part of PTA automatic welding. Combined with the power supply and the controller, it can control the rising/falling height of the plasma welding gun and the swing control of the welding gun. The carriage is composed of two cross-connected sliding plates. The sliding table is adjusted and moved by a servo motor and a stepping motor respectively, which drives the lead screw to rotate, and then drives the nut to drive the slide plate to move. It consists of a support plate, a gun frame, welding torch and two-dimensional manual sliding table. The welding gun adjustment slide and the swing slide can be installed separately and used separately. During the welding process, the welding torch can be used to manually adjust the horizontal and vertical positions of the welding torch.

Technical Parameters