If you are a welding manipulator manufacturer of pressure vessels, or other large pieces (such as rims), you may already have some welding manipulators in your welding facility.
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Alternatively, you may combine submerged arc welders with long seam welds and homemade equipment with steering rolls for circumferential welds. Either way, an investment in upgrading a manipulator or even a complete manipulator system can pay for itself quickly through increased productivity and quality.
When purchasing standard column and boom manipulators, it is important to fully understand all possible welding and production requirements. These factors will determine which option is best for your welding equipment.
If the quality of the automatic welding manipulator is not up to standard, it will not only reduce the welding quality but also affects the entire welding operation process. Therefore, when choosing an automatic welding manipulator, we must pay attention to the influence of the brand. Generally speaking, seeing the brand is equivalent to identifying quality. The quality of the equipment is the life of the production line and the guarantee of efficiency.
First of all, in the process of selecting an automatic welding manipulator, the object of consideration is equipment made by a regular brand manufacturer.
Secondly, pay attention to the product services provided by the manufacturers of automatic welding manipulators. The level of service is an important standard for customers to measure the added value of manufacturers. The more comprehensive the service system, the more secure it is during production.
The above two points are analyzed from the perspective of the automatic welding manipulator manufacturer. For the equipment itself, it is necessary to learn to judge its quality and performance, not just the blind pursuit of low-priced automatic welding manipulator equipment.
For the production industry, especially for quality management, equipment is extremely important. The choice of equipment is not good, it not only affects the delivery time but also affects the quality of the finished product. Therefore, to carry out production better and more safely, it is necessary to select the appropriate automatic welding manipulator according to the standard.
When welding pressure vessels, consider the following
What's the point: Does the manipulator standstill? Is it responsible for both long seam welding and circumferential welding? Will the base rotate to handle multiple welding stations?
Will the long seam of the pressure vessel be longer than the stroke of the manipulator? In this case, a station wagon and guide rail assembly suitable for welding on the move will be required. This will enable the manipulator to weld the outer long seam smoothly at a constant rate as it moves along the length of the pressure vessel on a track.
In order to weld the inside of the long seam, is the manipulator extended long enough to weld the required length? To control the speed of the boom, make sure you have a variable frequency drive (VFD). Linear bearings are also a good way to ensure smooth movement and repeated positioning of welded joints.
Is a soldering head required for future upgrade to a series solder or hopper mounted solder recovery system? If so, you need to consider the capability of the manipulator.
After selecting the welding manipulator, there are other options available in the fully functional welding kit.
Welding power source
DC-only power supplies based on transformers or inverters can provide cost-effective welding solutions, but inverter-based systems have additional advantages, such as increased welding deposition rates, power savings, and in some systems cloud-based production monitoring networks.
How to adjust the welding head?
The 180° pivot block can easily change the weld head from the long weld direction to the circumferential weld direction.
Manual welding sliders are durable and cost-effective, but require the operator to rotate the adjusting knob to place the weld.
The electric cross rail allows the operator to make fine adjustments by controlling the cantilever.
The combination of dynamic cross sliders and tactile seam tracking automatically ensures that the critical first weld is completed without the need for fine adjustments by the operator.
Laser seam tracking is the most expensive option, but when using root path memory on the first pass, it can track the seam until all subsequent passes.
How do you control the system?
An integrated digital control system with a human-machine interface (HMI) screen provides a single control point for all variables and eliminates the clutter of multiple manipulator control boxes.
Depending on the size of the part, the HMI can be installed at the end of the welded armor on the ground. If the HMI is mostly on the ground, an integrated welding camera should be used so that the operator can safely and easily view the welding area.
Flux recovery system selection
There are a number of flux recovery systems mounted on the funnel. However, a closed-loop flux recovery system with vacuum and pressure feed provides maximum flexibility and power and produces the lowest load on the solder head. These systems also allow the boom to enter smaller diameter pressure vessels when welding long joints in the vessel.
Buying a welding manipulator is not just a manipulator. This is an integrated system, and success or failure will depend on getting all the pieces right and working together.
Contact us to discuss your requirements of Sale Stoody Hardfacing Wire. Our experienced sales team can help you identify the options that best suit your needs.
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Manual Welding Manipulator vs. Automatic Welding Manipulator
With the remarkable development of the welding field, one of the core criticisms that appeared in the industry: Automated vs. Manual welding, which would be better?
Some would claim that automatic is preferable to manual nowadays. Other people might suggest the contrary, and some would suggest that it’s optimal to have both in your store.
There are a variety of things to remember when selecting the welding process to be used in your shop – efficiency, expenditure, the scale of the tasks, and more.
welding manipulator operates
First, let’s shed some details on the disparity seen between the two welding processes.
Automated welding is classified into two groups. Mostly welding is often performed by an automated welding unit.
Human interaction falls into two positions: either they run the equipment, or they watch the entire welding phase while ensuring that the devices function efficiently.
This approach used to be suitable exclusively for large-scale welding activities, such as mass manufacturing of pipes and vehicles, but as industries learn the advantages of welding optimization, small and medium-sized enterprises have often switched to welding automation.
In the meantime, in manual welding, the individual welder conducts its welding procedures, and the accuracy of the materials relies heavily on their expertise. This is perfect for newcomers, professional DIYers, and business owners that require limited welding operations.
Manual weld manipulators contain manipulators of static weld heads. In contrast, automatic manipulators are those that are operated by a device. The distinction between them is the rotation of the beam. If you want to manually adjust the weld head, you should treat it as a manual manipulator.
Buying automated welding manipulators is not often the right option. In reality, manual manipulators are commonly sought-after. Manual manipulators have high demand in the marketplace.
Automated welding can yield at least twice as much as a professional welder and manual welding can yield. It also helps you to replicate the welding step without impairing the accuracy of the production.
But you can’t completely depend on the automatic systems for the job of five welders. Simply put, the computer is still vulnerable to failure or malfunction.
In the meantime, in manual welding, you have to weigh the potential of a human welder – how long it can conduct the welding operation without stretching too hard, can the welder execute its duties reliably, what if the welder gets ill, etc.
However, professional welders can produce almost flawless, predictable consistency and percentage of results in a cost-effective manner.
Automated welding may manufacture components of the same specification with a consistent pace and operation. It might not, though, be suitable for minor touch-ups, where a human welder may simply do it with a fast torch on potential missing areas.
However, manual welding may be vulnerable to typical quality issues such as weld spatter forming, density, and poor penetration, to name a couple.
Automated devices are designed to allow any changes that you have to make to suit your welding activities. Props to their integrated swivel casters, they also have fast versatility.
However, in terms of moving from one welding process to the next, it might take much longer for you to change the automatic system for another welding period.
On the other side, a human welder will quickly move from one workspace to another to execute various welding activities.
Manual welding devices can consume more time, but when it comes to finishing multiple welding within a short period, manual welding is much more optimal.
Automated devices will save you a lot of labor and manufacturing costs. You won’t have to employ eminently competent welders to do the work – anyone who can run automatic systems will be adequate.
Because there is less human labor required, you will reduce the risk of human error and reduce the amount of waste generated.
Spending on an automated welding system may be expensive, particularly for start-ups. While there are budget-friendly alternatives for moving to weld automation, some will also find the initial expenditure greater than the spending on manual welding.
But in the long term, you will reap the cost-effective advantages of automated welding.
Manual welding can be suitable, funding-wise, for start-ups, small companies, and others that do not require large welding activities.
What you need to do is spend in a manual welding unit, some welding tools, and a professional welder. The sum of these expenditures is lower than the expense of automatic processes.
But in the long term, you could find it as expensive as welding automation. There are labor charges, depreciation, and the cost of processing waste.
Not to mention the emergency accidents in your store, such as your welder experiencing an incident during the welding operation.
It always boils down to the marketing strategy in the end. Will you plan to double demand to please more clients in the long run? Are you planning to cut costs without losing the efficiency of production?
If you want the most of your investment and add more revenue to your company, welding automation is worthwhile!
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