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Rotary welding positioner RWP 1350.3221

 

Necesary choice

The green color indicates an element or the part that have to be installed to the machine in one of the offered variants already during its production and the machine cannot be forward into the operation without it, or order it.

 

Construction surcharge

Yellow coloring means an element or the part which have to be installed into the machine in some of the offered variants already during its production. In principle it is a device extending functionality.

 

Free equipment

The gray coloration indicates an element or the part which is possible to fit the machine at any time later. Assembly is possible by the end user. In principle it is an equipment which expands functionality.

... Rotary welding positioner and manipulator of stand design intended for circumferential welding in hard and challenging works in industrial use.

... Positioner is characterized by strong construction, perfect design and sufficiently dimensioned components. High-quality drive guarantees perfect smoothness and constant rotate speed even under eccentric loads by welded product. Each HST CREATIVE rotary positioner is equipped with digital control system R3 specially designed for circumferential welding and successful automation of this process, it also has a controlled output for switching the welding source.

 

 

  • RWP 1350.3221, version Mk.I, is heavy rotary welding positioner of stand design with 1000 mm working plate and maximum working load of 3850 kg. It goes about a flawlessly and high developed system of the highest construction level getting the possibilities of rotary positioners above their conceptual possibilities. The spindle speed range is set on higher level rather for processing of lighter products with smaller diameter, for that the positioner is equipped with less torque.
  • Sandwich steel construction houses a spindle and driving mechanism. The spindle has a flange giving the possibility of fixing the standard working plate with radial grooves, or universal chuck. The mounted drive with motion screw ensuring the tilting of spindle is fixed by the lever storage. Control system R3 is integrated into the positioner chassis and protected by the steel cover with polycarbonate glass cover against the suppression of the welded metal.
  • The tilting of spindle has a motoric drive and there is a possibility of changing the tilting even by the loading of welded product. The spindle is powered with the electric motor which allows shank pitch changes from 0 - 90° under load ensuring the optimum welding position.
  • The work with positioner can be easier while using the foot speed rotation proportional controller which allows to set the speed of spindle rotation. Hand controller is another alternative for the remote control of the positioner. In addition to controlling the speed of rotation both, the foot control and hand controller, may include a selector for the direction of rotation.
  • There is the possibility to deliver the positioner with integrated system for divorcing the forming gas through the spindle.
  • HST CREATIVE positioners are suitable for MIG/MAG and TIG welding methods including pulse arc welding and plasma welding.

 

 


 

Using possibilities in a terms of weld type and technology

  Manual circumferential welding, remote control of the rotation speed, the possibility of switching the direction of rotation with an ergonomically integrated selector.

  Connection of the welding source with communication cable directly to the positioner. 

  Tilting of the spindle continuously by gearbox.

  Motor-driven elevation of the spindle.

  The spindle has a through hole for supplying the forming gas under the weld.

X  The spindle has a through hole for welding of pipes.

X  Linear and radial oscilation.

 

Main benefits

√  Digital stepper motor control provides stable rotational speed also with eccentric loading.

√ The control system supports welding automation. Setting the rotation angle and the welding source switch OFF angle.

√  Welding in manual mode with rotation speed control by proportional foot controller.

√ The positioner can be connected into automated production system with welding source. 

√ Durable design with protection of sensitive parts, transmission of welding current by a professional milled CuCrZr wiper.

WORKING PARAMETERS

VALUE

Maximal static loading 

3850,0 Kg

Torque on shaft of spindle rotation

3780,4 Nm

Torque on shaft of spindle elevation

3402,0 Nm

Speed range 

0 - 2,8 rmp

Working loading **

24/7
TECHNICAL PARAMETERS

VALUE

Diameter of spindle flange - recommended diameter of universal chuck 315,0 mm
Recommended working plate 1350,0 x 21,0 mm
MOTION AXES VALUE 
Rotation of spindle Controlled axis
Elevation of spindle 0 - 90°, axis controlled by buttons
TECHNOLOGY OF WELDING AND CONTROLLING  VALUE
Suitable methods of welding MIG/MAG TIG, Plasma Weld, Laser
Electric current for DC transfered by spindle  450A
Electric current for AC transfered by spindle  550A
Connection of welding device through START/STOP system Yes
Foot switch for regulation of the main spindle and START/STOP function * Yes
ELECTRIC POWER AND CONNECTING PARAMETERS VALUE 
Electric power supply 3x400V/N/PE/50Hz
Compressed air (dry, clean) * 0,5 - 0,7 MPa
Protective gases for root protection * 1 independant way
Description of working place Stand design, recommended to anchor
Level of IP IP 51 C
Input power ***
DIMENSIONS VALUE 
Height 1000 mm
Width 1332 mm
Depth 1995 mm
Net weight (without clamping element) ***  420 Kg

 

* 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.

 

...Subject to change the technical parameters without notice.

....The information given here describes entire R3 control system with all possibilities which however may not be available for every positioner depending on technological possibilities of specific positioner. It also depends on selected positioner configuration. Therefore is always necessary get acquainted with the specific positioner at first whether its technological possibilities, even with regard to the configuration you have chosen, support all functions described below, or not. Information given in here are the overview about possibilities ofcontrol system, not the positioner and do not give explanation of individual components because of difficult comprehensibility of more complicated functions and equipment. For more details, please, contact the technical department or sales of HST CREATIVE.

 

R3 Control system for rotary welding positioners HST CREATIVE

 

√ Simple controlling adapted for easy understanding by the operator.

 Large LED display shows all necessery values of key features.

√ Internal MENU is divided into graphic blocks for intuitive orientation.

√ Digitally controlled delay of welding, rotation speed and other features.

√ Rotation speed of the spindle is controlled by the central rotary knob in standby mode for faster response.

√ Division of the values settings for rotation, for controlling the welding source, welding arm, or forming gases.

√ Program controlled and adjustable welding arm and forming gas control.

√ Possibility to save own programs and settings into a memory of the control system using a programmable interface inside of the system.

 

r3---nahled.jpg

 


 

Technological functions of rotary positioners control system

 

Controls:

  • 2 Step. This function requires the operator to press and constantly hold the foot switch or the button of the hand controller. Working cycle is started and when the foot switch or button of hand controller is released working cycle will stops. This is so-called two-motion mode. It can be active only if the Automatic rotation is not activated. Typical usage of this mode is welding when the operator sits so it is possible to immediately respond to the needs of welding rotation.
  • 4 Step. This function requires the operator to press and release the foot switch or the button of the hand controller. Working cycle is started and when the foot switch or button of the hand controller is press and release once again working cycle will stops. This is so-called four-motion mode. It can be active only if the Automatic rotation is not activated. Typical usage of this mode is welding when the operator is standing. That allows the movement at working place of the operator. Spindle is rotated uninterrupted.
  • Automatic rotation. This is a mode of automatic rotation checking. That means, the spindle is rotating by a predetermined angle from 0 ° to 730 °. By the pressing of the foot switch or the button of the hand controller the working cycle is started which is automatically terminated after reaching the predetermined rotation angle. The angle of rotation can be set in block "Rotation" in the MENU of WORKING PROGRAM, see below.
  • Low speed limit. Specifies the minimum adjustable speed of rotation (RPM) of spindle rotation in STANDBY MODE. I.e. the minimum rotation speed of the spindle from which the speed can be increased. Below this value set in this block the spindle can not be rotated. Therefore, if you want to use a full speed range of positioner, it have to be adjust to 0.001 rpm. Maximum adjustable value is always equal to the maximum possible speed of specific positioner, please see the production label.

 

Rotation:

  • Diameter. Adjusting of welding diameter. Control system R3 will automatically calculates the progressive welding speed - the relative feed rate of the torch. This value will be displayed in the STANDBY MODE on display screen. Settings in centimeters in the range from 0.0 to 300.0.
  • Rotation direction. Settings of direction in the rotation axis (Choice: Clockwise, or counterclockwise).
  • Rotat. delay. The function can be usefull for a better material melting before welding. Adjust the delay between switching ON of the welding source and starting of the spindle rotation. Settings in seconds with an accuracy to one-tenth in the range of 0.0 to 15.0 sec.
  • Angle of rotation. Choose the total angle by which the spindle will turns around its axis. The limit is 730 °. This function is active only when Automatic rotation mode is activated in block "Controls", see above.
  • End welding angle. It defines the point where the control system R3 switches OFF the welding source. Settings in angle degrees. Limit value is 730 ° but the total value can not be higher than the value adjust in the Angle of rotation. This function is active only when Automatic rotation mode is activated in block "Controls", see above.
  • Return to 0. It defines the returning of the spindle to initial position to find the starting position of welding =(e.g., directionally defined tools), or to unwrap the energy and gas hoses. This function is active only when Automatic rotation mode is activated in block "Controls", see above.

 

Gas:

  • Function is active only when the positioner is equipped by the valve for the switching of the gas (optional element).
  • Pre-gas. Serves to fill up the space of weldment root by protected – forming gas. It defines how long the gas valve will be switch ON before the system gives a command to ignition of the welding source. Settings in seconds in the range from 0.0 to 15.0 s. If 0.0 s is adjusted the function is inactive.
  • Pos-gas. It defines a time how long the valve will be switched ON after the command to switch OFF the welding source has come. Settings in seconds in the range from 0.0 to 15.0 s. If 0.0 s is adjusted the function is inactive.

 

Torch:

  • Function is active only when the positioner is equipped with a pneumatic arm for full welding automation (optional element).
  • Before welding. Choose the type of the movement of the torch to the welded product before welding process. (Choice: Automatically, i.e. torch will be incline automatically to the product when the working cycle is starts, or Manually, i.e. the torch waits for a command via the key on the control panel, before starting of the working cycle)
  • After welding. Choose the type of the movement of the torch from the welded product after welding process. (Choice: Automatically, i.e. the torch will be moved automatically from the product after the ending of the working cycle, or Manually, i.e. the torch waits for a command via the key on the control panel, after the ending ofthe working cycle)

 

Welded parts:

  • It can go about any part that fulfils the dimensional and weight restrictions of positioner without limitation of welding methods.
  • The welding process can take place at any angle of inclination of the spindle within the capabilities of positioner. This is completely unindependent on the eccentric load of the positioner by means of digital drive concept.
  • The control system is able to control the angle of rotation and the angle of switching the welding source off unindependently to each other. There is a possibility to reach the perfect connection of weld bead by the automated welding. Of course, there is a possibility of manual controlling.

Basic configuration of the machine

C

Rotary welding positioner RWP 1350.3221

Complete base ready for precise configuration

(( 1 )) Selection of controller type and clamping tools
(( 2 )) Selection of technological accessories and improvements
(( 3 )) Selection of welding source and other accessories and complements

Basic equipment for automatization

1.1

Foot controller FPS01. ON/OFF

Basic type of foot controller with START/STOP function

(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS02, FPR03/04, HCR01/02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected to standardized socket at any time and selected in control system

1.2

Foot controller FPS02. ON/OFF>L/P

Foot controller with START/STOP function and extended functionality for changing the direction of rotation

(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01, FPR03/04, HCR01/02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system

1.3

Foot controller FPR03. ON/OFF+RPM

Foot controller with START/STOP function and extended functionality for proportional speed regulation

(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01/02, FPR04, HCR01/02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system

1.4

Foot controller FPR04. ON/OFF>L/P+RPM

Foot controller with START/STOP function and extended functionality for speed regulation and dir. changing

(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01/02, FPR03, HCR01/02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system

1.5

Hand controller HCR01. ON/OFF+RPM

Hand controller with START/STOP function and extended functionality for proportional speed regulation

(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01/02, FPR03/04, HCR02)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system

1.6

Hand controller HCR02. ON/OFF>L/P+RPM

Hand controller with START/STOP function and extended functionality for speed regulation and dir. changing

(( √ )) Necessary for intended function of machine, HAS AN ALTERNATIVE (FPS01/02, FPR03/04, HCR01)
(( Combination )) None
(( Options )) None
(( Condition )) Can be connected any time to a standardized socket and selected in the R3 control system

Options for automatization of welding

2

SET for mounting of input of forming gas through spindle with solenoid control

SET for solenoid control of forming gas and its supplying under the weld through hollow spindle

(( √ )) Auxiliary element that improves the operation by switching the forming gas, NO ALTERNATIVE
(( Combination )) None
(( Options )) None
(( Condition )) Assembled and mounted directly at the production

3

Cable for connection of welding source (without connector of welding machine)

Separate cable terminated with connector on the machine side with no connector on the welding source side

(( √ )) Cable for connecting to the welding source for switching the welding arc, NO ALTERNATIVE
(( Combination )) None
(( Options )) Other cable lengths can be ordered on request
(( Condition )) Can be installed in a simple operation without use of special tools

Other accessories and clamping

4

Ground cable 50 mm2, length 3,0 m

Separate ground cable on both sides terminated with a standard connection of 13mm

(( √ )) Copper cable closing the electric arc between the welding source and the machine, NO ALTERNATIVE
(( Combination )) None
(( Options )) Other cable lengths can be ordered on request
(( Condition )) Can be installed in a simple operation without use of special tools

5

Legs for increase of stability when the base is not firmly fix to the floor

Structural accessory to increase stability if the machine is not firmly anchored to the floor

(( √ )) Legs for increase of stability when the base is not firmly fix, NO ALTERNATIVE
(( Combination )) None
(( Options )) None
(( Condition )) Can be installed in a simple operation without use of special tools

6

Extension of R3 control system for additional 34 memory boxes

SW extension of R3 control system with programmable environment with possibility of saving other programs

(( √ )) Extends R3 control system by 34 memory boxes for saving of own programs, NO ALTERNATIVE
(( Combination )) None
(( Options )) None
(( Condition )) Installed directly at the production

0.A

Working plate 1350x21

Working plate of 1350mm with concentric circles, thickness 21mm, 8 grooves 215x17mm, weight 229,9kg

(( √ )) Plate can be mounted on spindle flanges without transition elements, HAS AN ALTERNATIVE
(( Combination )) None
(( Option )) Other plates can be choose, but these have to be mounted using transition elements
(( Condition )) Can be installed in a simple operation without use of special tools

0.B

Universal chuck 315mm

Three-jaw universal chuck with gears adjusted for welding, hole 108mm, weight 42.5kg

(( √ )) Chuck can be mounted on spindle flanges without transition elements, HAS AN ALTERNATIVE
(( Combination )) The chuck can be fitted with extended segments (custom made solution)
(( Options )) Other chucks can be choosed, but these have to be mounted using transition elements
(( Condition )) Can be installed in a simple operation without use of special tools

Rotary welding positioner RWP 1350.3221

Rotary welding positioner RWP 1350.3221

Rotary welding positioner RWP 1350.3221

Rotary welding positioner RWP 1350.3221