China Multifunctional Hot Wire TIG Cladding System

In total the automatic surface welding machine for inner walls of valves is composed of 6 systems:
1. Surface welding machine head, 2. Cross operation frame, 3. Control system, 4. Hot-wire power supply, 5. Welding power supply, 6. Water cooling system
II. Technological method:
The automatic surface welding for inner walls of valve adopts hot-wire TIG surface welding technology with welding wire at Φ1.0-Φ1.2 diameter. The surface welding can automatically arrange weld passes by means of automatically increasing one weld pass space after completing surface welding of one circle along inner walls of valves, as shown in figure below.
III. Main technical indices:
1Range of pipe inner diameter: Φ45-Φ800mm.
2Height of pipes: <=1000mm.
3Length of welding torch: 1100mm.
4Automatic tracking accuracy of arc voltage: ±0.3V.
5Pulse current of cladding: 240-260A.
6Arc voltage: 12-16V.
8Diameter of electrode: Φ2.4-Φ3.2mm.
9Diameter of wire: 1.0-1.2mm.
10 Single-layer cladding thickness: 2.5-3.5mm.
11 Flow of protective gas: 8-12L/min.
12 Cooling mode: forced water cooling.
13 Ignition mode: high-frequency.
3. Welding system:
3.1The welding power supply adopts TT5000 DC pulse argon arc welding power supply produced by Austria Fronius Company. The welding machine is characterized by dynamic characteristic, stable and reliable continuous operation, and its pulse function satisfies the technological requirements of transverse surface welding.
3.2TT2200 hot-wire power supply of Fronius Company is adopted to form a complete set.
3.3KD 1500 DH RAP wire feeder of Fronius Company is adopted to form a complete set.
3.4Self-made water cooled automatic TIG welding gun that can bear the rated current of 300A and exhibits perfect protective effect is adopted.
4.Water-cooling system:
FK 4000R-FC water-cooling system of Fronius Company is adopted as matching water-cooling device to satisfy the need of long-time continuous operation.
V.Description of operation:
(1). Preparations before welding:
1.Identify inner diameter and height of main pipes, diameter of perforation, height of perforation and through-in pipe length of the welded parts in accordance with product drawings of the welded parts.
2.Ensure that inner walls of the parts to be welded are cleaned free of oxides and oil, and then lift to underneath of the rotational machine head.
3.Warm up the parts to be welded to the designated temperature, and check whether waterways, electric circuits and gas circuits are normal or not to complete preparations before welding.
(2).Description of automatic welding and electric operation:
This device is mainly used for fully automatic surface welding of inner walls of perforated cylindrical parts, the control system automatically calculates all start-stop positions of welding through the set part data to start and stop welding automatically during welding, i.e. when reaching the edge of hollow holes, welding automatically stops and arc is suppressed, and then the welding gun rotates to the opposite edge of hollow holes to restart arc and welding automatically. During welding the welding gun rotates clockwise. At maximum two perforations are permitted on main pipe, and the axis of perforations must intersect with and vertical to the axis of main holes.
The parts are placed on plane directly without need of rotating turntable, and during welding the welding gun rotates. This device has the function of positioning rotational center of the welding gun automatically. Before welding the welding gun is only required being moved into the holes for surface welding to execute locating procedure, the system will automatically look for center and locate. During welding the arc length control technique is adopted to ensure the distance between tungsten needle and parts is always kept consistent to guarantee better tolerance for irregularity of parts.
1. Startup
Before startup ensure reliable connection of communication cables between the welding machine, hot-wire power supply and control cabinet and reliable connection of welding cables and hot-wire cables with the welding gun and parts. After confirming that each air switch and CB inside the control cabinet are in closed state, dial the power supply key switch on the door of control cabinet clockwise, the power indicator lamp on cabinet door is on; ant then release the emergency stop switch on manual operating box, the power indicator lamp on operating box is on, and meanwhile man-machine interfaces on control cabinet and manual operating box are lightened and the home as shown in Fig.1 and Fig.2 is displayed, the energization is successful.
VIII. Equipment failure and troubles shooting

No.TypesCausesTroubles shooting methods1Unable to arc1. Far distant from tungsten electrode to parts
2. The surface of part not clear
3. Water shortage in water tank
4. Pipe bending
5. metal chips inclusions
6. Failure on high frequency circuit1. Adjust the distance between tungsten and parts within 2mm
2. Clean the surface of parts
3. Add water in water tank
4. Smooth pipe
5. Clean up the metal chips around conductive ring
6. Check high frequency circuit2Tungsten electrode burning fast1. The quality of tungsten electrode is not good
2. Tungsten electrode too sharp
3. Nitrogen impurities
4. Welding gun leaking water
5. Confused with air
6. The parts has much grease and rust stains1. Change nice cerium tungsten electrode
2. Keep diameter of 1-1.5 platform on tungsten electrode end
3. Change nitrogen with purity of 99.99%
4. Repair the welding gun
5. Repair air line or un-tightening nozzle
6. Clean the parts3Porosity1. The nozzle is not tightened
2. Blow weld area by air
3. Welding gun leaking water
4. Break off or block off protection air
5. The parts has much grease and rust stains1. Tighten the nozzle
2. wind-proof
3. Repair the welding gun
4. Repair air line
5. Clean the parts4Weld undulating1. Over-current
2. Arc too high
3. Arc tracking frequency is high
4. Arc tracking accuracy is high
5. Welding speed instability1. Choose appropriate current
2. Arc voltage below 16v
3. Reduce arc tracking frequency
4. Reduce arc voltage tracking accuracy ± 0.3v appropriate
5. Do not change welding speed frequently5Unable locating1. Touch side wall or metallic conductive material during locating
2. No operate to reset
3. Welding machine no enter the "touch" mode1. Put the parts on the center of rotation as possible, and ensure the welding gun to move the center. Remove metallic conductive material around
2. Reset operation
3. Check circuit of welding machine, or no-reset of welding machine or no-enter "manual" mode6Unable to reset1. Touch metallic conductive material when resetting
2. Circumference high frequency interference1. Remove metallic conductive material around
2. Reset awaiting the end of high frequency around7Servo alarm1. Circumference interference
2. Guide rail being caught by sundries
3. Head hit other objects1. Remove the interference around
2. Remove the sundries in guide rail or screw.
3. Remove the sundries around welding machine8No arc voltage tracking1. Touch the cancel tracking by mistake
2. Stepper motor catching
3. Arc voltage tracking accuracy too low
4. Arc voltage interval time too large1. Reset arc voltage tracking
2. Detect stepper motor circuit and stepper motor screw
3. Adjust arc voltage tracking accuracy to±0.3v
4. Adjust arc voltage tracking interval time as normal value9Interrupted arc in welding process1. Touch the power switch by mistake
2. Welding machine alarm1. Check the power switch or electrical circuit
2. Check one (1) or two (2) times on circuit whether is in good condition when welding machine alarming to prevent form overheat.10


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Our welding system and welding technique is top in the world .
It can welding for 30 degree elbow pipe inner side. 90 degree.
For any questions,please feel free to contact me.
Best regards,
Crystal
Harbin Rainbow Technology Co.,Ltd.
www.rainbowtechnology.net
Phone :86 15204631239