Cylinder Welder - Hydraulic Cylinder Welding Solutions
Our cylinder welders are developed for applications ranging from flange welding, Circular port welding, Rectangular port welding, Rod-eye welding, End cap welding and Name plate welding of hydraulic cylinders and tanks by GMAW or GTAW process.
Cylinder Welder Features & Benefits
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- Faster Movement : Runs up to 120mm/sec
- Swift Welding : Variable from 5mm/sec to 30mm/sec
- Complex profiles ranging from, Linear, spherical, conical & helical interpolation can be done
- Wide screen human machine interface
- Load capacity : 1 ton
- CAD2MOTION software support included
- DXF Import programming option available
- Closed cage cable management systems
- Gearbox upgraded from 16Arcmin to 6Arcmin precision set backlash
- Milled Bottom base frame mounting bed
- Motion Control Systems with 64bit compared to 32bit position precision registers & with 533Mhz Arm11 processor
- Servo Systems upgraded form MINAS to A6 which optimises complete closed loop motion control with safety interlocks.
- Additional Input & Output Module for safety systems & provision for expansion of axes
- New & Improvised NIKIT – Teach User Interface with 100 lines of single teach program & expandable up to 250 lines
- IIOT module integrated for online data & alert monitoring (requires internet connectivity). All the data logging & machine process alert files with program upgradation can be done online
Lap Joint
Multiple Pass
Butt Joint
T Joint
Curvature
Oscillation
Weaving
Corner Joint
Cylinder Welder Applications
Circular Port
Name Plate
SS Accumulater
SS Pressure Cover
Rectangular Port
Rod-End Welding
Aluminium Tank
SS End Fillet
BOOM Cylinder
FET Cylinder
STEERING Cylinder
Pressure Vessels
Data Logging and Cloud Monitoring
The machine Data Logger represents leading edge technology in welding and machine data collection and logging. The micro-controller based weld data acquisition system provides a means of measuring and documenting all basic machine parameters when used with external PC.
Cloud-based monitor that requires either an Ethernet connection or can be used on a cellular network. Once the physical connections have been set and powered, the rest of the setup is
Basic Feature
- Input & Output Monitoring
- Maintenance Monitoring
- LAN Module
- Sequence Reports
- Purging Enable / Disable
- Remote Monitoring
- Machine Data Logging
- Weld Cycle Limits
Advanced Feature
- Error Report Sheets
- Gas Pressure Monitoring
- Wire Feed Monitoring
- Air Pressure Monitoring
- Camera Monitoring System
- Operator Data Logging
- + Basic Features
Monitoring Benefits
Operator Data Logging
- Can get the reports of operator work timings in the machine.
Air Pressure Monitoring
- Complete machine pneumatic line air pressure can be monitored.
Error Report
- Machine errors, input/output errors, sequence errors etc. Can be monitored through the report generated by the system.
Sequence Report
- Machine sequence. Flow chart can be monitored.
Machine Data Logging
- Machine used time, production rate, power consumption etc can be monitored.
Weld Cycle Limits
- Can monitor and set the weld cycle limits per shift or based on the production requirements.
Wire Feed Monitoring
- MIG / TIG wire feeding can be monitored. (Helps in planning for the pre ordering of wire spools without interrupting the production)
Maintenance Monitoring
- Machine maintenance report, online service, programming modification/ change, copy etc can be done.
Purging Enable/Disable
- Fine art of getting a URUNAMI weld bead by creating a gas chamber inside the component. (feature is available only for the orbital welder)
Camera Monitoring System
- Can monitor & access the camera setting and features. (If camera is used in the machine)
Remote Monitoring
- All features of the machine can be monitored over the internet through this Machine facility.
LAN Module
- LAN cable connecting port is provided to connect & transfer the data from control system to cloud storage facility over internet.
Gas Pressure Monitoring
- Welding gas pressure can be monitor.
Input & Output Monitoring
- Machine IP/ OP can be monitored.
Model Specifications
CW-O-150505/ CW-C-150505
- Machine size: 2 meter x 1.5 meter x 2 meter
- Stroke: X:1.5m; Y: 0.5m; Z: 0.5m; a: 360ᵒ
- Weld speed: 30mm/sec
- Number of axis : 4 axis
- Axis repeatability: +/- 0.2 mm
- Interpolation Repeatability : +/- 0.1 mm
- Machine bed parallel accuracy: +/- 0.2
- HMI screen: 7” High resolution screen
CW-O-100505/ CW-C-100505
- Machine size: 1.5m x 1.5m x 2m
- Stroke: X:1.0m; Y: 0.5m; Z: 0.5m; a: 360ᵒ
- Weld speed: 30mm/sec
- Number of axis : 4 axis
- Axis repeatability: +/- 0.2 mm
- Interpolation Repeatability : +/- 0.1 mm
- Machine bed parallel accuracy: +/- 0.2
- HMI screen: 7” High resolution screen
NOTE: O– Open loop system (Stepper motors) ; C-Closed loop system (Servo motors)
Add-ons
- Cartesian XYZ Axis :
Axis are built with aluminium extrusion, slides over the guide rails, with precision ball screw and nut mechanism. Provided with safety mechanism including soft and hard limits. Cables are managed with drag chain and duct facility. Model available with open loop and closed loop system.
This unit is included in the main system. - 5th Axis Rotary Positioner :
This system is built rigidly to with stand vibration and rotate smoothly with a higher loads. Provide with a chuck mounting plate.
Available with open loop and closed loop system.
5th Axis Movement table -500 mm stroke. (optional) - Cylinder Clamp :
This system is built to hold the hydraulic cylinders rigidly while welding. Automatic Pneumatic sliding and holding takes place based on the controller signal.
Cylinder clamp sliding -500 mm stroke. - Port Locator :
This system is to hold and locate the circular / rectangular port with the hy-draulic cylinders rigidly while welding. Automatic Pneumatic sliding and holding takes place based on the controller signal.
Port locator sliding -500 mm stroke. - Torch Rotary Unit :
This system is to hold and rotate the MIG/ TIG torch kit. It acts as a 4th Axis.
Available with open loop and closed loop system.
This unit is included in the main system. - Tail Stock Unit :
This system is to hold and rotate the Hydraulic cylinder in circular and rotary type welding of end caps etc. Provided with Morse taper/ plate.
Forward and reverse motion is provided with pneumatic cylinder.
Available Accessories
- Welding power source MIG
- Welding power source TIG
- Auto Voltage Controller with linear axes 100mm
- TIG wire feeder axes
- Fume extraction system
- Port adaptors
- Cloud Monitoring
- Remote access
- Auto darkening Welding helmet
- Gloves & welding apron
- UPS –3KVA
- Auto torch cleaning system
- Camera monitoring system
- Weld Parameter integration
- Customized welding fixture
