PLC Control Welding Positioner with Servo Motor For Hardfacing and Pipe Tilting
Various applications of pipe welding positioners are available, ranging from spooling pipes to positioning large cumbersome components like chassis components or structural steel.
It is very beneficial to use welding positioners when welding pipe, shafts, wheels, elbows and other fittings.
Positioning valves using pipe turning positioners is a common method for rotating or repositioning workpieces with a large offset load, as is the case with welding turntables.
The pipe welding positioners and welding rotating tables manufactured by MISA Welding Automation are suitable for a wide variety of pipe handling applications.
1. The load capacity is from 2 tons to 500 tons
2. Can be tilted and rotated
3. Enhance safety
4. Allow both skilled and entry-level welders to make high-quality rotary welds
5. Improve employee morale
6. Use semi-automatic functioning to limit worker fatigue and increase production speeds
7. Can be matched with the manipulator to realize automatic welding
Welding rotators and positioners are primarily used for manipulating and positioning workpieces during welding and fabrication processes. Here's how each equipment is typically used:
Welding Positioners:
- Complex Geometries: Positioners are used for manipulating workpieces to achieve precise positioning and orientation during welding.
- Optimal Welding Angle: They tilt, rotate, and elevate workpieces to position them at the optimal angle for welding, ensuring access to all sides of the joint.
- Enhanced Control: Positioners offer fine control over the orientation of the workpiece, enabling welders to maintain consistent weld bead appearance and quality.
- Applications: They are used for welding components with complex geometries such as aerospace parts, automotive chassis, structural steel beams, and other large assemblies where precise alignment and manipulation are crucial.
The welding positioners are use to manipulate workpieces to achieve precise welding angles and orientations, essential for complex geometries in industries like aerospace, automotive, and heavy equipment manufacturing.
Indeed, MISA Welding & Cutting Automation Co., Limited has a broad global footprint, supplying equipment across various continents including Europe, America, Asia, and Australia. Here are some highlights of their international reach:
Europe
- Industries Served: MISA supplies welding and cutting equipment to key industries such as automotive manufacturing, shipbuilding, and heavy machinery.
- Trade Shows: Participation in trade fairs like SCHWEISSEN & SCHNEIDEN in Germany helps MISA connect with European clients and showcase their latest products.
North America
- Industries Served: In North America, MISA's equipment is used extensively in oil and gas, construction, and aerospace sectors.
- Customer Base: They have built a strong customer base in the U.S. and Canada, known for their reliable and high-quality welding solutions.
Asia
- Regional Presence: MISA has a significant presence in Asian markets, including China, Japan, South Korea, and Southeast Asian countries.
- Local Partnerships: Collaborations with local distributors and direct sales strategies help them cater to the diverse needs of the Asian industrial sector.
Australia
- Mining and Resources: In Australia, MISA's equipment is crucial for mining operations, construction projects, and resource extraction industries.
- Adaptation: Their equipment is adapted to meet the specific requirements of the Australian market, ensuring compliance with local standards and regulations.
WHAT TO KNOW ABOUT WELDING POSITIONERS
Fixed Type Welding Positioner Hydraulic Type Welding Positioner Elevating Type Welding Positioner
Why Choose MISA Welding Positioners:
√ Standard match with CUL and CE
√ Professional design team
√ Motor power supply is equipped with safety protection
√ Perfect after-sales
√ 13 months warranty.
Welding Positioners - The Comprehensive FAQ Guide
Welding positioners made by MISA are all powered variable-speed machines that can rotate in either direction and can be controlled remotely by various switch options.
What are Welding Positioners?
To work at the correct angle and a consistent surface, welders use welding positioners to hold a workpiece and rotate it.
With its fast rotation speed, it can support significant weight even when bearing a lot of weight.
Welding positioners are designed to ensure that the workpiece is always in the most advantageous welding position.
Example of what a welding positioner looks like
Welding positioner improves the welding output
By eliminating waste in multiple aspects of their work, positioners improve productivity.
The purpose of welding positioners is to ensure as much arc time as possible.
In order to move cranes, chains, grippers and other types of rigging equipment effectively, welders often have to wait for the appropriate positioning of the workpiece, something that may have to be done more than once for one weldment.
Positioners also make it possible for the welder to manipulate the part more quickly.
Large parts can be positioned by one operator, eliminating the need for multiple people to reposition the part.
As a result, there is a labor savings and employees are freed up for other tasks.
Application display of welding manipulator
Welding positioner improves welding quality
Welding positioners produce consistently high-quality welds, which is one of the major benefits.
It is difficult to produce quality welds when the part moves during the welding process.
If the material is securely fastened, sufficient penetration of the weld will be possible, as well as the ability to complete all welds without interruption.
In terms of weld quality, welding positioners solve many problems since they rotate the workpiece at a controlled rate and speed for a continuous, penetrating weld.
Advantages of a welding positioner
* Tilt and rotate the work piece to make the welding level and ship-shaped, such as the best position for welding.
* High-quality DC motor, smooth operation of the worktable, stepless adjustment of welding speed, large adjustment range, and high adjustment accuracy.
* It can be fixed on a workbench or a special tool for manual welding, or it can be used with a welding manipulator to realize automatic welding. It can also be used for cutting, grinding, assembling, testing and other processes.
* The clamp and the workbench choose a simple mechanical connection method with high positioning accuracy; it is especially suitable for welding flanges, steel pipes and other joints.
* The hand control box or foot switch is used to control the desktop rotation, which is easy to control the rotation; easy to use and simple to operate.
5 things welders need to know about weld positioners
When selecting, operating, and maintaining a positioner, welders should consider these five suggestions, regardless of the size of the weldment.
- Confirm the center of gravity (COG)
It is important not only to take the weight and size of the weldment into account when selecting a positioning device, but also to consider how far the weldment's center of gravity is from the device. The center of gravity refers to the point at which the weldment balances on all axes equally. The point at which the weldment equalizes the pressure on each axis is the COG. The positioner is torqued more when the distance from the device increases. When welders add material and parts to a positioner, the COG changes, so these changes are important to consider.
Variable-speed motors control the table's rotation. It can be controlled either manually or automatically. Choosing the right positioner motor and control depends on the size and speed required for the desired welding operation.
Motor and control choices will be determined by the positioner manufacturer's specifications. A welder should make sure the capacity is adequate for the weldment by checking both horizontal and vertical load specifications. It is important that the positioning device can withstand as much force as possible.
- Connect the weldment correctly
This point in time is where the weldment would naturally separate from the positioning device, because that is where the weldment is attached. Fixtures for production are intended to be used repeatedly for a particular application. An automatic alignment fixture, such as this one, is permanently mounted to the positioner and is shaped so that it's easy to align parts.
The three-jaw chuck is often used to attach round parts. When the part is extended from the table, it should not pull away from the jaws. During and after the welding process, the part may expand or contract depending on how hot and how cold it is, which can affect the grip the chuck has on the part.
In sizing the positioning device, consider the weight and distance added by fixtures and chucks.
How Does The Welding Positioner Work?
It is easy to understand how a weld positioner works - the device holds on to the particular workpiece by actively clutching and gripping it.
When it moves and rotates, it will get into the position that a welder requires.
You can imagine that it replaced the welder's hand in a more precise, accurate and automated way.
What Is 3 Jaw Welding Chuck?
They're known as a surface, a part of a welding positioner that could properly hold hexagonal and round workpieces.
The three-jaw welding chuck can be fixed on the table and clamp the workpiece firmly, and keep the position still when the workpiece rotates.
What's the Difference Between Manual, Semi-Automatic, and Automatic Welding Positioners?
People don't see the differences between them; what makes them different?
In manual welding positioners, the turntable would need to be moved and rotated. It can either be controlled by a foot pedal or by a lever that you can manipulate by hand.
Welding positioners that work with extra accessories such as a torch or stand are called semi-automatic positioners.
Due to the fact that the positioner moves on its own, while the torch only stagnates, it's semi-automatic.
Automated weld positioners use robotics or automated movements to position welds.
In this positioner, the welding head and the rotator are controlled by machines, so no human intervention is needed.
Why Welding Positioning Is Important?
In welding, positioning is not just for the weld's benefit - it offers a variety of advantages to the welder, as well.
To achieve the quality and quantity of welding needed, overhead welding is used.
By understanding what weld positioning does and how it is beneficial to welders, we can easily summarize how important it is.
The many benefits of weld positioning include the ability to meet required positions without moving and stabilizing the weld.
How Does The Welding Positioner Ensure The Safety Of Welders?
One of the benefits from the advantages above is that your welders are safer.
How can it keep welders safe?
That is because of the characteristics of manual welding positioner:
- No need to use ladders, scaffolding and lifts
- Can improve working condition on the ground
- No need for heavy equipment such as cranes and forklifts to fix the workpiece
- No need for welders to move weldments
How to use manual welding positioner correctly?
People tend to believe that welding positioners can't be operated properly, but that's not true.
You can use it in the best and safest possible way by following these simple steps:
- Put the positioner on a stable and flat surface to ensure your safety.
- Choosing the rotational speed will save you from having to change it between welding.
- Set up your welding equipment and make sure it's connected to a ground current.
- Position the welding positioner horizontally at all times
If you follow these steps, you will never have issues with your manual weld positioner!
Which Materials Can Be Used For Welding Positioner Welding?
Torches aren't necessarily carried by welding positioners.
Using a welding positioner, a large workpiece is rotated to be welded.
Welding positioners are responsible for assisting with the positioning of the workpiece during welding.
You can weld certain materials with weld positioners if they can grasp or clutch them.
Welding positioners are commonly used for welding the following materials:
- Tubes and Fittings
- Tanks and Vessels
- Pipes and Elbows
- Uneven Workpieces
- And Many More!
When it comes to the particular workpieces that you'll be welding, welding positioners are not that picky.
What Is The Welding Turntable?
Simply put, it is a rotary machine that can help you complete welding operations.
The welding turntable is a device that can rotate the workpiece at a uniform speed. It can be controlled (manually) or set to automatic.
Example of what a welding turntable looks like
Welding Positioner vs. Welding Turntable
Welding positioner is a general term for equipment that can be used to assist you in completing your project.
The welding turntable is a kind of welding positioner. Its function is similar to a rotating table, so you don't have to worry about the positioning of the workpiece when welding.
In addition to the standard welding positioner can rotate, the faceplate can also be tilted to change the angle of the workpiece, which is more convenient for welding.
How To Use The Welding Turntable?
Using the welding positioner turntable is very simple. In fact, it can be classified into the following steps:
- Before preparing for welding, load the workpiece on the workbench.
- Then use a chuck and bolts to fix the workpiece on the worktable.
- Use the hand control box or foot control box to start the rotation.
- If you use a manual welding turntable, you must hold the filler metal and/or welding head. Otherwise, you can set them to execute at the speed you want.
- Once it is over, you can unload the workpiece from the workbench; the welding is complete.
You can think of it as a machine that frees your hands from the workpiece.
Kindly Noted:
1. You can choose Fixed type or Elevating type .
2. Welding Positioner can tilting from 0° to 120°, rotation 360° via VFD control.
3. Standard Voltage is 380V , 50HZ , 3PH. Other voltage please kindly let us know.
4. Controlled is remote-control box, optional is foot switch
5. If customer need more special requirements , we could study with our engineer.
FAQ:
1. What is the size of the faceplate?
The faceplate of the positioner can be selected according to the load capacity , or customized according to customer requirements. The faceplate has T-slots which can be used to fix the chuck.
2. What is the difference between the positioner and turning table?
The turning table can only rotation, and it is 1 Axis. The positioner can rotation and tilting, and it is 2 Axis. Customers can choose according to their needs.
We also have many types of positioners to choose from to meet the work needs of customers for different workpieces.
3. Can the positioner be used with a chuck?
Yes. There are some T-slots on the table to fix the chuck. T-slots can be customized according to the size of the chuck. And we can also provide the chucks you need.
4. Replacement parts can provide it?
We provide it for free during the warranty period, and charge for it after the warranty period.
5. Do you provide warranty?
We provide a 13-month warranty and can provide customers with technical guidance for life.
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