​Lighting Pole Seam Weld Machine

Lighting Pole Seam Weld Machine

D60tod400 Lighting Pole Seam Weld with Sub ARC Weld

Technical Specification

1 General Specification

a) Welding machine designed for main production purpose and intended for assisted automatic welding with manual loading, parts set up and unloading.

b) Machine manufacturing and assembly made according to following codes and standards:

Mechanical system: relevant ISO and GB standards

Electrical system: IEC as reference

c) Automatic continuous welding with solid flux for poles pre-formed by bending in one or two shells with the following main technical datas:

Shaft length...................................... 16 m max.
Thickness.................................... from 2 to 6 mm
Material...................................... Q235,Q345,Q450, or ASTM A572

Polygonal section shaft (6 to 12 sides).... 8 sides (standard)

Welding speed............................. 0.3 to 2.0m / min

Repositioning speed.......................... 20-30 m /min

Diameter............................... (OD50flat to flat)&OD60 to OD400 mm

%4. Min. Diameter 60mm at Pole wall thickness 3mm or 4mm

%4. Min. Diameter 86mm at Pole wall thickness 5mm

%4. Min. Diameter 90mm at Pole wall thickness 6mm

Taper......................................less than 35 mm /m
Shaft putting on the carriage mobile under the weld torch

Welding start from the base big end to the top small end of shaft.

Others special features:

Floor mounted pressurized  flux tank
one half-shell and 2 half-shells capability

Round and Polygonal conical shaft

60 to 80 % penetration capability 
Three push pneumatic cylinders for pole unloading after weld. (Optional)
After installation, the weld bed height from shop floor between 950mm and 1100mm.

2 Mode of operation:

a) Preliminary settings and thrust of lateral rams under manual control, with proportional and pressure regulated hydraulic control
Automatic welding with constant operator control and monitoring

b) Manual setting of welding parameters and ram pressures

3 Safety:

a) Casings over transmission

b) Emergency stop at the control station and two ends of machine.

4 Limit of scope:

a) Supply of inter connections with other production processes are not included

b) Loading and unloading tables/conveyors are not included.

5 Welded steel structures:

a) Mechanically welded frame, high rigidity stress relieved Q235 construction steel. One base plate is provided for fixing to the ground.

b) Vertical axis gantry comprising a steel frame, a guide table on the front and 4 guide cages with rollers

i. Vertical travel: ....................   460 mm(may change)

ii. Vertical load capacity:............ ≈15 000 daN

c) Two cross roller units. Each roller is fitted onto an articulated support actuated by a hydraulic cylinder. The units have angular and vertical adjustments by manual. 

d) A vertical rolling unit incorporating the welding torch with manual position adjustment, a pre-load roller with an adjustable value, a self-centering system on ball bush, two equalising rollers including one for separation and an articulated flux supply system. This assembly is mounted on rigid profiled section steel plate side pieces supported by a beam linked to the vertical transfer gantry. 

e) One head self balancing system

f) A side ladder incorporating welding wire reels and electrical connections and cable chain

g) A steel protection plate is provided to protect the gear motor

h) Transmission of the weld carriage by rack and pinion, driven by geared motor unit. AN acceleration and deceleration phase is planned in order to minimise any overload on the gear starting or stopping. The motor speed and control are achieved by programmable electronic speed regulator.

i) One unit of gear reducer and motor control welding drive and fast moving. The motor is Siemens Frequency Motor, The highest rotate 6000rpm.

j) Painting: Steel structure will be covered by epoxy paint. the paint colour is according to the customer's requirement.

k) Optional:

i. Because of requirement of two piece pole welding and diameter up to Max. 400mm. Suggest to have turners to help two seam welding when the pole diameter bigger than 250mm.

ii. Two units of Turners can be convenient to weld multi-seam shaft; Turners are in the front of Seam weld machine. Loading and unloading position are in the front of Seam weld machine.

6 Welding system including:

a) Welding head comprising a process console with automatic digital display, latest model geared motor unit for wire unwinding, unwinding accessories for wire from 1.2 to 1.6 mm

b) Single wire torch assembly(one torch)

c) One generator (Lincoln 1 x DC600 – 100 %), NA5 controller.

d) Slides system for positioning adjustment of wire torch

e) Double 20 kg wire drums capability

f) Flux recycling unit including:

i. Recycling module type, air pressured feeding, including control valves, suction nozzle, piping and connections.

ii. Optional: Import flux hopper with heat: Weld ENG HFH-100 Headed Flux Separato
Flux Separato

11 Spot lighting with direction adjustment
Connection box between generator and control box

7 Hydraulic system

a) The control of the 2 axis is hydraulic with an open loop adjustment controlling the pressure only

i. Two Japan NaChi pressure reduce valves and digital amplifies
Two back pressure balance valves, located in the top push and cross push hydraulic circles, work when welding thin shaft, so that it can get the good stability work point in the reduce valve.

ii. Pressure adjustment with single-circle potentiometer in two series.

iii. 250 liters fitted tank (may change)

iv. Optional: Parallel refrigeration cooling unit (with Heating function)

b) China made hydraulic cylinder with PARK seals and Germen seals.

c) Motor pump unit comprising:

i. 5.5 kW, 1500 rpm, 380/450 V 50 Hz electric motor

ii. Lantern and coupling

iii. Variable rate pump set to max. 40 l / min

d) Pressure filter

e) Return filter

f) 1 Set of necessary valves, proportional pressure reduction, distributor, flow limiter, controlled valves, for the hydraulic regulation

8. ELECTRICAL SYSTEM:

a) Automation system:

i. In order to position the shaft in the welding area, the system will be fitted with an automated positioning system controlled by an open loop incremental encoder fitted to the rack.

ii. A shaft detector cell will trigger a pre-selected definitive count which will control the distance to be travelled by the post until its halt under the welding torch or any other defined position. 

iii. System will cell and coder for automatic positioning of shafts

iv. Japanese AC frequency driver for welding carriage movement.

v. SCHNEIDER components and SIEMENS Motors.

b) Programmable PLC with spare I/O with Japan's Mitsubishi PLC

c) Control panel:

i. Offset control station with electric and proportional control lever (ram forward movement)

ii. Control cabinet with circuit breaker and indicator on the front

iii. Control and power equipment, protection

iv. AC system 450V, 60Hz, three Phases

v. Control panel position opposite of pole loading

d) Wiring and cabling

i. Cabinet wiring

ii. Machine wiring

iii. Cable ducting and troughs, steel or aluminium cables chains

iv. Modular wiring using HARTING or other type plug-in connector

9 Important Part List

10 Engineering:

a) Mechanical design using Autodesk Inventor pro 2008:

b) Overall assembly 3D drawings

c) Sub assembly drawings for auxiliary equipments

d) General nomenclature

Hydraulic design:
Diagrams
Part list
Layout

Piping list
Electrical and automation design:

11 Documents:

a) One set of the following documents in English will be provided:

b) Installation drawings, mechanical, electrical, hydraulic, program

c) Operation and maintenance instruction manuals

d) Spare parts and consumable list

12 Installation:

a) The customer will provide all necessary handling equipment, consumables and helpers.

13Testing and commissioning:

a) Workshop test:

i. Welding cell will be preassembled and tested at factory

b) Test and completion at site

i. Tests will be done using two different types of mast configurations

14 Handling and packing

a) Dismantling into modules, packing with wood and plastic film protection

15 Tools:

a) Roll for round and 6 and 8 sides shaft

b) Head top roller + blade