Vertical Cladding Station is fully automated PLC based Hot Wire GTAW cladding station which shall be fixed in the workshop. There will be a water cooled Torch mounted on slides arcing with the rotating job and the filler wires fed automatically in the weld pool.
The welding torches will be quick change (1G/2G) type which shall give total flexibility to the machine. The welding parameters like current, voltage, welding speed, wire feed, step over etc will be programmable and controllable via PLC and will have overrides through a hand held wireless remote pendant.
- Process: twin hot wire auto pulsed tig
- Min dia: 42 mm x 500 long before cladding
- Min dia: 34 mm x 500 long after cladding in 2 layers
- Max dia: 2000 mm x 2000 mm long
- Max loading capacity: dia 2400 mm x 2500 long
- Max tilting of torch: 45 deg either side
- Max weight: 7000 kg
- Column height: 4600 mm
- Max height with z slide up: 5600 mm
- Floor space: 7000 mm x 5000 mm
Functions in manual mode:
- Boom “up” “down” movement
- X “in” “out” movements
- Z “up” “down” movement
- Z slide tilt cw/ccw
- Wire for/rev
- Rotator cw/ccw inching
- Rotator 90deg inching for fast truing
- Gas test and flow adjust
Functions in auto mode:
- Cycle start and down slope
- Incr/decr of:
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- Current (5 amps per touch default)
- Voltage (0.2 v per touch default)
- Rotation (10 mm/min per touch default)
- Wire feed (25 mm/min per touch default)
- Step distance (0.5 mm per touch default)
- Avc on/off
- Wire on/off
- Change from base to bore and vice versa
- AC Servo motors for X, Rotator Wire Feeder and Tilting
- AC Servo Brake motor for Z and boom UP/DOWN
- Panel A/C for control panel
- Single power connection required from customer end to our DB
- Base and Bore cladding with AVC
- Auto AVC selection for ID and OD
- Auto speed compensation for taper bores and face cladding
- Weaving if required for face cladding
- Choice of STRING or SPIRAL Bead
- Over ride of Volt|Current|Weld Speed|Wire Feed|Step distance from the Pendant.
- Full control of Power source from PLC/HMI/PENDANT
- Touch Retract function for fixed HF distance and consistent starts
- Torch and wire retract on down slope
- One touch 90 deg rotation in manual mode for quick truing of job
- Dry run (test) mode for parameter checks
- Separate cycle for job cooling
- Data logging of parameters like volt, current, wire feed and welding speed
- Real time graphical representations of essential variables including heat input
- Correction of parameters in real time through Pendant
- Total wire consumption (indicative) in kg on display
- Interlocks with Water flow, Gas flow and XY limits and indication on alarm page
- Interlocks with Lower and Higher limits of voltage and current
- Virtual full function pendant on HMI
- Different pages for Alarm, Data, Display Operation and Data Log/Trend
- XZ positions and Rotator angle on display page
- Engineering parameters on a password protected page
- Remote access to PLC through team viewer or similar software
- Original Legal software and PLC program loaded in a laptop
- Android based Wireless Pendant with unique IP addresses
- Display of values of essential variables on Pendant
- Special weld cycles for cross bores
Special Feature for Cross Bore cladding:
Once parameters are entered correctly and cycle start pressed, it will start cladding at the bottom continuously until it reaches the bottom most point of the cross bore.
At this exact point the start stop function will commence, starting and stopping at the precise locations i.e at the edge of the cross bore. This will continue until the topmost point of the bore before going back to normal clad mode.
This function is theoritically possible but practically may have limitations.
