Equipment Positioning: A fully automated device specially designed for welding end caps of oil collecting pipes in transformer radiators. Through fully automated processes including precise positioning of prefabricated oil collecting pipes, pneumatic cylinder clamping, automatic rotation, and automatic welding by a welding torch, it solves the problems of low efficiency and poor consistency in traditional manual welding, and is suitable for large-scale standardized production scenarios.
Core Functions and Working Principles
Loading and Clamping
Operators place prefabricated oil collecting pipes (with end caps to be welded) into the equipment station. The pneumatic cylinder group automatically clamps and positions them (clamping accuracy: ±0.2mm), ensuring the end caps are concentric with the axis of the oil collecting pipes.
Rotational Welding
A servo motor drives the worktable to rotate 360° at a constant speed (rotational speed adjustable from 5-20r/min). Meanwhile, the welding torch (standard CO₂ gas shielded welding torch) automatically swings along a preset trajectory to complete continuous welding of the end cap circumferential seam. Single welding time only takes 30-60 seconds (depending on pipe diameter).
Unloading and Inspection
After welding, the cylinders automatically release, and workpieces are transferred to the unloading area via a conveyor belt or manipulator. An optional laser weld inspection module (real-time detection of parameters such as penetration depth and weld width) can automatically alarm and reject unqualified products.
High-Efficiency Production Design
Adopts a dual-station rotation structure (one station welding while the other is loading), with a theoretical production capacity of 120-180 pieces/hour, increasing efficiency by 5-8 times compared to manual welding.
Supports quick switching between multiple specifications: By replacing positioning fixtures (quick-release structure, replacement time <5 minutes), it adapts to oil collecting pipes with a diameter range of φ89-φ114mm and end cap thickness of 3-10mm.
Equipment Structure and Components
|
Component |
Design Features |
|
Frame and Drive System |
High-strength cast iron frame, stress relieved by vibration aging; servo motor + precision planetary reducer drives the rotating worktable, positioning accuracy ±0.05mm. |
|
Pneumatic Clamping System |
Uses three-jaw centering cylinder + elastic pressure plate, with stable and adjustable clamping force, compatible with oil collecting pipes of different lengths (200-1900mm). |
|
Welding Execution Mechanism |
Cantilever welding torch bracket (X/Y/Z three-axis linkage), supports torch angle adjustment (0-45°); standard anti-collision sensor automatically retracts for protection in case of abnormalities. |
Equipment Advantages
Stable Welding Quality
Automated control eliminates manual operation fluctuations, resulting in uniform weld formation. The deviation of weld leg height ≤±0.3mm, and the airtightness test pass rate ≥99% (leakage rate <0.1MPa/min).
Significant Reduction in Labor Costs
One operator can monitor 2-3 devices simultaneously, reducing the demand for welding operators by over 80%; no professional certified welders are required, and ordinary workers can operate after training.
Typical Application Scenarios
Applicable Workpieces
Oil collecting pipes for transformer radiators, oil conservator connecting pipes, cooling oil pipes, etc., with a pipe diameter range of φ89-φ114mm. End cap types include flat welding end caps and flanged end caps.
Welding Processes
Fully automatic CO₂ gas shielded welding (solid core wire/flux cored wire), with an optional TIG welding module for stainless steel materials.
Target Customers
Transformer manufacturing enterprises (such as State Grid suppliers), pressure vessel manufacturers, HVAC equipment processing plants, and other large-scale welding scenarios.
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