Racking Beam Welder - Multi profile pallet rack beam welding solution
As one of the pioneers in welding solutons we have successfully designed and developed a mult stage tandem beam welding soluton that caters to the racking industry, constructon industry and whole lot of other similar applicatons.
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From a beam length of 500mm to 5000mm & profiles of 40mm to 200mm the system addresses highest number of variables in components for welding. Our fourstageparallelloading,unloading&weldingprocess contributes to the lowest amount of tme required to weld any standard beams. For example a 40mm * 60mm beam gets produced within 22 seconds, this is practcally tested and currently in use in one of the leading racking industry.
Racking Beam Welder Features & Benefits
- Faster Movement : Runs up to 150mm/sec in Closed loop system.
- Swift Welding : Variable from 5mm/sec to 50mm/sec.
- Complex profiles ranging from, Linear, spherical, conical & helical interpolation can be done.
- 12” Wide screen Human Machine Interface.
- Load capacity on fixture bed is up to 15kgs on single fixture, combined load is up to 80kgs.
- CAD2MOTION software support option.
- DXF Import programming option available.
- Closed cage cable management systems.
- Gearbox with high precision and low backlash of 6 Arcmin.
- Milled Bottom base frame mounting bed.
- Motion Control Systems with 64bit compared to 32bit position precision registers & with 533Mhz Arm11 processor & enabled up to 24 axes.
- Ethernet communication-based Servo Systems which optimizes complete closed loop motion control with safety interlocks.
- Additional Input & Output Module for safety systems & provision for expansion of axes as option.
- New & Improvised NIKIT – Teach User Interface with 100 lines of single teach program & expandable up to 250 lines also available.
- 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.
- Play / Pause feature for step-by-step analysis of weld program.
- Component presence monitoring system for weld safety.
- Aluminum Al6164 for component fixture & Main Rotary plate for high heat dissipation and low holding torque.
- Multiple cycle selection for either two side welding or four side welding of the component.
- Average production rate of 25 sec per component output rate for a 40*60 structural beam right from loading to unloading.smoother delivery.
- Auto unloading system with ejecting mechanism & roller assembly for smoother delivery.
OVERLAP OF
WELD BEAD AT JOINTS
SPATTERLESS
WELD BEAD
AUTO SETTABLE DIFFERENT WELD BEAD LENGTHS
REPEATABILITY OF WELD BEAD EVEN AFTER BEAM INTOLERANCE OF +/- 1MM
Racking Beam Welder Applications
Z Beam Welding
Structure Beam Welding
Roll Form Beam Welding
C Beam Welding
E-Commerce Industry
Pharmaceutcals
Food Processing Industry
Automobile Industry
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
- X1A, X1B, X1C, X1D AND X2A, X2B, X2C, X2D
AXES:
Stroke: Collective 1200mm
Speed(Peak): 100 Rpm
Interpolation Speed: 30mm/Sec
- Y1C AND Y2C
Stroke: 250 Mm
Speed(Peak): 100 Rpm
Interpolation Speed: 30mm/Sec
- FIXTURE ROTARY: R1E AND R2E:
Stroke: Endless Rotation
Speed(Peak): 30°/Sec
Master & Slave Motion
- Z1A, Z1B, Z1C, Z1D AND Z2A, Z2B, Z2C, Z2D
AXES:
Stroke: Individual 250 Mm
Speed(Peak): 100 Rpm.
Interpolation Speed: 30mm/Sec
- ROTARY R1C AND R2C
Stroke: 360°
Speed(Peak): 40°/Sec
- COMPONENT BEAM CLAMPERS C1 (1-4) & (5-8):
Beam Clamp Stroke: 150mm Pneumatic
Beam Profile Adjuster: 10mm – 300mm Screw Rod
- COMPONENT CHILD PART CLAMPERS C2 (1-4) & (5-8):
Clamp Stroke: 80mm Pneumatic Swivel Clamp
Clamp Profile Adjuster: 100mm – 250mm
Available Accessories
- Welding power source TIG
- Welding power source MIG
- Fume extraction system
- Cloud Monitoring
- Remote access
- Auto darkening Welding helmet
- Gloves & welding apron
- UPS –3KVA
- Auto torch cleaning system
- Camera monitoring system
- Weld Parameter integration
- AVC
- MIG connector kit
- Special customised fixture – Manual / Auto
