Rotary welding positioner RWP 48.51
MACHINE VARIANTS
Necesary choice
The green color indicates an element or the part that have to be installed to the machine in one of the offered variants already during its production and the machine cannot be forward into the operation without it, or order it.
Construction surcharge
Yellow coloring means an element or the part which have to be installed into the machine in some of the offered variants already during its production. In principle it is a device extending functionality.
Free equipment
The gray coloration indicates an element or the part which is possible to fit the machine at any time later. Assembly is possible by the end user. In principle it is an equipment which expands functionality.
Rotary welding positioner of table design with hollow spindle intended for circumferential welding in industrial use also with high hourly loading.
Rotary positioner is equipped with quality drive guarantees perfect smoothness and constant rotate speed even under eccentric loads by welded product. Hollow spindle brings possibilities to weld fittings, pipes and other pipe and rod material. Each HST CREATIVE rotary positioner is equipped with digital control system R3 specially designed for circumferential welding and successful automation of this process, the positioner also has controlled output for switching the welding source.
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RWP 48.51 is ergonomically designed rotary welding positioner of table design with maximum load capacity 50 kg. It goes about simple but high effective positioner with specific design using solely first class constructional components.
- Positioner can be supplied in three production versions - Mk.I, Mk.II, or Mk.III. The spindle speed range for Mk.I version is set higher for rather lighter products of smaller diameter for rotation at higher speed however less torque is available. The Mk.II version has universal torque and spindle speed range for use with the standard sizes of welded products. The spindle speed range of Mk.III version is set lower. However higher torque is available for use with bulkier products of larger diameters with weight closer to the maximum allowed loading of the positioner. Therefore the choice of version should depend on the expected use.
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High quality steel frame carries structure of massive spindle with through hole of 48 mm. Spindle solution allows to conveniently use working plate with maximum diameter of 400 mm as well as 160 mm universal chuck with through hole of 48 mm. Control system R3 is integrated into the machine chassis and protected by stell cover with the polycarbonate glass cover against the suppression of the welded metal. The positioner has table design for placement on the edge of the working table.
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The spindle has variable tilt features 0 - 110° ensuring the optimal welding position. Tilting of spindle is driven manually by gearbox and it is possible to change the tilt also when the welded product is loaded.
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The positioner is equipped with integrated flange for mounting the welding arm which enables automatic operation of the positioner and can be equipped with pneumatic system of the arm of the welding torch. The construction is created in such way that the position of the welding arm is changed by the tilting of the spindle.
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The torch arm has pneumatic stroke and four degrees of release. At the end of the arm there is precise support of the torch position with backlash-free adjustment in two axes +/- 15 mm and the possibility of rotation by 90° with position locking. The torch holder can be designed for MIG or TIG torchs (others are on request).
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There is the possibility to deliver the machine with integrated system for divorcing the forming gas through the spindle.
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The work with positioner can be easier while using the foot speed rotation proportional controller which allows to set the speed of spindle rotation. Hand controller is another alternative for the remote control of the positioner. In addition to controlling the speed of rotation both, the foot control and hand controller, may include selector for the direction of rotation.
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HST CREATIVE positioners are suitable for MIG/MAG and TIG welding methods including pulse arc welding and plasma welding.
Using possibilities in a terms of weld type and technology
√ Manual circumferential welding, remote control of the rotation speed, the possibility of switching the direction of rotation with an ergonomically integrated selector.
√ Automatic welding when the positioner is equipped with accessories developed for this purposes. Connection of the welding source with communication cable directly to the positioner.
√ Tilting of the spindle continuously by handle and gearbox.
√ The spindle has a through hole for supplying the forming gas under the weld.
√ The spindle has a through hole for welding of pipes.
X Motor-driven tilting of the spindle.
X Linear and radial oscilation.
Main benefits
√ Digital stepper motor control provides stable rotational speed also with eccentric loading.
√ The control system supports welding automation. Setting the rotation angle and the welding source switch OFF angle.
√ Welding in manual mode with rotation speed control by proportional foot controller.
√ The positioner can be connected into a fully automated production system with pneumatic arm and welding source control.
√ Elaborated torch arm with many degrees of releasing achieving high variability for inner and outer welding.
√ Durable design with protection of sensitive parts, transmission of welding current by professional milled CuCrZr wiper.
|
WORKING PARAMETERS |
VALUE |
|
Maximal static loading |
50,0 Kg |
|
Torque on the shaft of spindle rotation (Mk.I / Mk.II / Mk.III) |
49,9 / 121,0 / 241,0 Nm |
|
Torque on the shaft of spindle elevation |
Manual Axis |
|
Speed range (Mk.I / Mk.II / Mk.III) |
0 - 20,0 / 0 - 8,0 / 0 - 4,0 rmp |
|
Working loading ** |
16/6 |
| TECHNICAL PARAMETERS |
VALUE |
| Maximal turning diameter (limited only when there is arm for automatization of welding) * | 950 mm |
| Hole through the spindle | 48,0 mm |
| Diameter of the spindle flange - recommended diameter of universal chuck | 160,0 mm |
| Recommended working plate | 400,0 x 11,0 x 48 mm |
| MOTION AXES | VALUE |
| Rotation of the spindle | Controlled axis |
| Elevation of the spindle, manually by gearbox | 0 - 110°, manual axis |
| Tilting of the welding arm * | Full functionality, manual axis |
| Adjustment of the welding arm basic position (3 joints) * | Full functionality, manual axis |
| Adjustment of the torch precise position * | +/- 15,0 mm, manual axis |
| TECHNOLOGY OF WELDING AND CONTROLLING | VALUE |
| Suitable methods of welding | MIG/MAG TIG, Plasma Weld, Laser |
| Electric current for DC transfered by spindle | 350A |
| Electric current for AC transfered by spindle | 270A |
| Connection of the welding source through START/STOP system | Yes |
| Foot switch for the main spindle rotation regulation and START/STOP function * | Yes |
| ELECTRIC POWER AND CONNECTING PARAMETERS | VALUE |
| Electric power supply | 1x230V/N/PE/50Hz |
| Compressed air (dry, clean) * | 0,5 - 0,7 MPa |
| Protective gases for the root protection * | 1 independant way |
| Description of the working place | Edge of work table, necessary to anchor |
| Level of IP | IP 51 C |
| Input power *** | - |
| DIMENSIONS | VALUE |
| Height | 452 mm |
| Width | 696 mm |
| Depth | 635 mm |
| Net weight (without clamping element) *** | 110 Kg |
* Optional item, or more versions are available which differs according to function. Mentioned parameters are valid for maximal options.
** 8/5 = lower loading in one duty period /// 16/6 = industrial loading /// 24/7 = non - stop loading
*** Parameters can not be provided with 100% correctness. Configuration of the machine must be taken into consideration. Mentioned parameters are valid for reaching maximal effective value.
...Subject to change the technical parameters without notice.
The information given here describes entire R3 control system with all possibilities which however may not be available for every positioner depending on technological possibilities of specific positioner. It also depends on selected positioner configuration. Therefore is always necessary get acquainted with the specific positioner at first whether its technological possibilities, even with regard to the configuration you have chosen, support all functions described below, or not. Information given in here are the overview about possibilities ofcontrol system, not the positioner and do not give explanation of individual components because of difficult comprehensibility of more complicated functions and equipment. For more details, please, contact the technical department or sales of HST CREATIVE.
R3 Control system for rotary welding positioners HST CREATIVE
√ Simple controlling adapted for easy understanding by the operator.
√ Large LED display shows all necessery values of key features.
√ Internal MENU is divided into graphic blocks for intuitive orientation.
√ Digitally controlled delay of welding, rotation speed and other features.
√ Rotation speed of the spindle is controlled by the central rotary knob in standby mode for faster response.
√ Division of the values settings for rotation, for controlling the welding source, welding arm, or forming gases.
√ Program controlled and adjustable welding arm and forming gas control.
√ Possibility to save own programs and settings into a memory of the control system using a programmable interface inside of the system.
Technological functions of rotary positioners control system
Controls:
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2 Step. This function requires the operator to press and constantly hold the foot switch or the button of the hand controller. Working cycle is started and when the foot switch or button of hand controller is released working cycle will stops. This is so-called two-motion mode. It can be active only if the Automatic rotation is not activated. Typical usage of this mode is welding when the operator sits so it is possible to immediately respond to the needs of welding rotation.
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4 Step. This function requires the operator to press and release the foot switch or the button of the hand controller. Working cycle is started and when the foot switch or button of the hand controller is press and release once again working cycle will stops. This is so-called four-motion mode. It can be active only if the Automatic rotation is not activated. Typical usage of this mode is welding when the operator is standing. That allows the movement at working place of the operator. Spindle is rotated uninterrupted.
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Automatic rotation. This is a mode of automatic rotation checking. That means, the spindle is rotating by a predetermined angle from 0 ° to 730 °. By the pressing of the foot switch or the button of the hand controller the working cycle is started which is automatically terminated after reaching the predetermined rotation angle. The angle of rotation can be set in block "Rotation" in the MENU of WORKING PROGRAM, see below.
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Low speed limit. Specifies the minimum adjustable speed of rotation (RPM) of spindle rotation in STANDBY MODE. I.e. the minimum rotation speed of the spindle from which the speed can be increased. Below this value set in this block the spindle can not be rotated. Therefore, if you want to use a full speed range of positioner, it have to be adjust to 0.001 rpm. Maximum adjustable value is always equal to the maximum possible speed of specific positioner, please see the production label.
Rotation:
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Diameter. Adjusting of welding diameter. Control system R3 will automatically calculates the progressive welding speed - the relative feed rate of the torch. This value will be displayed in the STANDBY MODE on display screen. Settings in centimeters in the range from 0.0 to 300.0.
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Rotation direction. Settings of direction in the rotation axis (Choice: Clockwise, or counterclockwise).
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Rotat. delay. The function can be usefull for a better material melting before welding. Adjust the delay between switching ON of the welding source and starting of the spindle rotation. Settings in seconds with an accuracy to one-tenth in the range of 0.0 to 15.0 sec.
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Angle of rotation. Choose the total angle by which the spindle will turns around its axis. The limit is 730 °. This function is active only when Automatic rotation mode is activated in block "Controls", see above.
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End welding angle. It defines the point where the control system R3 switches OFF the welding source. Settings in angle degrees. Limit value is 730 ° but the total value can not be higher than the value adjust in the Angle of rotation. This function is active only when Automatic rotation mode is activated in block "Controls", see above.
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Return to 0. It defines the returning of the spindle to initial position to find the starting position of welding =(e.g., directionally defined tools), or to unwrap the energy and gas hoses. This function is active only when Automatic rotation mode is activated in block "Controls", see above.
Gas:
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Function is active only when the positioner is equipped by the valve for the switching of the gas (optional element).
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Pre-gas. Serves to fill up the space of weldment root by protected – forming gas. It defines how long the gas valve will be switch ON before the system gives a command to ignition of the welding source. Settings in seconds in the range from 0.0 to 15.0 s. If 0.0 s is adjusted the function is inactive.
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Pos-gas. It defines a time how long the valve will be switched ON after the command to switch OFF the welding source has come. Settings in seconds in the range from 0.0 to 15.0 s. If 0.0 s is adjusted the function is inactive.
Torch:
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Function is active only when the positioner is equipped with a pneumatic arm for full welding automation (optional element).
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Before welding. Choose the type of the movement of the torch to the welded product before welding process. (Choice: Automatically, i.e. torch will be incline automatically to the product when the working cycle is starts, or Manually, i.e. the torch waits for a command via the key on the control panel, before starting of the working cycle)
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After welding. Choose the type of the movement of the torch from the welded product after welding process. (Choice: Automatically, i.e. the torch will be moved automatically from the product after the ending of the working cycle, or Manually, i.e. the torch waits for a command via the key on the control panel, after the ending ofthe working cycle)
Welded parts:
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It can go about any part that fulfils the dimensional and weight restrictions of positioner without limitation of welding methods.
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The welding process can take place at any angle of inclination of the spindle within the capabilities of positioner. This is completely unindependent on the eccentric load of the positioner by means of digital drive concept.
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The control system is able to control the angle of rotation and the angle of switching the welding source off unindependently to each other. There is a possibility to reach the perfect connection of weld bead by the automated welding. Of course, there is a possibility of manual controlling.
Basic configuration of the machine
C
Complete base ready for precise configuration
(( 1 )) Selection of controller type and clamping tools
(( 2 )) Selection of torch welding arm and the functionality of torch holding elements
(( 3 )) Selection of technological accessories and improvements
(( 4 )) Selection of welding source and other accessories and complements
Basic equipment for automatization
1.1
Basic type of foot controller with START/STOP function
(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS02, FPR03/04, HCR01/02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected to standardized socket at any time and selected in control system
1.2
Foot controller with START/STOP function and extended functionality for changing the direction of rotation
(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01, FPR03/04, HCR01/02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system
1.3
Foot controller with START/STOP function and extended functionality for proportional speed regulation
(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01/02, FPR04, HCR01/02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system
1.4
Foot controller with START/STOP function and extended functionality for speed regulation and dir. changing
(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01/02, FPR03, HCR01/02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system
1.5
Hand controller with START/STOP function and extended functionality for proportional speed regulation
(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01/02, FPR03/04, HCR02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system
1.6
Hand controller with START/STOP function and extended functionality for speed regulation and dir. changing
(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01/02, FPR03/04, HCR01)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system
Options for automatization of welding
2
12VDC switchboard and 1,2m hose for controlling of ARM FLEXI pneumatics, integrated into the machine
(( √ )) Device for controlling of welding arm movement, NO ALTERNATIVE
(( Combination )) Suitable to supplement this device with an ARM FLEXI welding arm
(( Options )) Can be used also for switching other pneumatic devices with the same working pressure
(( Condition )) Assembled and mounted directly at the production
3
Six - sided column with manually moveable holder and mechanical fixation, length 1000 mm
(( √ )) Column for arm systems designed for automized welding, HAS AN ALTERNATIVE (ARM LIFT 400/800)
(( Combination )) Suitable to supplement this device with an ARM FLEXI welding arm
(( Options )) None
(( Condition )) Can be installed in a simple operation without use of special tools
4.1
Support of the ARM LIFT 400/800 system with locking. Max turning diameter depend to the machine type
(( √ )) Support element of arm systems for automized welding, HAS AN ALTERNATIVE (ARM LIFT HOLDER B)
(( Combination )) Used as support element of ARM LIFT 400, or ARM LIFT 800
(( Options )) None
(( Condition )) Can be installed in a simple operation without use of special tools
4.3
Support column with vertical movement by gearbox, stroke of 400mm
(( √ )) Column for arm systems for automized welding, HAS AN ALTERNATIVE (ARM LIFT 800, ARM FIX 1000)
(( Combination )) Suitable to supplement this device with an ARM FLEXI welding arm
(( Options )) Mounted to the machine with one of the supporting elements (ARM LIFT HOLDER A, nebo B)
(( Condition )) Can be installed in a simple operation without use of special tools
4.4
Support column with vertical movement by gearbox, stroke of 800mm
(( √ )) Column for arm systems for automized welding, HAS AN ALTERNATIVE (ARM LIFT 400, ARM FIX 1000)
(( Combination )) Suitable to supplement this device with an ARM FLEXI welding arm
(( Options )) Mounted to the machine with one of the supporting elements (ARM LIFT HOLDER A, nebo B)
(( Condition )) Can be installed in a simple operation without use of special tools
5
Assembled arm 2x280mm - four angle adjustment, pneumatic controlling for a simple automized welding
(( √ )) Welding arm for a simple automized of welding, NO ALTERNATIVE
(( Combination )) This item have to be further fitted with item ARM 1 JOINT HOLDER, or ARM 2 SLIDE
(( Options )) None
(( Condition )) Can be installed in a simple operation without use of special tools
6
Articulated segment enabling a clamping of a straight welding torch with diameters of 28 - 42 mm
(( √ )) Item is necessary for intended function of the machine, HAS AN ALTERNATIVE (ARM 2 SLIDE)
(( Combination )) None
(( Options )) None
(( Condition )) Can be installed in a simple operation without use of special tools
7.1
Cross head with precise adjustment of +/-15mm in axes X and Z and rotation of torch holder with fixation per each 30°
(( √ )) Item is necessary for intended function of the machine, HAS AN ALTERNATIVE
(( Combination )) This item have to be further fitted with item (ARM 2 TILT TORCH HOLDER)
(( Options )) None
(( Condition )) Can be installed in a simple operation without use of special tools
7.2
Holder for MIG or TIG torch with tilting function at five fixed angles per each 15°
(( √ )) Item is necessary for intended function of the machine, NO ALTERNATIVE
(( Combination )) ARM 2 SLIDEMICRO is mounted on this part in the case of cold wire feeder is installed
(( Options )) Select a diameter of the torch, standard is 34mm. It have to always be a straight torch
(( Condition )) Can be installed in a simple operation without use of special tools
7.3
Cold wire feeding end element with the possibility of precise adjustment +/-5mm with cooled girder
(( √ )) Precisely made set feeds cold wire directly into the weld, NO ALTERNATIVE
(( Combination )) Mounted on the ARM 2 TILT TORCH HOLDER
(( Options )) None
(( Condition )) Can be installed in a simple operation without use of special tool
8
SET for solenoid control of forming gas and its supplying under the weld through hollow spindle
(( √ )) Auxiliary element that improves the operation by switching the forming gas, NO ALTERNATIVE
(( Combination )) None
(( Options )) None
(( Condition )) Assembled and mounted directly at the production
9
Set of internal electronics and installation elements for connecting of feeder CW06 ROBOT
(( √ )) Extends functionality of machine for the switching of the feeder working cycle, NO ALTERNATIVE
(( Combination )) Designed for use with the CW06 ROBOT cold wire feeder
(( Options )) Can be used with any kind of device on the analog START/STOP principle
(( Condition )) Assembled and mounted directly at the production
10
Separate cable terminated with connector on the machine side with no connector on the welding source side
(( √ )) Cable for connecting to the welding source for switching the welding arc, NO ALTERNATIVE
(( Combination )) None
(( Options )) Other cable lengths can be ordered on request
(( Condition )) Can be installed in a simple operation without use of special tools
Other accessories and clamping
11
Special structural tool facilitates the manipulation of the machine
(( √ )) Tool is poked through a hollow spindle, manipulated by means of forklift device, NO ALTERNATIVE
(( Combination )) None
(( Options )) None
(( Condition )) No assembly required, ready to use immediately
0.A
Working plate of 400 mm with concentric circles, thickness 11mm, hole 48mm, weight 10,3kg
(( √ )) Plate can be mounted on spindle flanges without transition elements, HAS AN ALTERNATIVE
(( Combination )) None
(( Option )) Other plates can be choose, but these have to be mounted using transition elements
(( Condition )) Can be installed in a simple operation without use of special tools
0.B
Three-jaw universal chuck with gears adjusted for welding, hole 48mm, weight 6.8kg
(( √ )) Chuck can be mounted on spindle flanges without transition elements, HAS AN ALTERNATIVE
(( Combination )) The chuck can be fitted with extended segments (custom made solution)
(( Options )) Other chucks can be choosed, but these have to be mounted using transition elements
(( Condition )) Can be installed in a simple operation without use of special tools
 Rotary welding positioner RWP 48.51 |
 Rotary welding positioner RWP 48.51 |
 Rotary welding positioner RWP 48.51 |
 Rotary welding positioner RWP 48.51 |