Weld Overlay Machine

Weld overlay machine has optimized structure, the main improvement is update of control system, it has a more humanized operation interface.

The welding head made a number of improvements, making the machine running process more smoothly, totally enclosed rocking slider can guarantee the stability of the swing and maximum flow, to ensure the use within the cycle.

Reasonable smoke dust removal system can effectively remove 90% of dust in production,to provide better working environment for operators. Equipped with the basis of the bottom beam for the customer from the trouble of pouring concrete foundation, convenient installation, convenient for user to move the machine.

1. Machine parts:

 

Ø	Item	Number	Details
Ø	Main body	XHY-LDH4000Ⅱ	6m*4 m*2m(can be customized)
Ø	Rail	38kg rail LGD12 rail	6.0m*2 sets 3.5m*2 sets
Ø	Welding elevating body	Two sets	Welding torch lifting driven by reducer and lead screw, guide bar adopts double cylindrical linear guide rail
Ø	CNC system	One set	F2300B CNC system
Ø	CNC programming software	One set	Standard software
Ø	Horizontal servo motor and drive	One set	400W servo motor and drive (JAPAN PANASONIC)
Ø	Longitudinal servo motor and drive	One set	750W servo motor and drive (JAPAN PANASONIC)
Ø	Swing mechanism	Two sets	Servo motor drive reciprocating motion	ball	closed	sliding
Ø	Wire mechanism	Two sets
Ø	Surfacing welding platform	One set	Provided by seller
Ø	Welders	One set	AOTAI MZ-1000
Ø	Dust removal system	Two sets
Ø	Base	One set
Ø	Wire feeding parts		D2 steel with HRC 60
Ø	Bearings		Germany
Ø	Chrome powder adding torch	Two sets

2.Technical parameter:

Ø	Single layer welding thickness （mm）	2.5mm～6.5 mm
Ø	Welding torch lifting range(mm)	160mm
Ø	Longitudinal range (mm)	4000 mm
Ø	Horizontal range(mm)	2600mm
Ø	Plate welding effective length (mm)	3500 mm
Ø	Plate welding effective width (mm)	2500mm
Ø	Rail precision	u Main rail straightness :0.4mm/1000mm u Idle rail straightness: 1mm/20000mm u Parallelism:+0.2mm/1000mm
Ø	Intersection point offset	≤1mm
Ø	Straightness	0.5mm
Ø	Roundness	≤1mm
Ø	Diagonal difference	≤2mm
Ø	Repeated positioning accuracy	±0.4mm/10m

3.Working environment:

Ø	Environment temperature	-10-45℃
Ø	Relative humidity	＜90% No condensation
Ø	Surrounding environment	Ventilation. No greater impact
Ø	Power supply voltage	220v±10% control system, driving system 380 v±10% welding source
Ø	Power frequency	50HZ
Ø	Input power	10KW
Ø	Grounding type	Centralized and directly

4.Parts Introduction:

 1.Gantry structure ( 4 m )

Weld overlay machine consists of main beam and two longitudina frame components. Main beam using box structure, longitudinal end frame is made by steel plate welding, the driving system is in the center of the longitudinal frame, ensure the running stability of the machine. Can add operation platform on the main frame, to facilitate the operation of the equipment.All frame structure will anneal after finish welding, which makes the surface of the structure are of good quality and eliminate the welding stress.

2. The horizontal guide rail and transmission

Transverse guide using embedded steel cylindrical bi-axial core linear guide. Servo drive control mode: high precision gear and rack driving, with high-precision precision gear box and ac servo system, under the control of the CNC numerical control system, combined with optical encoder to control the speed and position detection, it is easy to control the working precision of the machine. Machine speed control adopts frequency control of motor speed drive amplifier, can not only ensure the machine work within the whole speed range with good transmission characteristics, and in the speed range to ensure the position precision machine.Bi-axial core linear guide Transverse guide mode

3. CNC control system

Ⅰ. Fang Ling F2300A type control system introduction

This two axis digital controller welding system is developed by Shanghai Jiaotong University, suitable for welding and plasma cutting processing industry. All operations have menus and graphical prompt, function perfect, simple operation, easy to use. System adopts high speed ARM9 and DSP control structure; make the welding process more stable and reliable.

Ⅱ. System configuration

• Display screen: 10.4 inch 800 * 600 high resolution LCD screen, 260000 colorLCD
• CPU: industrial ARM9chip
• Cardiac file storage: electronic storage tray1G
• Memory: 256MB
• External interface:USB
• Keyboard: PCB lamination keyboard, PS2 Omron button
• Case: All steel structure completely shielding, anti-electromagnetic radiation, anti-interference,anti-static

Ⅲ. System characteristics

• Control shaft number: 2 axis linkage (customizetri-axial)
• Control accuracy: + / – 0.001mm
• Coordinates range: + / – 99999.99mm
• Maximum pulse frequency, 200 KHZ; Highest speed: 15m/min
• Maximum program lines: Line150000
• Largest single program: 6M
• Time class resolution: 10ms
• System working power supply: DC + 24 v DC powerinput
• System working conditions: temperature -10 ℃ to + 60 ℃;No condensation 0-95%relative humidity

Ⅳ. System function

• Chinese/English menu system, a key switch from Chinese toEnglish;
• 45 kinds of commonly used graphics library (including grid pattern), can choose to setsize;
• SupportEIA code (G code) and Fast CAM Free CAM, PM2000 and other kinds of nesting software;
• Graphic scale, rotation, mirror, matrix arrangement, and staggered, repeatarrangement;
• Graphic platecorrection
• Customize coordinate system, support 2 dimension coordinates of all eightpossible;
• Customize all types of input and output port (normally open or normally closed) andserial number;
• Convenient check and troubleshooting all IO status self-diagnosis system and keystate;
• Import and export individual or the whole documents;
• Parameter backup and onlineupgrade;
• According to the thickness of the steel plate can be automaticallyat the corner speed limit, effectively prevent burning;
• Selected rows andpick;
• Static/dynamic processing and graphic display, graphiclarger/smalle enlarges state dynamic tracing solderjoints;
• Break-point memory functionprotection;
• Can set different administrative authority and thecorresponding password; safeguard the rights and interests of management;
• Can online upgrade of the

4. Welding power source

This equipment is equipped with standard Shandong Aotai MZ-1000 INVERTER type sub merged welding machine; invert welder can be customized according to customer’s requirement. All you can use open arc welding machine.

5. Welding head lifting body

• Designed for gantry CNC weldingmachine
• High sensitivityinduction
• built-in lead screw, smooth and stableoperation
• up and down limit switch, reduce loss of motor and prolong servicelife

6. Wire feeding mechanism

Muti-function wire feeding machine add control circuit board on the basis of SB – 10 type A/B/C to control welding procedure and wire feed speed, convenience for power supply systems. A general welding procedure on the circuit board can realize automatic control, such as plenum, lag stop gas, inching ahead of wire feeding, some dynamic air supply, and other functions but also has: slow wire arc, ensure stable arc, less spatter; Arc extinguishing control, prevent the wire adhesion artifacts and fill arc crater and motor drive circuit non-contact current limit and overload protection function. Has strong ability of the network voltage and wire feed resistance fluctuations wire feed stability. Use it to replace imported wire feeding machine disrepai due to complex circuit, can restore the effect to the host power supply.

AdoptTaiwan TBI ball screw, Taiwan CPC party guide  Thus greatly improving the repositioning precision of the slide and the service life.

ProductSliding table is made of stainless steel belt is fully closed structure, has very good dustproof performance.

7. Welding platform and Clamping devices

Welding platform, in order to prevent deformation of reinforcement plate with a platform, and its structure are mainly carbon steel elements. Plate clamping devices is mechanical.

8. Longitudinal guide rails and drive device (servo motor + reducer)

Longitudinal guide rail is made with precision processing characteristics of rail, rough plane first, after the plane, after processing the surface between the behavior of tolerance is 0.02 mm, each guide 2 meters long. Of adjusting plate under the each guide rail, guide rail connection through plate and adjusting bolt is fixed on the heavy beam. Vertical machine operation is running along the guide rail. Sections are equipped with longitudinal guide rack, the rack on the output of the gear meshing; realize two-way drive host longitudinal motion.

Longitudinal working precision and positioning precision of the demand is higher, the machine adopt the bilateral high precision gear and rack driving, mesh between gear and rack is spring compression type, this can reduce the meshing error on one hand, but also improve the driving stability. Machining precision and installation accuracy is essential condition for ensuring the accuracy of the host, with high-precision precision planetary gear box and ac servo system, under the control of the CNC numerical control system, combined with optical encoder to control the speed and position detection, it is easy to control precision machine work. Machine speed control adopts frequency control of motor speed drive amplifier, can not only ensure the machine work within the whole speed range with good transmission characteristics, and within the speed range to ensure the positioning precision of the machine. The gantry stable linear motion in the movement.

Longitudinal rack with high precision machining. To guide the installation of the precision and the gear rack clearance error to eliminate problems, mainly determined by the machining accuracy of single rail. My company’s guide machining precision can guarantee all the flatness of 0.02 mm, when mounted on the guide rail extension, we use wire fixed at both ends of the guide rail, through adjusting the floor height, guide about location, when

the guide rail to adjust to within the scope of installation accuracy, with press pressure guide rail. Using tension rod connections between guide rail, to ensure cooperation between guide and guide. Guide rail fixed method can accord user requirements to provide h beam or concrete foundation drawings.

Cable transmission way: drag chain bracket is fixed at the end of foundation beam by a pair of channel steel side, through cable drag chain and mobile host synchronization.

9. Exhaust dust removal system

Our company specially designed for the equipment is a kind of smoke dust removal device, including smoke and dust collecting mouth, platoon pipeline, high power blower, dust collection box, etc., smoke export sealing connection be vacuuming pipe, dust collection pipeline on the pipeline with fan, vacuuming pipe outlet connections have dust collection box, dust collection box outlet connection pipe. The smoke dust removal device effectively purify the welding machine in welding process of smoke, dust, dust removal effect is good, effectively prevent the environmental pollution, effectively avoid the machine damage, at the same time protect the workers health and safety, and small volume, simple structure, easy to use.