AWL SUPERFINE LIFT 1100.T

Basic description

  • AWL SUPERFINE LIFT 1100.T is a modern welding automat designed for longitudinal welding using cooper underlay and both - sided clamping of the weldment of the maximal lenght of 1100mm. Root of the weld is protected by inert gas, system Cascade Gas.

  • The detailed mechanical construction, electronics, drivers and sophisticated technologie of welding are a good example of highly sophisticated technological unit for welding with TIG DC, TIG AC, Plasma Weld DC, Plasma Weld AC Method by welding of non - alloy steel, CrNi Steel, copper, aluminium, titanium and other materials like galvanized steel and aluminized steel
  • The steel construction of power arms of the machine is designed as a half - shell and spatial construction characterized by controlled flexibility. The overpressure of the workpiece to the welding mandrel is realized pneumatically through the gear levers with laterally adjustable segments made out of copper which take the heat from welding precisely away. Copper segments are equipped with grooves enabling optimal settings depending on the thickness and type of welded material. Underlying torn is fastened superficially into the machine construction through the central nut with lever plotting of the bending forces, the backing sheet on the thorn is made out of the high - quality alloy CuCrZr and because of this fact has a high lifespan in comparism with ordinary copper

  • The base of the machine is made out of steel and is carried by two ergonomically formed legs. All the electronical elements of the machine and the cooling system are located inside the base. The base can be delivered about 300 mm higher and by this step the maximal diameter of welded product can be higher (1500 mm)

  • Welding torch is carried by the precise support by which the torch is tilted into the horizontal position, so conditions of parts of the torch can be controlled and the failure caused by defect of these parts minimalized. In the main supporting part the advanced driving system with hole through spindle using the system motor > planetary gearbox > reinforced belt drive. Positioning with exatness of 0,2 mm and the range of speed from 10cm/min to 300 cm/min, the feed is 600 cm/min and makes the time between the welding process and its preparation shorter
  • The system of gas management functionality is one of the components of the device which is worth mentioning. The machine is equipped with three very precise flow - meters that accurately report the flow. Route 1 is the gas flow to the welding torch, route 2 is used to provide gas flow to the segments, route 3 is used to separate gas flow adjustment system Cascade Gas thus forming the weld as the weld root. The Cascade Gas system automatically splits forming gas into sections that open and close according to the current position of the torch that 10 or 15 out of holes can be opened at the same time. That always depends on the actual position of the torch. The result is that the consumption of the forming gas is reduced significantly by at least 70%. All the routes are equipped with precise flow meters. The Cascade Gas system is patented by HST CREATIVE and this solution reduces forming gas consumption by at least 70% and offers manufactures another dimension

  • The machine can be equipped with a highly sophisticated cold wire feeder HST CREATIVE CW 07. By using this feeder, thicker materials can be welded, which is required by the production of pressure vessels. CW 07 is fully controlled by the control system of the machine and the final exactness of feeding is 99% because of the settings possibilities

  •  In addition, construction equipment, we finally solved the problem of welding fume extraction by integration of flexible air duct directly to the structure. 95% of welding fume extraction are removed directly from the source (there are no fumes in the room) without negative effect on welding process, it is an advantage especially by welding of galvanized materials. Connection of this device is solved by tube or pipe with the diameter of 100 mm
  • The device is controlled by LCS 06 control system which has been designed especially for linear welding automats. The system has a wide range of sophisticated functions by which all the requirements of linear welding are solved. LCS06 controls the whole spectrum of interesting and sophisticated functions including UP/DOWN logic.

 

... The machine is suitable for working in the industry in different industrial branches. The machine is remarkable for its precision and sophisticated design. On the machine it is possible to weld tubes, galvanized pipes, smoke fues,... The control system LCS 06 provides a uniquely sophisticated attitude to functions, including the digital communication with a welding machine


 

Benefits of product

 

√  Mechanical construction with controlled flexibility and clamping by pressure segments with enable to adjust clamping pressure and distance for optimal results

  Use of high - percentage alloy of CuCrZr for underlying lath and for pressure segments, which can rapidly increase the lifespan of consumables 

  Positioning of the torch in horizontal position enables to do the vizual control of parts of the torch easier. By this step is the amount of rejects, caused by defects of the torch, eliminated 

√  Three - way system of technical gases with unique Cascade Gas system, which saves about 80% of gases, used for forming of root of the weld.

√  Liquid cooling system integrated directly into the construction of the machine enables to cool the thorn and the torch at the same time

  Cold wire feeder, controlled directly by control system, can be added and enables to perform normalized layered welds 

√  Integrated exhaust system suitable for high - vacuum extraction directly from the torch with high efficiency of exhausting of high - smoky methods 

√  Control system LCS06 with sophisticated functions and special - purpose programs for controlling of phase production and increasing of productivity 

Technical parameters

WORKING PARAMETERS

VALUE

Maximal progress speed of welding

 300,0 cm/min

Minimal progress speed of welding

 10,0 cm/min

Maximal specific pressure by clamping the tube/shell

  250,0 N/mm2

Minimal specific pressure by clamping the tube/shell

0,35 N/mm2

Duty cycle **

24/7
DIMENSIONS

VALUE

Maximal lenght of the shell/tube 1100,0 mm
Minimal lenght of the shell/tube 50,0 mm
Maximal diameter of the shell/tube (shape of the shell/tube is precisely rounded)
1500,0 mm 
Maximal effective diameter of the shell/tube  1800,0 mm
Minimal diameter of the shell/tube (choice of optimal thorn for welding) * 60,0 / 70,0 / 80,0 / 100,0 mm
Maximal effective thickness of welded shell/tube 3,0 mm
Maximal thickness of welded shell/tube 4,0 mm
Minimal effective thickness of welded shell/tube 0,25 mm
MOTORIC AXISES  VALUE 
Movement of the torch head Controlled axis
Precise adjustment of the torch position +/- 10,0mm,manual axis
Precise adjustment of feeding the wire position * +/- 5,0mm, manual axis
TECHNOLOGY OF WELDING VALUE
Suitable methods of welding TIG, Plasma Weld
Controlled forming of root of the weld Systém Cascade gas
Connection of welding device through START/STOP system Yes
Controlling of start sequence of welding machine  Yes
Precise controlling of pneumatic pressure of welded shell/tube Yes
Automatic paraelling of clamping the shell/tube * Yes
Controlled feeding of the wire *

Yes

POWER SUPPLY VALUE 
Power supply 3x400V 50/60 Hz
Pressure air (dry, clean) 0,55 - 0,9MPa
Protective gas for welding torch  2 independant ways
Ochranné plyny pro ochranu kořene svaru 1 independant way
Design Stand design
Level of IP IP 21
Input power for installation ***  
DIMENSIONS VALUE 
Height  
Width  
Depth  
Net weight ***  

 

* Optional item, or more versions are available which differs according to function. Mentioned parameters are valid for maximal options.

** 8/5 = lower loading in one duty period /// 16/6 = industrial loading /// 24/7 = non - stop loading

*** Parameters can not be provided with 100% correctness. Configuration of the machine must be taken into consideration. Mentioned parameters are valid for reaching maximal effective value.

Functionality in detail

 LCS 6 - digital control system is designed specially for linear welding machines. This system solves most of the needs during welding of longitudinal welds and contains a range of highly sophisticated functions.

  

Working modes

 

  • Fully automatic mode is available.

  • Manual welding mode is suitable for single-part production.
  • No Weld mode - does not weld, facilitates parameters setting of welding and the whole working cycle.

 

Welding modes

 

  • Uninterrupted welding mode

  • Tack welding mode allows make any amount tacks

  • Spot welding mode

  • Spotting with owerwelding mode
  • Mode with displaced start of welding
  • Centre start mode
  • Starting tack mode

 

Working function

 

  • Setting of forming gas pre-flow.

  • Setting of welding starting position.

  • Setting of torch moving delay for beginning material heating.
  • Setting of weld lenght.
  • Setting of switching off welding machine position.
  • Stiching function allows to make any amount of spots at any lenght.
  • Welding machine program option.

 

Programming

 

  • LSC 6 is system, which allows user to save complex settings of particular product in the memory boxes.

  • It is possible to name the memory boxes verbally and to pair them with programs on the welding machine.
  • 30 of free memory boxes

 

Supporting functions

 

  • Confirmation of  a welding arch. LSC 6 waits for the signal from the welding machine, when the signal is received  a program begins to use set working cycle. This is a fundamental function for welding of thin materials, especially aluminium welding. This function also eliminates unreliable ignitions.

  • Controlling system. High technical level of this product is emphasized by controlling system, which check correct settings and also block the machine in case of functional or user mistake. All faults are namely displayed and indicated by LED "Incomplete".

  • AR function. Very unique AR function allowing to weld metal plates, which are not cut straight, without switching or rotating the material. This function is very substantial in practice, because it is able to weld inaccurately cut plates with productivity, which the same machine without this function can never achieve.
  • Mid-product welding function. It allows to weld from the middle to the right, then the torch returns to the middle at the place already welded and then makes a weld to the left. This function is suitable for welding of thick materials, when the tubes are extremely inaccurate.

Options

 

 615x517_konfigurace.jpg

Necessary choice

Neccesary to be added to the machine. If you have any questions do not hesitate to contact us. Your offer can be successfully finished without these options.

Constructional surcharge

These options must be added to the machine during the production process. Later it can be connected with high costs or it is fully impossible.

Free options

These options can be mounted anytime. Later order of these options does not mean higher costs.

 

 

Basic configuration of the machine

A

AWL SUPERFINE LIFT 1100.T

Linear welding automat with maximal lenght of the weldment of 1100mm, diameter of welded material of 1200 mm, thickness of material of 0,3 - 3,0 mm.

Delivery includes the machine equipped with sophisticated control system LCS06, integrated cooling system of 16kW, system of forming gas Cascade Gas and precise regulation of working pressure, floating flow meters, foot controller start/stop (2x), console for welding source.

1.A

Thorn type 1100.1.066 FORM

Thorn for minimal dimension of product 70 mm for 1100.T version (∅ 66 mm)

1.B

Thorn type 1100.1.1076 FORM

Thorn for minimal dimension of product 80 mm for 1100.T version (∅ 76 mm)

1.C

Thorn type 1100.1.1096 FORM

Thorn for minimal dimension of product 100 mm for 1100.T version (∅ 96 mm)

Basic equipment for automatization

4

SUPERFINE base with hydraulic lift

For tubes of the diameter up to 1500mm

9

SET TIG COLD WIRE HEAD

Wire feeder of cold wire CW07 with TIG torch head and SET for feeding the wire of 1,0m with micromovements for precise adjustment

10.A

SET PLASMA COLD WIRE 250A

Feeder of cold wire CW07 and head of the torch of PLASMA method equipped with set for feeding the wire 1,0m with micromovements for adjustment of final position. Shield as the protection while welded is also included (PAW method).

10.B

SET PLASMA COLD WIRE 150A

Feeder of cold wire CW07 and head of the torch of PLASMA method equipped with set for feeding the wire 1,0m with micromovements for adjustment of final position. Shield as the protection while welded is also included (PAW method).

11.A

ARM 2 SLIDE MICRO

Precise system of CW cold wire feeding +/- 5mm (axis X/Z)

14.A

SET NO WIRE TIG HEAD

Segment for additional gas cover of the weld (for TIG torch)

14.B

SET NO WIRE PLASMA HEAD

Segment for additional gas cover of the weld (for Plasma torch)

Pictures and photos

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL

FINGER AWL