Pillow plate welding machine
I.No. 1 CNC CONTROL DEVICE FOR WELDING STAINLESS STEEL PLATES WITH
PLASMA AND TIG AUTOMATIC SYSTEM,
for the production of heat exchangers from steel sheet of up to 2000mm
width, with the following characteristics: reference Your drawing
PUNTA20R6_L7, without Roller Conveyors and Applying Protection
Film.
a. The plant positions the spot-welding units and the sheets to be
both spot and edge welded. The welding units are carried on pneumatic
driven slides for vertical travel and on two independent motorized
axes for transversal-travel. Each axis carries two torches, one for
spot and transversal seam weld, and the other for longitudinal seam
weld.
The sheets are transferred by two couples of motorized rollers that
allow sheets of considerable length to be processed, with a minimum of
1600 mm.
b. An electronic device (PLC) controls the machine, governing via the
program the logical sequence of the processing cycle. The PLC is
connected to a touch sensitive display terminal (Touch Screen), that
allows the variable parameters for the single processes, times and
positions for welding to be input and memorized in the resident
programs.
c. Two spot-welding and two continuous-welding units are provided each
with a welding generator, made up of a torch carriage, with a special
patented sheet holder, for longitudinal, transverse and spot welds.
d. N° 1 SCOTCH BRITE BRUSHING UNIT to clean the bottom side of dimple
jacket from the welding’s oxide, it is made the brushing unit inside
of welding machine; between the torch’s crossbeam and the output
rubber roller. The unit moves transversely on carriage by pinion rack
system; to the vertical position controlling, a pneumatic actuator
rotates the brushing unit’s arm. The brushing is made by a
scotch-brite dish.
e. N° 2 FRONIUS TT3000 JOB TIG generators for seam welds
f. N° 2 SBI PLASMA SPOT WELDER PSW-500 V2.1 generators for spot
welds.
g. Spot welding, which employ two spot-welding units, are carried out
on a copper bar with cooling.
h. The longitudinal weld, using two spot-welding units, is effected on
a copper roller.
i. The transversal weld will be done with one of two longitudinal
torches 90° rotate.
j. The welding devices, and accessories are carried at the side of the
machine, while the respective controls and electrical components will
be installed in the electric panel:
k. The electrical energy supply rating is approximately 40 kW,
including the welding generators, supplied at 400 Volt, 3 phase, 50
Hz, plus neutral and ground.
l. No. 2 Remote Weld Monitoring Camera System, with manual control for
longitudinal and transverse seam weld on the edges of the jacket
sheets.
m. The machine will be equipped with applications:
1. No. 2 Application Cold Wire System”, for longitudinal and
transverse seam welds.
2. PUNTACAM APPLICATION. CAD-CAM software that allows to create the
work program from a drawing file. With this application the machine is
added of an industrial computer to work with Ronzani Puntacam
software.
3. ARCAM APPLICATION. Added to Puntacam software and special rotating
equipment, allows to make arcs and diagonal seam welds.
With this application the transversal seam weld will be done with one
of two longitudinal torches 180° rotate.
All communication in panel will be prepared in Polish language.
GENERAL DESCRIPTION
THE AUTOMATIC SYSTEM OF DIMPLE JACKET WELDING is suitable for working
sheets up to 2000 mm, wide and 6000 mm long, with overall dimensions
The machine has the following characteristics:
• The automatic system of welding executes the positioning of the
torches for the spot and seam weld around the border so as to form the
dimple jacket structure. The torches are fixed on a pneumatic slide
with pneumatic cylinders for vertical movement and on two motorized
independent pneumatic slides for transversal movement. The sheets are
moved by two pairs of motorized rolls which allow the processing of
sheets of remarkable length. The minimal length is of 1600 mm.
• The welding parameters are controlled by the PLC with a specific
software that controls the operation schedule. The interface of
communication between the operator and the machine consists of a touch
screen control panel from which it is possible to select the position
and the welding time programmable in a residential memory – copy to
hard disc.
• There are 2 working units with 2 generators. Two units are made up
by 2 slides hold-torch with special equipment pressing sheet . The TIG
torches groups can be turned by 180° to permit the transversal and
longitudinal seam welding, or diagonal and arc seam welding.
• The Plasma spot welding is done on an inferior crosspiece that
supports a branch bar, with connection to ground and distribution of
the protecting gas by cooling system. This crosspiece is lowered
during the movement of the sheet to prevent damages on the inferior
surface.
• The continuous welding is done on a Copper and Aluminium roller,
with connection to ground; the TIG torches can be turned by 180° on
the roller to permit the transversal and longitudinal seam welding, or
diagonal and arc seam welding.
• The components of welding are assembled under the roller
conveyor.
• The machine is provided by a monitoring system for the
longitudinal and transversal welds, this system has 3 cameras fixed on
its support with optical screen photosensitive and two monitors
located on the control board. The position of every single torch can
be adjusted manually by 3 joysticks situated on the control pulpit.
• Longitudinal and transversal seam welds can be realized on the
edge of the sheet thanks to a monitoring system. The position of every
single torch can be adjusted manually by 3 joysticks on the control
pulpit.
System is working under control procedure and will switched off
machine in below circumstances:
- no power or any medium needed for process : electricity, water
cooling, gas for TIG and PLASMA welding system.
II. TECHNICAL DATA OF MACHINE
Machine is prepared for welding steels according group 8, 9, 10.
- Dimple jacket machine RONZANI
Max sheet width 2000 mm
Min sheet length 1600 mm
Pillow plate thickness min 0.6 mm max 2.0 mm
Base plate thickness min 1.0 mm max 20.0 mm
Longitudinal Feeding sheet by 2 couples of rubber rollers
Longitudinal Feeding sheet speed max 8 m/min
Longitudinal Feeding Engine OMRON Sigma II 220 V 400W 1.27 Nm 3000
RPM
N° Torch’s transversal carriage 2 (each carriage has 1 Plasma + 1
TIG)
N° Plasma torches 2
N° Tig torches 2
Max transversal stroke for each carriage 1800 mm
Transversal carriage speed max 8 m/min
Transversal Feeding Engine OMRON Sigma II 220V 200W 0,637Nm 3000
RPM
Lower side cooling bar: the copper bar has two different circuits, the
first with
water-cooling circuit used to refrigerate the bar itself, and the
second with
protection gas used to protect the dimple jacket during welding.
Water chiller HITEMA model ECA 001
Gas cooler generally mix Ar + CO2
copper bar length 2050 mm
- SBI PLASMA SOURCE DC PSW – 500
Supply voltage: 3x400V+N/50Hz
Power connection: 5x32A CEE plug, 6mm²
Max. power consumption (50% on-time): 15kVA
Cos ϕ : 0.99
Max. impulse current: 510A
Degree of protection: IP23
dimensions (L x B x H): 1050x360x750mm
weight: ca. 70kg
Control range plasma gas 0.2 – 5 l/min
Control range protective gas 0.2 – 20 l/min
- FRONIUS TIG SOURCE TransTig 3000 Job
Main voltage 50 -60 Hz 3 x 400 V
Main voltage tolerance +/- 15 %
Main fuse protection (slow) 3 x 400 V 16 A
Primary cont. power 3 x 400 V -100 % d.c. 6,1 kVA
Cos phi 1 0.99
Welding current three-phase TIG 3 -300
Welding current three-phase MMA 10 -300 A
Welding current single-phase TIG 3 -300 A
Welding current single-phase MMA 10 -180 A
Welding current at 10 min / 40 °C 50 % d.c. at 300 A
Open-circuit voltage 85 V
Standard working voltage TIG 10,1 -22,0 V
Standard working voltage MMA 20,4 -32,0 V
Ignition voltage (Up) 10 kV
Type of cooling / insulation class AF / B
Dimensions l/w/h (mm) 560/250/435
Dimensions l/w/h (inches) 22.0/9.8/17.1
Weight 24,2 kg
Marks of conformity CE
Protection IP 23
- Lower brushing unit
Travel length: 2100 mm
Max work length: 2000 mm
Feeding speed : min 2 max 9 m/min completely variable
Pneumatic Slewing function; max work pressure: 0,6 MPa
Diameter of wheel: 250 mm
Width of wheel: 100 mm
Wheel rotation completely variable up to 3000 RPM
Hood for dust suction
Power of grinding motor: 3 kW 2poles 400V/50Hz 3 Phases.
Power of carriage motor: 1,1kW 4poles 400V/50Hz 3 Phases.
- Control panel PLC programmable controller. All functions can be
controlled
separately.
Dimension: 1200 mm x 1100 mm x 1615 mm
Remote assistance by Ethernet connection
Computer Dell OptiPlex 780 or similar
Software Cad/CAM EdgeCAM Milling Base
- Electrical features
Operating Voltage and frequency 3 x 400Volt + N + PE- 50 Hz
Installed power 35,0 kW
Main switch 4 x 63A
Electric line 5x16 mm2
Compressed Air Supply Pressure. 0.6 MPa (6 bar).
- Machine dimension
Length: 2200 mm
Width: 3100 mm
Height: 2200 mm
Pass line: 915 mm
Machine Weight 2,5 tons
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