The welding rotator is auxiliary welding equipment. It uses the friction between the welding workpiece and the roller to drive the cylindrical (or conical) welding workpiece to rotate. The welding rotator is often used in combination with the welding manipulator. They can weld the inner and outer longitudinal seams and inner and outer circumferential seams of cylindrical workpieces.
The welding rotator consists of a base, a power driving device, active and driven rollers, and other structures. The welding rotator mainly uses the driving device to perform the active rotator operation, and there will be friction between the active rotator and the cylindrical workpiece. This friction force can mainly drive the rotation of the workpiece, thereby realizing effective displacement. Let the inner and outer circumferential seams and inner and outer longitudinal seams of the cylindrical workpiece be in the horizontal position where welding is needed, and the welding manipulator can realize automatic welding work. This can not only improve welding quality to the greatest extent but also effectively improve work efficiency.
Welding rotator composition
Next, we will introduce the main parts, main parts and parts details of the welding rotator.
The main unit of the welding rotator
The traditional welding rotator consists of two parts:
Roller support unit
Electric drive
Roller support unit
The idler bracket, or more commonly referred to as the "base", is the component that carries the wheel or the medium that performs the rotation or twisting of the workpiece.
The components of the idler support unit include:
Drive steering wheel
Driven wheel frame
Electric drive unit
Similar to the idler support unit, the electric drive unit is also composed of different parts. For the benefit of everyone, the electric drive is a part of the rotator, which emits power and energy to make the welding rotator work.
The main parts of the welding rotator
Different welding rotators have different parts. In addition, some manufacturers have added certain components to it.
However, the parts that will never be taken out include:
Idler
Driving wheel (something used to rotate material or workpiece)
Wheel frame (thing that supports the wheel)
Transmission (device that controls the speed of rotation)
Controller (something used to change and modify the rotation speed)
Direct current (DC) motor (what makes movement concrete and real)
Even if only one of the components is missing, the welding rotator will not work properly.
These are the parts of the welding rotator. Some welding rotator manufacturers and suppliers may add some parts to supplement it, but these are parts of traditional rotators and are indispensable.
Part details of the welding rotator
The rollers can be steel wheels or polyurethane wheels.
The drive motor adopts an AC variable frequency motor. If high precision is required, servo motors can be used.
The roller support bearing adopts the spherical roller bearing, which has the characteristics of strong load-bearing capacity and impact resistance.
All shaft parts are quenched and tempered, and the tooth part is quenched and tempered.
Welding the base profile and plate welding, stress relief. In addition, the frame has undergone shot blasting and rust removal treatment, which has sufficient strength to ensure long-term use.
The electric control system consists of a control box and a hand control box. The control box and the hand control box are connected by super soft multi-core cables to ensure reliable use.
The role of welding rotator
During the welding process, the welding rotator will be used to complete related operations. The design and production of the rotator frame adopts advanced technology, and at the same time, the automatic tracking system is used to achieve the application purpose, so that the positioning is more accurate. When the roller frame is processed and produced, the process design can be carried out according to the operation requirements, so that the roller frame can better meet the needs of the industry.
In the process of processing and production, any problems encountered can be analyzed, controlled and adjusted by appropriate methods. In addition, the welding rotator will be tested with appropriate process parameters, which can make the parameter setting more reasonable, make the processing operation consistent with the equipment setting, and achieve better operation control effects.
When processing by welding the rotator, the welding process is more stable and reliable. It can not only reduce the probability of failure, but also has a good isolation effect, preventing air from entering the equipment, and the equipment will not be affected by the high temperature environment.
The use of welding rotators can improve the quality of machining operations. Make the product processing and production effect more reasonable and achieve a more ideal application effect.
The difference between welding rotator and welding positioner
The welding positioner is a device that can clamp and rotate the workpiece according to the set angle. It can be at different angles so that you can weld on a stable level. Workpieces of any shape can be loaded on the welding positioner.
Welding rotators are different. After the workpiece is loaded, it will continue to rotate according to the speed you want. The wheels on the rotator allow movement; this is why only round and cylindrical objects can be used with it.
Why does the workpiece move on the welding rotator?
When using the welding rotator, the rotator and the weldment are round and the length is the same, and the axis is also parallel, it will not cause movement. If one of the rollers of the roller frame is broken, the selection of the workpiece on the roller frame may cause movement. Of course, if the shape or size of the workpiece is irregular, it will also cause movement. This is because the axis of the rotator and the axis of the workpiece are not parallel.
What are the effects of using the welding rotator on the processing quality?
In the welding process, the welding rotator will be used to complete the related operations. The design and production of the rotator frame use advanced technology, and at the same time achieve the application purpose through the automatic tracking system, so that the positioning is more accurate. When processing and producing through the roller rack, the process design can be carried out according to the operating requirements, so that the roller rack can better meet the needs of the industry.
In the process of processing and production, any problems encountered can be analyzed, and controlled, and adjusted through appropriate methods. In addition, the welding rotator will be tested with appropriate process parameters, which can make the parameter setting more reasonable, make the processing operation and the equipment setting consistent, and achieve better operation control effects.
When processing through the welding rotator, the welding process is more stable and reliable. It can reduce the probability of failure, and can also achieve a good isolation effect, prevent air from entering the equipment, and the equipment will not be affected by the high-temperature environment.
The use of a welding rotator can improve the quality of processing operations. Make the product processing and production effect more reasonable and achieve a more ideal application effect.
Application of welding rotator
Welding rotators are widely used, suitable for many industries and adapted to many processes.
Which industries can benefit from welding spinners
In the application scenarios of welding rotors, storage and pressure vessels are one of the most common parts produced by welding rotators. The most common applications include welding:
Oil storage tank
Water tank
Shipyard and ship parts
Pressure vessel
And more
Which welding processes can the welding rotator assist?
Available processes for welding rotators:
Submerged arc welding (SAW)
Tungsten inert gas (TIG) welding
Metal inert gas (MIG) welding
Arc welding
And more
If you choose to use welding rotators to complete any of these processes, then you can get higher quality and higher production efficiency products. We are a welding rotator supplier. Please feel free to contact us if you need them!