QUAD HEAD CLADDING STATION

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

Purpose: To Carry Out CRA Clading Of Pipes From 10”To 36”

Quad head twin wire 12 metre cladding station in single setting

• Fabricated pipe structure to withstand loads of up to 10 tons
• Rope tightening hydraulic arrangement for 6 tons
• Easy and safe manual (pump) tensioning of rope
• Pulleys with rope dia groove mounted on the top plate
• Hydraulic pressure vs load chart label on the frame

• Headstock to accommodate up to 36” pipe through the bore
• Slewing ring-mounted jaw plate on either side
• 4 screw jaws with extensions to hold pipes from 10” to 36”
• The rotator fixed rigidly on a skid-type frame
• The guide rod and pulley for smooth up/down movement
• Motorized hydraulic up/down movement to maintain rope distance for different-size pipes
• 10” color touch screen HMI mounted on the side

• Self-centering rollers to keep the pipes in the center
• Fixed rigidly on skid type frame
• Springs on both sides for adjusting pipe oblong shape
• Easily adjustable single roller set through LHRH screw
• Capacity – pipe size 36”|5 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

• Hollow pipe structure with guide rods and racks
• Carriage plate with guide pulley rollers and pinion
• Fabricated and machined structure to house inverters torch end|wire feeders|spools|terminals|motors, etc

• 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 4 power sources, 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
• Independently controlled AVC units for all 4 torches
• Camera for all 4 heads

• CNC machined anodized aluminum body
• Dual roller for twin wire feeding
• 400 w Omron servo motor
• Encoder control to measure wire feed in real time
• 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
• 10” wireless android tab at another end of the trolley with wheels

• 5” wireless android-based industrial mobile pendant
• Ip 68 water resistant
• Rubberized body

• Pipe dia                 10” (id 220 mm) to 36”
• Pipe length           1 m to 12 m
• Wire option           single wire/twin wire and on/off
• Arcing                     any combination in 4 heads
• 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, sov and gas flow switch
• Digital display for torch position and balance to clad
• Auto return of the torch and rotator to last stop position
• Servo motor controlled AVC using push rods
• Total consumable in kg on display (indicative only)
• Wire feed, welding speed and rpm on display
• Screw type 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 in any combination from 1 to 4

Manual functions:

1. Torch head 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 different combination of the 4 heads.
3. Torch head selection for overrides of functions
4. Increment/decrement 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