1. General description
ZF series automatic straight seam welding machine is mainly used for cylindrical straight seam welding, and welding carbon steel and stainless steel sheet in 0.5 ~ 3mm thickness.
2. Main structure
ZF series automatic straight seam welding machine consists of main components: frame, principal axis, running gear, pressed bodies, locking mechanism, welding torch and lifting device, wire feeder, operation box, air source treatment system, electrical control system.
1) Frame:
divided base, cabinet, and beams, cantilever frame structure is designed to facilitate operation of sufficient strength and rigidity, to be as the skeleton and the carrier plane. Beams with blade, with spindle clamping the work piece on the copper pad, and remove heat evenly when welding. Knife-edge using keyboard-style pendulum structure, an internal air bag pressed, each knife-edge pressure evenly; copper knife-edge Crimping work piece to prevent work piece damage.
2) Principal axis:
It is made from seamless steel tube structure, the copper pad on the above, sealed tank inside the copper pad, which pass argon gas and cooling water; shaft flange with slip-ping button below the screw can be to change the distance between spindle and copper knife-edge, to adapt to different thickness of work piece; principal axis are equipped with a flange-side end-positioning plate for positioning the work piece.
3) Running gear:
The trolley is used to complete welding run in a straight line, it adopt imported DC servo motor, worm gear reducer, gear rack drive, with variable speed, so that make the torch run a smooth uniform movement in the high-precision linear , to ensure the welding quality. One trolley is equipped with a welding torch and adjust the lifting device. Lifting the gun and cylinder linear rail-oriented drivers. And it is also equipped with cross fine-tuning device for accurate adjustment of torch position. In addition, the control box fixed in the trolley and can move along with the trolley to facilitate the operation.
4) Locking devices:
Locking device connect with principal axis and stents, to enhance the stiffness of the principal axis; at the same time, locking device is also equipped with proximity switches, the electrical interlock to enhance reliability.
5) The wire feeder:
In the welding process, it can automatic fill wire welding, wire feed head adopts dual-drive wire feeder, it has strong wire feeding ability, smooth; strong in guide wire device interchangeability, smooth wire feeding can meet the wire needs to fill a variety of processes.
6) Clamping device:
Knife-edge use of keyboard-style pendulum structure, an internal air bag pressed, the pressure evenly, copper knife-edge Crimping work piece to prevent work piece damage. (See Figure 1)
7) Electric control system:
Control by using the PLC programmable, main electronic components using imported products, pneumatic components from a joint venture company; the whole system compact structure, high degree of automation, security, and reliability.
3. Main Technical Parameters
Technical Parameters | ||
Model | ZF-2000 | |
Welding Speed (mm / min) | 300～1300 | |
Maximum Welding Stroke（mm） | 2000 | |
Suitable Work piece Diameter（mm） | φ250～φ900 | |
Support Shaft Size（￠） | 200 | |
External Interface | Power Supply | 220V AC，50Hz |
Gas Source | compressed air（pressure≥0.6MPa） | |
The technical parameters above table may be subject to change due to the continuous improvement (subject to change without notice)
4. Operation
1. Welder operation (Please refer to "welder manual")
Welding preparation: in order to ensure welding machine and other auxiliary equipment in normal operation, please firstly check the supply of water, electricity and gas, are reliable to grounded.
2. Work piece clamping:
clamp work piece from the starting welding point, setup should guarantee that welds without leaving any gap, welding the end point without leaving any gaps; (or remain 0 ~ 1 mm / m gap, according to length of the work piece, thickness and welding process parameters). Detail as follows:
a. According to the length of the work piece, adjust the trip of the trolley.
b. Moved the work piece to spindle to face positioning plate. to adjust the work piece patchwork alignment groove center of copper pad.
c. Press "front plate and back plate" to keep all the blade press tightly in the work piece.
2. Welding torch adjustments:
Through the cross fine-tuning and welding torch fixture, make adjustment of alignment to welding gap.
4. Welding operations
ZF series automatic straight seam welding machine, it has two work modes: manual operation or automatic operation is available for users to select.
1) Manual operation:
All functions have to run by rely on independent control function button, generally run early in the device, adjusting the welding quality and performance to the best condition. Details are as follows:
a. Clamp tightly the work piece.
b. Regulate the operating switch on the operation box into "manual" model.
c. Press "gun up / down" button, so that gun fall to weld seam, then regulate the cross fine-tuning device to maintain the best arc-starting gap with the weld gap.
d. Press "gun right" button to move gun, at the same time, adjust the speed knob to the optimum welding speed, memory speed instruction instructions instrument value.
e. To adjust limit block according to the length of the work piece.
f. Confirm it correct after several adjustments.
2) Automatic Operation:
After many times of manual operation, operator may welding work piece in batch under the welding quality reach permission.
Details are as follows:
a. Welding arc wires are connected well with welding machine.
b. switch the operating on the operation box into "automatically" model, clamp the work piece according to the above "work piece clamping", and consider whether it also needs to feed wire. Press "automatic welding" button, the device will run automatically.
c. Automatic welding process:
Gun down, start arc – welding horizontally (forward right) - closed arc welding torch (welding ends) - welding torch up, back (forward left).
