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Special Welding Machine For Blast Furnace
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Special Welding Machine For Blast Furnace

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AUTO SAHW-I type submerged arc automatic horizontal welding machine is a new generation of high-efficiency vertical cylinder horizontal seam single-side submerged arc automatic welding machine, which is independently developed and produced by Nanjing Aote Electric Co., LTD., absorbing new welding technologies and new processes. The equipment adopts advanced welding technology to improve the welding efficiency and ensure the welding quality.

The equipment relies on the rack riding on the wall plate to complete the ring joint welding, which is mainly used in the storage tank, blast furnace and tower transverse ring weld welding.

Excellent performance of the welding system is a reliable guarantee of welding quality and construction progress, taking into account the use of the construction site environment, submerged arc welding machine using storage tank automatic welding special welding system, it can work in a variety of harsh environment, effectively ensure the stability of machine operation, improve the construction efficiency, reflecting the high efficiency of automatic welding. It also has good operability, maintainability and reliability, is not easy to damage, low failure rate.

1. Main components of the device

The whole set of equipment is mainly composed of welding walking frame, submerged arc automatic welding system, flux recycling system, operating box, distribution cabinet, etc.

The welded walking frame is a welded steel structure made of square steel and steel pipe, which is mainly composed of five parts: top cover assembly, telescopic body assembly, bottom plate assembly, lifting adjustment mechanism and power assembly. The top cover, expansion body and bottom plate constitute the main body of the welding walking frame, the internal and external sleeve structure, by disassembling the positioning pin, can realize the extension and shortening of the frame, so as to adapt to different sizes of the plate, and the corresponding position of the weld, flexible realization of different plate welding requirements. The walking device adopts modular design. By adjusting its installation position, it can conveniently realize the dual-purpose function of inverted installation. A ladder is mounted on the side of the frame to allow the operator to get up and down the top platform or to add flux. The exterior of the frame is equipped with steel plates, and the outside of the frame can also be covered with rain cloth to facilitate wind protection or reduce the impact of bad weather.

The powertrain is composed of a drive motor, transmission and speed change controller, which is located at both ends of the cantilever beam of the frame, and is connected with the cantilever beam in an active way to adapt to the adjustment of different curvature, and can be adjusted in the range of 0-2200mm /min. The powertrain is connected with the welding control system of the system, and the welding speed can be preset. During welding, the speed controller is used to adjust the speed of the frame to the speed required for welding. The speed of the frame is the welding speed.

The welding system adopts the original welding power supply imported from Lincoln, and supports the submerged arc wire feeder and integrated control system.

The submerged arc welding head is installed on the beam of the lifting adjustment mechanism of the frame through the upper and lower and front and rear regulators. The welding cable and control cable are connected with the main control box (installed on the right column of the frame) and the welding power supply to realize the remote control operation of welding current and voltage. The upper and lower and front and rear regulators are convenient for the operator to control the position of the welding wire in the weld path.

With the walking of the welding frame, the flux is stored in the welding area through a special support structure to protect the welding arc.

During operation, the bracket is pressed against the panel wall by the weight of the frame itself, and the flux is dropped by gravity from the recovered flux bucket mounted on the top of the frame to the flux hopper. During the welding process, the submerged arc flux hopper is opened and the flux is transported along the conduit to the flux bracket mounted on the carrier wheel, thus covering the weld path and protecting the welding arc. In order to reduce the waste of flux in the construction, with the walking of the welding frame, the high-power recycling machine is used to recover the remaining flux on the bracket into the flux barrel to achieve recycling. The secondary hopper is set up at the lower part of the recovery hopper to prevent the flux from being continuously supplied during the recovery process, and the control power supply is turned on separately to avoid affecting the arc.

1. Technical description of bidding equipment

1. Basic parameters of the workpiece

Single cylinder height: 4m;

Material: European standard S355;

Wall thickness per circle: 55mm/60mm;

Tank diameter 10.5 m /11.5 m;

2. Welding process requirements met by the bidding equipment

Welding current range: 150-1000A;

Welding voltage range: 23-46V;

Welding preheating temperature: Min 110℃(THK>50mm);

Welding heat input: 1.0-4.0KJ /mm;

Welding groove: suitable for "V" type, "X" type, "K" type groove welding;

Welding position: 2G;

Welding wire Angle: 0-30°;

Welding process: SAW(primer + filling cover);

Back root cleaning: guide the field to make temporary flux holding equipment, to achieve single-side welding back without carbon arc gouging root cleaning process;

Liner: Ceramic liner can be applied to eliminate back root cleaning;

Electrical characteristics: DCEP DC reverse connection, stable arc;

Welding quality: MT/UT pass rate ≥98%

The top end of the top panel of the product is installed with a top cover. Nanjing OTT suggests using a light transverse welding machine to achieve the top ring of transverse seam welding to solve the problem that the single side transverse welding machine can not be hung on the tank panel;

3. Main technical parameters

Suitable input voltage: 380V+10%, 3PH, 50Hz;

Adaptable plate thickness: 8-80mm;

The maximum plate width of the adaptive cylinder: 4m;

Adapt to the tilt of the barrel wall panel: transverse butt welding can adapt to the tilt of the barrel wall panel ≤15°(outside);

Suitable for steel: carbon steel, low alloy steel, high strength steel, stainless steel, etc.

Adaption groove: K, V, X type;

Suitable welding position: circular joint cross butt;

Suitable wire diameter: Φ2.4 - Φ4.0mm(commonly used Φ3.2);

Type of submerged arc welding: single wire, multi-layer multi-pass forming;

Equipped with automatic flux recycling device and convenient flux filling device;

Flux tray up and down adjustment device stroke: 0-100mm;

Welding torch adjustment: adjustable up and down, front and back, travel 0-100mm;

Operation box control panel: all Chinese instructions, easy to operate

Welding power supply: Lincoln power supply imported from the United States, external power supply, rated output current 1000A, rated load duration rate 100%, equipped with submerged arc welding wire feeder. Power supply for original import, delivery, provide certificate of origin, international transport insurance policy, customs clearance documents;

Welding power supply location: equipped with special power storage protection box, supporting the welding of domestic well-known brand cable, 150 square not less than 60m;

Welding speed 0-2200mm/min;

The fastest walking speed is 3000mm/min;

Operating vehicle running system: adapt to different cylinder curvature changes, with a wide range and high precision speed regulation ability, welding power and the whole machine linkage operation;

Operation car body weatherproof car body with aluminum alloy weatherproof cover, with 10-16 tons forklift fork loading;

The equipment is designed for skid mounting. After forklift fork loading, transported to the required position, hoisted by crane to the required welding position, manned welding tank;

Nanjing Aote provides free technical support in automatic welding operator certification and welding process evaluation.

4. Performance description of main components

4.1 Frame and walking device

The retractable welded walking frame adopts the semi-closed structure, adopts the rolling curtain waterproof cloth to prevent wind and rain, and the internal and external square steel pipe columns are pumped to adjust the height of the frame.

The frame adopts modular combination mode, and the welding walking frame adopts two column structure made of thick wall steel pipe, and the pumping joint connection is safe and reliable, ensuring the rigidity of the whole frame and the stability of welding walking.

The two sets of walking wheels are the main driving wheels to meet the driving requirements of the project's large plate length frame;

The walking system is driven by variable frequency motor, and the driving wheel is treated with high frequency surface quenching;

There are 2 sets of guide wheels with pressure adjustment on the frame;

The upper and lower and front and rear adjusters of the welding gun are arranged in the frame. The effective stroke of the adjuster is 100mm, which is a dust-proof closed structure.

4.2 Submerged arc welding system

The Lincoln DC-1000 is a multifunctional welding power source designed for semi-automatic and automatic welding, and its precise control provides excellent wide range MIG welding, flux-cored wire welding, and submerged arc welding.

LINCOLN DC-1000 Welding power supply configuration and parameters:

Power supply model: LINCOLN DC-1000;

Wire feeder: submerged arc special wire feeder;

Input voltage: 3P, 380V±10%, 50HZ

Output current range: 150-1300A

Output voltage range: 16-46V

Rated output: 1000A, 44V, 100% temporary load rate

The welding head consists of a tug, a flux belt, a wheel carrier, a cross slider, a wire feeder and other components. The wire feeder is installed on the beam of the rack lifting adjustment mechanism through the upper and lower and front and rear adjusters, and is connected with the main control box and welding power supply through the welding cable and control cable to realize the remote control operation of welding current and voltage.

Wire feeder is a special wire feeder for automatic welding;

Wire feeding system is wire drawing mode, equipped with welding wire straightening function;

Under the condition of 1000A welding current, the temporary load rate can reach 100%.

The size of the wire reel conforms to the domestic standard specifications, the weight of each reel ≯25kg;

The welding gun can be adjusted up and down, front and back, travel 0-100mm;

The welding gun can adjust the Angle, the adjustment range is ±15°;

4.3 Flux supply and recovery system

The flux protects the arc during welding by holding it in tow. When working, the support wheel is pressed against the plate wall by the weight of the frame itself, and the flux is dropped from the flux recovery bucket installed on the top of the frame to the flux hopper through the flux feeding pipe. During the welding process, the flux hopper is opened and the flux is transported to the welding arc area along the feed pipe. The residual flux from the bracket is recycled into the flux bucket by the recovery device for recycling.

Flux supply system adopts steel container, with moisture-proof performance;

Capacity ≥50L;

The adjustment of flux towing and towing adjusting system and welding gun adjusting system is convenient and practical.

The flux nozzle is adjusted by spline.

Equipped with a left and right flux nozzle;

4.4 Operation Box

Power control, welding control and current and voltage setting are obvious and convenient;

Wire feeding has a fine-tuning operating system;

With left and right walking direction switch;

With a separate, linkage welding walk selector switch;

With the flux recovery system operating status display;

4.5 Power Console and PDC

The welding system uses the original Lincoln imported power supply, and the welding power supply needs to be placed in the welding power platform. The platform adopts the micro-container structure, which is specially designed for the convenience of power lifting and rain prevention, and is equipped with a power distribution cabinet for walking frame and welding power supply.

The power distribution cabinet consists of two parts. One part is the welding power supply and equipment cable storage space, and the other part is the equipment power distribution cabinet, which includes circuit breaker and leakage protection.

The power distribution cabinet is made of steel plate, with rain proof function, suitable for long-distance transportation requirements;

The power distribution cabinet is equipped with a residual current circuit breaker. When the person is electrocuted or the grid leakage current exceeds the specified value, the residual current circuit breaker can quickly cut off the faulty power supply in a very short time to protect the safety of the person and electrical equipment.

5. Ring welding process description

By making temporary fluxholder equipment on site, the back side can be protected by fluxholder at the same time of single side welding, so as to realize the forming of both sides of single side welding and avoid the root gouging on the back side.

Nanjing Aote can provide technical support in automatic welding operator certification and welding process evaluation.

1, equipment spare parts, tools and warranty spare parts

1. Spare parts (single equipment)

2. Tool list (Single device)

3. Two-year warranty spare parts (single equipment)

3. Random data

1. The following technical information is provided for each device:

Equipment operation manual or operation and maintenance manual;

Related equipment structure drawings, electrical control drawings;

Packing list, spare parts list;

A list of wearing parts and a detailed list of manufacturers;

Welding power supply (welding machine) operation manual;

Factory inspection report, quality or qualification certificate;

Training materials, etc.

2. All documents are provided with 4 sets of paper (package), 4 sets of electronic version (word, excel, pdf, cad and other formats, CD burning or U disk).

3. All parts, spare parts, accessories, etc. are guaranteed for 10 years; When the equipment is replaced or production is stopped, the buyer must be notified 3 months in advance, and the production drawings of the discontinued parts and spare parts shall be unconditionally forwarded to the buyer.

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