The self-aligning welding rotator can automatically adjust to the diameter of the workpiece. Easy to operate. Four wheels can hold the workpiece tightly. The lower average force on each wheel results in longer service life.
The conventional welding rotator adjusts the wheel center distance through the reserved screw holes or lead screw. It can adapt to the change of workpiece diameter: drive-by cycloid reducer or worm gear reducer.
Steel wheels or polyurethane wheels are optional for rollers.
Drive motor adopts AC variable frequency motor. Can use Servo motor if high precision is required.
The roller’s support bearing adopts spherical roller bearing, which has the characteristics of strong bearing capacity and impact resistance.
All the shaft parts are quenched and tempered, and the tooth parts are quenched and tempered.
The welded base profiles and plate welding, de-stressed. And the frame is shot blasted and rusted, which has sufficient strength to ensure long-term use.
All shaft holes CNC boring machine and the precision of transmission gears are 7 grade to ensure the dimensional accuracy.
The electric control system is composed of a control box and a hand control box, and the electric control system adopts the Schneider AC frequency system to regulate the speed. The control box and the hand control box are connected by super-soft multi-wire cable to ensure reliable use.
Welding Rotator Applications:
Welding rotators are ideal auxiliary machine in pressure vessel, boiler, chemical equipment, oil and gas, storage tank, water tank, water pipe, shipyard, wind energy, etc.
Welding Rotator Parts:
1.Inverter: Taiwan Delta /Japan Yaskawa
2.Motor: Taiwan Qinwei / Chinese brand
3.Electric parts: Schneider /Siemens
4.Wireless Control box: Taiwan by Yuding
5.Bearing: NTN / Harbin
It can customize other brands also.
Welding Rotator Video:
For unique welding rotator, kindly inquiry us with following details.
1. Max. Loading capacity in tons or max. Work piece weight in tons or pounds
2. Tank/Vessel diameter range (min. and max.) in mm
3. Tank / Vessel final length in mm
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:
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.
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?
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!
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
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
Oil & Gas Industries
Petrol Chemical Industry
Power and Generation Industries
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?
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
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:
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 are most useful if you can’t suffice the workpiece using steel or rubber. Also useful in high temperature areas and situations.
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:
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.
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
Heat Exchange Units
And Many More
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!