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Home » Products » Special Purpose Machine » METAL GATHERING WELDING MACHINE

METAL GATHERING WELDING MACHINE

METAL GATHERING WELDING MACHINE
METAL GATHERING WELDING MACHINE
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Product Code : 15
Product Description

KVA RATING

75- 150 kVA, 100% duty cycle, water cooled 25deg. C, 2 Phase. 440 V.A.C. For your job specified.

MACHINE BODY

Reinforced fabricated steel structure with louvered covers for well ventilation. The body will house the 75-150 kVA transformer, the hydraulic power pack, hydraulic piston, hydraulic grippers, pneumatic electrode v guides, hydraulic upsetting cylinder, movable gripper male- female dove tail slide, movable dove tail slide, electrode holders, electrodes, pneumatic cylinder for moving electrode. The heavy duty frame front section will be made of ‘I’ Beam/ Channel and heavy metal plates with ample cross section to carry the heavy hydraulic components.

TRANSFORMER

A heavy duty transformer made as per IS - 4804 Part 1 is used as the main power source. Special sandwitch construction of coils helps to increase the coupling between the windings and offers maximum efficiency. Primary and secondary conductors are selected to suit the heavy demand current. Copper cooling tubes are brazed throughout the periphery of the secondary segments. Transformer core is made out of cold rolled grain oriented lamination sheets to reduce the core losses. Class F insulation materials used in the transformer help to withstand a temperature of up to 155º C. The coil assembly is varnished in F 50 varnish and vaccum impregnated. A special thermoswitch fitted on the secondary segment helps to cut out the control circuit when the temperature of the winding rises above the safe level, thereby protecting the transformer from overloading.

HYDRAULIC POWER PACK

The hydraulic power pack is the heart of the system which provides the dovetail ram and the rod to be gathered, linear and constant movement. The power pack is made of strong bell housing structure, consists of constant gear drive pump with motor. The power pack delivers oil to the hydraulic cylinder resulting in hydraulic piston linear movement. The hydraulic oil in the tank will be cooled via, shell tube heat exchanger keeping the hydraulic oil cool and the hydraulic cylinders more efficient. Shell and tube heat exchanger cools or exchanges heat of the oil travelling in the power pack, to increase the efficiency of the hydraulic power pack for completed day’s production. Heating up of oil slows down the power pack and also causes hydraulic seal breakage. To ensure safety of components and achievement of continuous production heat exchanger is an important factor.

HYDRAULIC CYLINDERS

The hydraulic cylinders are operated with the entry of oil in the inlet of the cylinder powered by the power pack. Cylinders will be hard grounded and precision honed, the bore of the cylinder is also honed, lapped and ground for regular wear and tear resistance. Leak-free fluid connection ports provided by standard SAE o-ring straight thread ports. Seal extrusion and tube seal leakage eliminated by precise centering of the tube to the head end cap.

PNEUMATIC SYSTEM

The basic pneumatic system consists of a pneumatic double acting cylinder, solenoid valve of 4 way 5 port, filter, lubricator, regulator, gauge and foot operating initiating switch for solenoid coil. The precision honed and lapped pneumatic cylinder, both sides cushioned, is directly connected to the ram with the help of coupling. Electrode force is varied by means of the air regulator knob.

WATER COOLING SYSTEM

All the current carrying components are internally water cooled and hence no external water spraying is required as in the conventional machines. The upper and lower bus bars are provided with built in water jackets. Cold water will be supplied through cooling tower at a temperature of 25 deg app. to ensure metal gathering machine and current carrying components in the machine to remain cool and work consistently and at a constant working hour period.

ELECTRONIC CONTROL SYSTEM

The Micro Processor Control is housed in a desk type control cabinet, which is normally suited for separate floor mounting. All the control knobs are housed on the desk behind a transparent acrylic guard door to prevent misuse by unauthorized persons. The control circuits used in the system are based on the latest technology of IC’s, transistors and thyristors. For easy operation and maintenance, all cards are modular type and wherever necessary, sturdy plugs and sockets are used for easy service. The control and foot switch circuit is connected to a low, safe and isolated control voltage.

OPERATION AND WORKING

Push button will initiate the sequence of control. Firstly, the bottom hydraulic cylinder will travel upwards pushing the job. Once it reaches the top electrode pneumatic grippers will hold or grip the job. The gripping electrode will have ‘V’grooves to avoid friction between job and electrode and at the same time the job moves smoothly bearing current contact. Now as the bottom hydraulic cylinder is pushed upwards current is passing between top electrode and grippers forming halo currents. As job begins to melt hydraulic pressure causes gathering of material at top electrode. Gathering also depends on skill of worker or operator operating the machine.

Afully synchronous digital timer of " 0 - 9 cycles ON " and " 0 - 9 cycles OFF " will feed exact " ON - Of " pulses to the heat control card. The heat control card generates pulses, which triggers the thyristor switch. The current of the welding transformer can be adjusted from 5% to 100% by means of the phase shift firing of the thyristor switch.

POWER ELECTRONICS PANEL

The thyristors, matching the KVA of the transformer connected, in inverse parallel constitute the thyristor switch. The thyristor switch is mounted on an ample water cooled heat sink section to facilitate smooth and efficient current switching to the welding transformer for continuous welding operation, without appreciable change in the heat sink temperature. Protection devices like thyrectors for high voltage transcients and thermoswitch for heat sink temperature control is incorporated.

Features :

  • The machine body will be made out of Reinforced Fabricated Steel Structure with good ventilation
  • The upper & lower arms will be robust type fabricated from heavy section.
  • The man transformer will be housed in the Basic Body
  • Heavy duty Transformer will be Made as Per IS- 4804 Part I as the Main Power Source.
  • Copper pipes will be used as secondary segments in which water will be passed for water cooling
  • The insulation of the Transformer will be class F to withstand Temperature upto 155oC
  • The coil assembly will be varnished in F 50 varnish & vacuum impregnated.
  • Special Thermo switch will cutout the control circuit when the temperature rises above the safety level protecting the transformer from Overloading.
  • Electrodes will consist of Copper alloys suitable section of hardness 68 Rockwell B scale.
  • Metal Gathering electrodes will have high percentage of Copper content phosphor Bronze bushing & Water cooled holder should be of ample section copper alloy casting.
  • The pneumatic systems will consists of a pneumatic double acting cylinder, solenoid valve of 4 way 5 port, Filter, Lubricator, regulator, gauge & Foot operating initiating switch for solenoid coil
  • Hydraulic regulator knob will be provided for varying electrode Force.
  • All the current carrying components should be internally water cooled. The copper bus bars will be provided with built in water Jackets.
  • Electronics Control system will be housed in a desk type control cabinet. All the control knobs will be housed so as to prevent the Misuse by unauthorized persons. The control circuit used in the systems should be based on the latest technology.
  • A fully synchronous digital timer of 0-9 cycles ON-OFF to feed exact pulse to the heat control card.
  • The Current of the Transformer should be adjustable from 5% to 100% by thyristor switch.

Technical Specification :

KVA Rating at 100% Duty Cycle

75-150 kVA 2 PH 440V AC

Max Upset

1:2 in dia
1:2 in Length @ 75k VA

Upsetting Force kgf

10000-22000

Hydraulic Power Pack Capacity (Tons)

25 Operational 5 F.O.S.

Power Pack Assembly

60-90 Ltr. Bell housing, O/H Motor Pump

Pump Details

Vane Pump / Gear Pump

Motor

2-3 H.P. 3 Phase 440V AC

Air Cylinder Dia. in mm

100

Stroke mm

25

Bottom Cylinder Force in kgf

8000 - 15000

Clamping Cylinder in kgf

1000-2200

Ram Stroke in mm.

200-500

FlL / LUB / REG / Gauge BSP

1/4 To 1/2

Short Circuit Current (kA Sec.)

16 To 25

Rate of Water F low(lpm)

25 To 40

Free Air consumption for 100 Operation with 25 mm. Maximum Working Stroke Ltr.

200 - 450

Supply Cable Size copper(mmsq.)

35 - 50

Main Supply Switch fuse rating in Amps

150 - 250 3 Pole

H.R.C Fuse rating in Amps

125 - 200


WELDTRONIC ENGINEERS
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WELDTRONIC ENGINEERS
1/1, Green Park, Opp. Vijaya Bank, Link Road, Malad (West), Mumbai - 400064, Maharashtra, India
Phone :+917042457406
Mr. Sharon Devassi (Managing Director)
Mobile :+917042457406
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