Welding Rotator Manufacturer | WALDUN

Welding Rotator – The Ultimate FAQ Guide

The use and importance of welding rotators in the industry has grown significantly. Because of the ideal benefits you can get from using it, you can expect better productivity with fewer errors.

However, not many people are well versed when it comes to welding rotators. Most traditional welders even think it wouldn’t help out in the process. In this guide, we’ll uncover the truths about these claims.

By the end of this ultimate FAQ Guide about welding rotators, you’ll definitely have the best and the clearest understanding of it.

What is a Welding Rotator?

A welding rotator is a machine you can use to help in welding cylindrical or rounded objects.

You can use it in welding either small or large-sized rounded objects.

How Does a Welding Rotator Function?

Many people don’t understand how a welding rotator works. But in reality, it actually functions quite easily.

It functions by rotating the circular or the cylindrical object to help and aid in welding. For heavy materials and workpieces, welders don’t need to change positions as the welding rotator would rotate it for them.

What are the Usual Parts of a Welding Rotator?

Different welding rotators have different parts. Moreover, there are manufacturers that add certain components to it.

But, the parts that would never be taken out include:

• Idler
• Driving Wheels (what turns the materials or workpieces)
• Wheel Frames (what supports the wheels)
• Transmission Device (what controls the speed of the rotation)
• Controller  (what is used to change and modify the speed of the rotation)
• Direct Current (DC) Motor (what makes the motion concrete and real)

Even if just one of these parts are missing, a welding rotator would not be able to function.

What’s the Importance of a Welding Rotator?

In the fast-growing industry, the need for safety and security remains to be at the top priority.

Using welding rotators can give you a ton of benefits, some of which include:

Safety and Less Effort for Welders

If you use a welding rotator, you would exert less effort as it’ll be rotated automatically.

This means that a welder would not need to move and rotate the workpiece manually; promoting safety and security to the welder and the workpiece.

Faster Productivity

All automations result to faster and better productivity. The function of a welding rotator to move the workpiece, means that the welder can do more and better.

Stronger and More Reliable Support

The support from the equipment itself is already enough to tag it to have stronger and more reliable support.

This can protect the workpiece, its quality, and its overall dimensions from deformity.

Is the Welding Rotator the Same as a Welding Positioner?

No, a welding positioner is different from a welding rotator.

The welding positioner is a device that can hold and rotate a workpiece depending on the angle set. It can be different angles, allowing you to weld at a steady level. Any shape of workpiece can be loaded to a welding positioner.

Welding rotators are different. Once the workpiece is loaded, it’ll rotate consistently depending on how fast or slow you want it. The wheels on the rotator allow the movement; that is why only rounded and cylindrical objects are the ones that can be used with it.

Advantages of Using Welding Rotators

What advantages can you get from using welding rotators?

These machines and equipment can help you get a ton of advantages.

The most common benefits and advantages you can actually achieve include, but are not limited to:

• Safety of your welders and the workpiece
• Accurate and precise welds
• Continuous welds with ease
• Higher productivity rate
• More efficient and more effective results
• Reduced working hours
• And many more

If you are to weld many different rounded or cylindrical products in the same ways, using welding rotators can get you the job done easier and more conveniently.

What Welding Processes Can Welding Rotators Assist?

You can use welding rotators if you are to perform any of the following welding procedures:

• Sub-Arc Welding (SAW)
• Tungsten Inert Gas (TIG) Welding
• Metal Inert Gas (MIG) Welding

Whatever welding procedure you need, using a welding rotator can help you drastically.

What is the Usual Price of a Welding Rotator?

Most manufacturers don’t broadcast the price of welding rotators because they’re expensive. However, to give you a gist of how much the average price is, you can think of it in between $10,000 to $30,000.

The price, of course, would depend on the size and the functionality you need with it. So, it’s best to check with the manufacturer of your choice.

Why Use a Welding Rotator?

Using a welding rotator can benefit you in numerous ways. But, the most common reason why you should consider using it is because of the savings it can give you.

With faster productivity, shorter working hours, and more accurate works – you’ll spend less money and you will be able to save more! Apart from that, you can ensure the safety of your workpieces and your welders!

Once mounted, the workpiece would depend on how you set the rotator’s settings to! No instability, no moving!

What are Pipe Rotators?

A pipe rotator is an auxiliary machine you can use to help you with your welding projects.

It’s a kind of welding positioner used for handling pipes and other cylindrical parts or objects. You can use it to clamp and clutch, rotate, tilt, and reposition the workpiece you’re working on.

Can Pipe Rotators be Used For Welding?

Yes! In fact, its main use is to assist and to complement the welding process.

It’s what you can use to hold a workpiece that is round or cylindrical; and move it in a whole 360-degree rotation.

What Pipes Can You Use With Pipe Rotators?

You can use pipe welding rotators for a wide range of pipe and tube fittings.

Here are some of the most common ones:

• Long Radius Bend Pipes
• Elbow Pipes
• Tee Pipes
• Flanges
• Wye Pipes
• And Many More!

Note: Pipe welding rotators assist the welding process; so more often than not, big and heavy parts and components are loaded to these machines. But, you can also use it for small to medium-sized pipes and workpieces.

What are Pipe Welding Rollers?

Pipe welding rollers are pipe rotators, they’re the exact same thing.

Don’t be confused when you see pipe welding rollers as some manufacturers refer to it as that.

What Benefits Can You Get From Using Pipe Rotators For Welding?

Using pipe welding rollers for welding can give you the following benefits and advantages:

Faster and Speedier Production

Your pipe rotators can help you get even to the most awkward and complicated parts. This makes production faster, more urgent, and hastier.

Stable and Consistent Welds (For Bulk Welds)

Pipe rotators can set your workpiece in place without it being misaligned. What does this mean for you?

Whenever you perform the weld, the rotator can move it more consistently with more stability; this makes all your welds exactly the same without any irregularities.

Safety and Security of Welders

Imagine welding a 50-ton pipe fitting; isn’t it dangerous for your welders? What happens when it gets mishandled?

Using pipe rotators dramatically increase the safety and security of your welders. It has been proven and tested.

Higher and Better Quality of Welds

Your welders wouldn’t anymore worry about how to handle the workpiece. With this, they can focus on the welding procedure itself, creating better and higher weld quality.

Are There Any Disadvantages of Using Pipe Welding Rollers?

When it comes to operation, there’s none.

But, if in case your pipe rotator malfunctions, you wouldn’t be able to push operations.

Why Do We Need Pipe Rotators?

There’s no way you can handle welding a 50-ton pipe fitting by yourself.

Even if you’re strong enough, it’ll be hard and rather impossible to turn it even with 2 to 3 people.

So, you need pipe rotators to easily and effortlessly weld even the heaviest workpieces.

Which Industries Can Find it Beneficial?

Many industries can find the use for pipe rotators beneficial. But among the most common that really utilize it are:

• Metalworking and Fabrication Industry
• Construction Industry
• Oil & Gas Industries
• Petrol Chemical Industry
• Power and Generation Industries
• Nuclear Industry

Oftentimes, industries that utilize heavy pipes and tubes find the best use for it. But, it can also be used in the automotive industry (i.e. creation of tanks, etc.).

Questions to Ask Before Purchasing a Pipe Rotator For Welding

In order for you to get the specific machine you need, consider asking these questions:

• Would the rotator meet the capacity requirement of the load?
• Is there a specific speed for power or turning for any of the projects?
• What specific type of wheels do I need?
• How big would the workpieces be? How many rollers would I need?

What are Turning Rolls?

A turning roll is a machine that helps in handling heavy materials (more than 100 tons).

It’s a type of auxiliary machine you can use to perform better and with more productivity. Welding turning rolls can assist your welding procedure in the best ways possible.

What Works Involve Usage of Turning Rolls?

You can use turning rolls in a lot of different industries that involve heavy equipment.

However, the most common ones you can use it for include:

• Pressure Vessel Creations
• Large, Small, and Medium Pipe Sections Creations
• Heavy Machinery Cladding
• Shipyard Creations
• Boiler Vessel Creation
• And Many More!

You can use it in many different fields and applications involving ton-weighted parts.

What are Pipe Turning Rolls?

They’re the turning rolls you’d have to use for the rolling of pipes and tubes. It can be small, large, and medium-sized pipes.

What are Tank Turning Rolls?

These are the turning rolls that house tanks instead of pipes. Similarly, these machines can also handle light to heavy type of parts and components.

Types of Turning Roll Wheels

You can choose from various types of pipe or tank roller wheels. However, the most common ones are:

Steel Wheels

If you’ll work on high temperature and high capacity equipment and parts, use steel wheels. They are the most useful if the engagement of the part has certain limitations.

Phenolic Wheels

Phenolic wheels are most useful if you can’t suffice the workpiece using steel or rubber. Also useful in high temperature areas and situations.

Rubber Wheels

Rubber wheels are the most common types of wheels for turning rolls; and this is because of their high friction capacity.

Is Welding Rotator the Same as Turning Rolls?

Technically, welding rotators and turning rolls are the same. They can be different depending on what process they’ll undergo.

Welding rotators are used to assist the welder; they’re also dubbed as welding turning rolls. But, generally speaking, turning rolls are machines you can use to assist with heavy workpieces.

It’s what you have to use if your parts, projects, and components can’t be lifted regularly.

How Much Weight Can Turning Rolls Support?

The usual and regular weight that turning rolls support sits between 100 lbs to 400,000 lbs.

Additionally, they can support workpieces and parts that have a diameter of 6 to 30 feet long.

What Features Do Turning Rolls Have?

Some of the physical features that welding turning rolls have include:

Flexibility

Welding turning rolls are flexible and can be used in many different applications. They’re known to be flexible and versatile, and they can support a wide range of weight classifications.

Easy Operations

Compare manually welding a 10-ton pipe versus when you use a welding turning roll. You’ll find it easier and more convenient to work on.

Allows Better Productivity

By using a welding turning roll, you increase productivity!

Automating it can give you better and higher chances of faster and more accurate work.

These are just some of the features you can get if you use turning rolls.

What Applications Can You Get With Turning Rolls?

You can use it for any cylindrical or rounded parts or components – that are preferably heavy.

In fact, you’ll be able to find a ton of uses for it, some of the most common applications include:

• Creation and Fabrication of Tanks and Vessels
• Car Tanks
• Pipe Spooling
• Heat Exchange Units
• Shipyards
• And Many More

What is the Welding Fit Up Process?

Understanding fit up is just like comprehending what it means.

It literally is the activity of fitting two (2) or more workpieces together to prepare them for welding.

What are Tank Fit Up Rolls?

Tank fit up rollers are the machines and equipment you use to fit them up.

Instead of utilizing heavy-equipment and tire them out, you can utilize tank fit up rolls. They’re similar to a welding rotator, but with added features like the rails where the rotators would move, and so on.

But, the features you can have will depend on the outputs and the results you want and need.

Automatic Tank Fit Up Rolls

Automatic tank fit up rolls are machines, automated to rotate depending on the program.

The fit up is and will go manual, but the rotation and the welding can be automated. You can find many automatic tank fit up rolls in the market; but totally, that would depend on what you need done.

Are Tank Fit Up Rolls Similar to Pipe Fit Up Rolls?

Yes, tank fit up rolls and pipe fit up rolls are the same.

They differ based only on the type of workpiece that you’ll work on. The machines and equipment used are similar, so don’t be confused about it.

What Advantages Can You Get With Tank Fit Up Rollers?

Using tank fit up rolls can actually have a ton of advantages for the workpiece, welder, and for your other equipment.

Less Fatigue From Welder

One of the main advantages you can get would be lower levels of welder fatigue. Because of the automation of tank fit up rolls, welders could stay in just a certain position while welding.

Without a tank fit up rolling machine, welders might find it difficult to fuse and join workpieces.

Reduced Crane Operations

In joining and welding two 100-ton tanks, people would be incapable to carry it; this is where the use of cranes come in.

Using cranes can carry heavy parts, but, it’d be time-consuming to line it up to another workpiece. With a tank fit up roll, the utility of cranes would be less.

This means that your cranes could be used up for other purposes; or it’ll experience less wear.

Faster and More Systematized Welding

It’s not an unknown fact that using welding positioners produce results faster. It’s also true with tank fit up rolls.

Using it can help you achieve the welds you need faster and more systematized; assisting you in producing better and higher quality welds.

Your Welders are Safer

Imagine if a crane lifts an 80-ton tank without any support from the bottom, would your welders be safe?

Tank fit up rollers can ensure the safety of your welders, 100% of the time. Apart from keeping the workpieces hanging, they can clutch workpieces – even those that are rounded or cylindrical in shape.

Oftentimes, many people think that tank fit up rolls would just be the same as welding rotators. But, welding rotators might not have the capacity to align and line up workpieces.

Tank fit up rolls can endure even the heaviest of workpieces, given they’re complete with the right set of tools.

Applications of Tank Fit Up Rolls

Most of the time, you can apply the usage of tank fit up rolls in heavy, rounded workpieces.

They can be in any industry such as the shipyard and shipbuilding industry; the petrochemical industry, mining industry, and so on.

So long as a certain tank or pipe is too heavy to handle, using it can heighten safety, efficiency, and accuracy of the weld.

What Types of Tanks Can You Fit Up With These Machines?

You can fit up whatever kind and type of tanks with these roller machines. But, the most common avenue would be tanks that are heavy, hard, thick, and dangerous.

However, you can also use thin-walled tanks, medium-sized aluminum tanks, or whatever in tank fit up rolls.

Tank Fit Up Rolls Prices

Rates and prices for the tank fit up rolls that you need would depend on the manufacturer. Because there are a lot of variations, you need to set they’re not freely priced.

It’s also not possible to have any average price for these tank fit up rolling equipment. But, you can expect that they’ll be priced upwards of $5,000 for medium-sized rollers, and $11,000 upwards for large and multi-axes fit up rollers.

Advantages of Using Turning Rolls For Your Project

Using turning rolls for your project can give you a ton of benefits and advantages. You can look at them as advantages for your welders, advantages for your projects, and so on.

If you use welding turning rolls, you can be sure that your welders are:

• Safer and more secure
• Going to produce more accurate welds
• Going to experience less fatigue and tiredness

For your projects, on the other hand, you can expect that:

• You’ll produce higher quality welds
• They’ll be finished faster and more urgently

Where Can You Get the Best Quality Welding Rotator?

There’ll never be a shortage of where you can buy good quality welding rotators in the market.

But if you are looking for the best and the most functional, we here at Waldun can help you.

Being the best in the industry shaped and molded us to create and manufacture high quality and reliable products. When you purchase our welding rotators, you’ll have no problems with any projects you have – light or heavy.

You can trust us if you need any type of welding rotator for your project. We can offer you welding rotators for light workpieces and materials; rotators for heavy workpieces; and so on!

Contact us now and get more information about our welding rotators!