HORIZONTAL CLADDING STATION

Auto Pulsed Hot Wire Tig Horizontal Cladding Station & Accessories as Per Enclosed

Purpose: To Carry Out CRA Clading Of Pipes From 6”To 36”

• Fabricated pipe structure to withstand loads up to 10 tons
• Hydraulic rope tightening arrangement for 6 tons with pressure relief valve for safety
• Easy and safe tensioning of rope with manual pump
• Mechanical stud locks in case of hydraulic failure

• Floating headstock to accommodate 6” to 36” pipe
• Slewing ring-mounted jaw plate on either side
• Jaws with extensions to hold pipes from 6” to 36”
• The rotator firmly bolted on the mainframe
• Motorized hydraulic up/down movement to maintain rope distance for different-size pipes
• Mechanical jack in case of hydraulic failure
• 10” color touch screen HMI mounted on the side for easy operation
• Up/down limit switch

• Self-centering rollers to keep the pipes in the center
• Bolted firmly to the mainframe
• Spring-loaded to accommodate oblong pipes
• Easily adjustable single roller set through LHRH screw
• Capacity – pipe size 36”|4 Tons EA

• Fabricated pipe structure to withstand 10-ton load
• Pulley and rope tightening arrangement
• Easy removal and assembly of rope
• Attached to the carriage track
• Both side limit switch

• Hollow pipe structure with rod guides and rack
• Carriage with guide pulley rollers and pinion
• Fabricated and machined structure to house torch end|wire feeders|spools|terminals|, etc
• Driven by 750 w servo motor for accurate movement

• Fully Digital Inverter Type Power Source
• Optimized For Automated Applications: Unique Second-Generation Digital
• System For Reproducible Welding Results of  The  Highest  Possible  Quality, Easy To Integrate Into Automated Systems
• Heavy Duty 550 Amps With 420 Amps 100% Duty Cycle.
• DI/DO and Ai/AO Signals to Plc.
• 95 SQMM HOFR Cables for Positive and Negative Leads.
• Extended Warranty Terms.
• Ac Hot Wire Power Source for Enhancing Deposition

• PLC – Omron with EtherCAT communication
• Motors – Omron with EtherCAT communication
• Servo drives for avc motors
• Phoenix (Germany) relay board and terminals
• MCB – Hager
• Enclosure – Eldon 2 door IP 55
• Industry-standard cables – minimum size used 0.5 sqmm
• Omron SMPS
• Lapp cables (Germany) for servo motor supply and encoder
• Male-female multi-pin connectors for field wiring
• 1000 w A/C for cooling drives and other components

• 4.5 kW capacity
• Refrigerated cooling with minimum 14 deg settable
• Flow and temperature interlock
• 3-phase Grundfos (Italy) pump
• SS manifolds to connect both master and slave
• Aluminum extrusion body
• Single phase preventer
• Independent flow switch for master and slave
• Working temperature up to 50 deg ambient

• RYB phase indication
• Single connection required from the customer side
• Independent MCB for power source, chiller, control panel, hot wire unit
• Neat routing through cable trays and drag chains

• The anodized aluminum tube housing
• Water-cooled copper tube for dc power
• Pu tubes for Gas|SS tubes with Teflon liners for wire feed
• Independent AVC slide units for master and slave torches
• Camera for master and slave heads

• CNC machined anodized aluminum body
• Dual roller for twin wire feeding
• 400 w Omron servo motor
• Encoder control to measure wire feed and consumption
• Liming 1:40 ratio servo gearbox
• Quick-release coupling for holding the liner
• Wire guide nipples for easy passage of the wire
• Insulated base plate

• 10” Touch Screen HMI for Data Entry, Operations, Alarms, Datalog, Display
• Optional wireless 10” Android Tab

• 5” wireless android based pendant

• Pipe dia                               6” (id 118 mm) to 36”
• Pipe length                         1 m to 12 m
• Wire option                        single wire/twin wire
• Arcing                                  single head/twin head
• Wire feed                            600mm/min to 5000mm/min
• Deposit rate                       up to 2.5 kg/hr/head
• Clad thickness                   up to 2.5 mm per layer
• Welding speed                  up to 600 mm/min

• Touch retract function with settable gap for hf strike
• Wire retract on downslope
• Interlocks for water and gas through independant flow switches for each head
• Machine mount flow meter, solenoid valve, and gas flow switch
• Digital display for torch position and balance to clad
• Auto return of the torch and rotator to last stop position
• Water cooled independent avc motors fixed inside the head
• Total consumable in kg on display (indicative only)
• Wire feed, welding speed and rpm on display
• Dual HMI/TAB at either end of the station
• 50 mm screw jaws for job holding
• Graphical display for volts, current, weld speed, wire feed and heat input
• Virtual pendant on the HMI to be used in the unlikely event of the pendant getting damaged

Data entry through HMI

1. Voltage
2. Peak and base current & pulse time/frequency
3. Start and end crater current
4. Upslope and downslope
5. Pre flow and post flow
6. Welding speed
7. Step distance and total clad length
8. Job diameter and cw & ccw selction
9. Torch selection (master|slave|both)

Manual functions:

1. Master /slave selection
2. Torch up/down
3. Torch lance in/out
4. Rotator cw and ccw movement
5. Rotator movement to 90 deg for easy truing
6. Rotator up/down
7. Wire in/out

Auto mode functions:

1. Start/down slope
2. Selection of cycle with only master, only slave or both
3. Master/slave selction for overrides of functions
4. Incr/decr of voltage, current, weld speed, wire feed
5. Wire on/off for either heads
6. Correction of x axis towards either side
7. Auto cooling cycle after downslope
8. Dry run for checking parameters
9. Dedicated cooling cycle