WA MultiSurfacer
TM
Automated Roll Cladding Technology
Reliable Repeatable Precise
About the Brochure This Welding Alloys Machines brochure describes the innovative features, benefits and integrated components of the MultiSurfacerTM and roll cladding machine range. Welding Alloys pioneered the design and manufacture of automated welding equipment; continually improving design and build quality with over 40 years of experience.
About Welding Alloys Welding Alloys Group is the world’s leading manufacturer of automated welding equipment and flux cored consumables; providing specialised services in cladding and hardfacing.
2 3
Contents Executive Summary D3-Touch Technology Introduction D3-Touch Technology Roll Cladding Machine Family Machines - Under the spotlight Welding Processes
2 3 4 6 8 11
Technology Driven Roll Cladding
$XWRPDWLRQ
Taking it to the next level‌ D3-Touch from Welding Alloys is a new control technology for automation allowing effective and efficient implementation of fully automated welding techniques and processes. Welding Alloys incorporates new technology into all MultiSurfacerTM machines improving performance and accuracy of the welding process. This technology complements the precision engineered mechanics resulting in maximum performance from our welding machines.
‡ 2(0 ‡ )XOO PL[ RI ZHOGLQJ SURFHVVHV ‡ 5HGXFWLRQ LQ ODERXU FRVWV SRVW ZHOG SURFHVVLQJ ZHOG VHWXS WLPH ‡ 6XSHULRU ZHOG TXDOLW\ ‡ 4XLFN UHFDOO RI VDYHG SDUDPHWHUV SRVLWLRQV ‡ 3UHFLVH VSHHG SRVLWLRQ FRQWURO ‡ *OREDO VXSSRUW QHWZRUN Automated Roll Cladding Technology
D3-Touch Driven Technology Control System Benefits
‡
6DYHV VHW XS WLPH WKURXJK WKH VHWWLQJ XS RI UHSHDWDEOH ZHOGLQJ SDUDPHWHUV
‡
3URYLGHV SUHFLVLRQ ZHOGLQJ UHGXFLQJ PDWHULDO ZHOGLQJ FRQVXPDEOHV XVHG
‡
3URGXFWLYLW\ LPSURYHPHQW WKURXJK KLJK HIILFLHQF\ ORZ GRZQWLPH
‡
6\VWHP LV VLPSOH WR XVH DQG SURJUDP ZLWK RQO\ WKH UHTXLUHPHQW IRU RQH RSHUDWRU
‡
)XOO WUDFHDELOLW\ RI PDWHULDOV XVHG DQG WKH ZHOGLQJ SURFHVV
‡
0LQLPLVHV KXPDQ LQWHUIHUHQFH GXULQJ SURGXFWLRQ
‡
6DYHV WLPH DQG FRVW LQFUHDVHG HIILFLHQF\ DQG UHSURGXFLELOLW\
' Touch LQWXLWLYH FRQWUROV
' Touch ZHOG SDUDPHWHU VFUHHQ
Control System Features
‡
7RXFK VFUHHQ KLJK GHJUHH RI PRWLRQ SURFHVV FRQWURO
‡
5HDO WLPH V\QFKURQLVDWLRQ
‡
7RXFK VFUHHQ ZLWK LQWXLWLYH *8, *UDSKLFDO 8VHU ,QWHUIDFH
‡
,QWHJUDWHG SURFHVVLQJ
‡
'DWD ORJJLQJ IXQFWLRQDOLW\
‡
%XLOW LQ FRQGLWLRQ PRQLWRULQJ IDFLOLW\
‡
6HOI UHPRWH GLDJQRVWLFV
‡
5HPRWH PRQLWRULQJ
)XUWKHU GHWDLOV DERXW ' Touch DUH RXWOLQHG LQ D VHSDUDWH OHDIOHW
4 5
3URJUDPPDEOH &XVWRPLVDEOH FRQWUROV
:HOG FRQGLWLRQV PRQLWRULQJ VFUHHQ
Automated Roll Cladding Technology
Roll Cladding Machine Family Roll Cladding Welding Alloys new roll cladding machines are designed to operate and synchronise seamlessly with D3-Touch technology. The mechanical design stage for MultiSurfacerTM machines incorporates 3D CAD modelling software and finite element analysis for stress and strain distribution. R500-MultiSurfacerTM (Simultaneous cladding of four small diameter rolls)
The product features for the latest MultiSurfacerTM machines are designed to achieve perfect quality welded materials whilst the ease of operator interaction and application requirements are kept at the centre of our design philosophy. Flexibility is a key feature of the MultiSurfacerTM machine range and includes: ‡
R1000 and R3000
‡ ‡
$GDSWDELOLW\ IRU RSHQ DUF VXEPHUJHG DUF RU JDV shielded welding &RQILJXUHG ZLWK VLQJOH RU PXOWLSOH ZHOGLQJ KHDGV 2SHUDWH ZLWK VLQJOH RU WZLQ ZLUH IRU PD[LPXP productivity
A WA laser scanner unit constantly monitors the roll diameter which gives an accurate reading resulting in an evenly finished VXUIDFH PLQLPLVLQJ WKH ZHOGLQJ PDWHULDOV XVHG DQG DVVRFLDWHG costs.
Milling Unit Roll Cladder with Laser Scanning & Milling Station
The WA range of MultiSurfacerTM has the ability of being expanded; one of these modular expansions available is our WA Milling Unit. This unit provides a rough machined finish during the final weld pass of the process. By carrying out the machining during the final ZHOG SDVV WKH UROO VWLOO FDUULHV UHVLGXDO KHDW DOORZLQJ WKH XQLW WR FXW WKURXJK D VRIWHU PDWHULDO H[WHQGLQJ LWV OLIH DQG LQFUHDVLQJ WKH production efficiency.
R6000+
‡ (DVLHU PDFKLQLQJ GXH WR VRIWHU PDWHULDO ‡ 3URORQJV OLIH RI WKH FXWWLQJ WRRO ‡ 5HGXFHV DGGLWLRQDO SURFHVVLQJ RI UROO ‡ 5HGXFHV RYHUDOO H[SHQGLWXUH LQ PDQXIDFWXULQJ WKH UROO
Preheating MultiSurfacerTM preheating station benefits include: ‡ ‡ Roll Cladder with Preheating Station
‡
6 7
3URYLGHV QHFHVVDU\ SUHKHDWLQJ RI FRPSRQHQW 8VHV H[LVWLQJ UROO PDQLSXODWLRQ V\VWHP ZLWK WKH SUHKHDWHU underneath the roll to maintain preheat and interpass temperatures 6XSHULRU TXDOLW\ ZHOGHG FRPSRQHQWV
%HVSRNH PDFKLQH VSHFLILFDWLRQV DUH DYDLODEOH WR RUGHU WA Roll Cladding Machines Rolls
R500
R1000
R3000
R6000
R12000
R20000
R50000
Single
500
1000
3000
6000
12000
20000
50000
Twin
2 x 500
2 x 1000
2 x 3000
2 x 6000
2 x 12000
2 x 20000
2 x 50000
Single
1000
1200
2000
3000
3000
10000
10000
Single
300
500
600
1000
1000
1500
2000
Twin
300
500
600
1000
1000
1500
2000
X Welding head oscillation maximum travel (mm)
-
200
200
200
200
200
200
200
Z Axis maximum travel (mm)
-
500
500
1000
1000
1000
1000
1000
Y Axis maximum travel (mm)
-
400
400
400
400
400
400
400
Component rotation (rpm)
-
Äş
Äş
Äş
Äş
Äş
Äş
Äş
Wire speeds (m/min)
-
Äş $YDLODEOH RQ DOO UROO FODGGHUV
Wire sizes
-
$YDLODEOH RQ DOO UROO FODGGHUV
SPECIFICATION Maximum component weight (kg) Maximum unsupported component length (mm) Maximum component diameter (mm) 2
Welding Processes Open
-
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Gas
-
Yes
Yes
Yes
Yes
Yes
Yes
Yes
6XEPHUJHG
-
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Automated Roll Cladding Technology
Machines - Under the Spotlight 1
Wire Feeder (remotely controllable via D3-Touch) ‡ 4XLFN UHOHDVH IHHG JHDUV ‡ ,QWHJUDO ZLUH VWUDLJKWLQJ XQLW ‡ $GMXVWDEOH IHHG JHDU WHQVLRQLQJ ‡ /LJKWZHLJKW FDVW DOXPLQLXP ERG\ ‡ $ELOLW\ WR IHHG VLQJOH WZLQ ZLUH
Software features: Data Logger ‡ /RJV ZHOGLQJ FRQGLWLRQV Sequence Programmer ‡ 6DYHV PDFKLQH SDUDPHWHUV IRU ZHOGLQJ FRPSOHWH FRPSRQHQWV ‡ :HOGLQJ UHSHDWDELOLW\
2
Spindle Module ‡ &RQWUROV VXUIDFH VSHHG ‡ $XWR 'LDPHWHU DGMXVWPHQW ‡ 6WHS DQJOH FRQWURO IRUZDUG DQG EDFNZDUG
‡ $OWHUQDWH PRYHPHQW 5 8 3
Quick lock grip (Chuck-jaws) ‡ 6DIHO\ VHFXUHV FODPSV UROOV RQ D VXVSHQVLRQ PRXQWHG OLQHDU VOLGH ZD\ V\VWHP ‡ 6HOI FHQWHULQJ
4 6 2
4
Pendant Control ‡ -RJV ; = :LUHIHHG 6SLQGOH DQG 2VFLOODWRU D[HV ‡ (PHUJHQF\ VWRS EXWWRQ ‡ 6WDUW 6WRS ZHOG ‡ &RQWUROV 6SLQGOH 2VFLOODWRU IXQFWLRQV
5
Fume Extraction & Filter Box ‡ 6DIHO\ H[WUDFWV ZHOGLQJ IXPHV GLUHFWO\ IURP WKH ZHOGLQJ KHDG ‡ 0RGXODU DOXPLQLXP GXFWLQJ ‡ 6HPL DXWRPDWLF ILOWHU FOHDQLQJ
8 9
6
Milling Unit ‡ 3URYLGHV D URXJK PDFKLQLQJ SURFHVV WR FODG UROOV ‡ 0DFKLQHV UROO GXULQJ ILQDO ZHOG SDVV
All MultiSurfacerTM machines have been fitted with the latest health and safety features. The technical features have been upgraded for maximum performance and achieve outstanding component reproducibility and quality time after time.
7 10
9
Linear slide ways )RU VPRRWK DQG WURXEOH IUHH RSHUDWLRQ RI ; = FDUULDJHV
7 1
3
8
Oscillator )LWWHG WR SURYLGH VPRRWK OLQHDU WUDYHO RI ZHOG KHDG UHVXOWLQJ LQ D SUHFLVLRQ ZHOG GHSRVLW
11
9
Flux recovery system featuring: 9DFXXP SXPS +RSSHU 6HSDUDWLQJ FRQYH\RU $LU ILOWHU 6HOI FLUFXODWLQJ UHFRYHU\ V\VWHP )OX[ SUHKHDW
11
Clamping System 3QHXPDWLF FODPSLQJ V\VWHP (DV\ RSHUDWLRQ 3URYLGHV FRQVWDQW OLQHDU SUHVVXUH WR WKH UROO XS WR WKH ZHLJKW RI WKH UROO 3UHFLVH FRQWURO RI FODPSLQJ IRUFH 6HOI FHQWHULQJ RI FODPS IRU UROO WKHUPDO H[SDQVLRQ DQG FRQWUDFWLRQ
Automated Roll Cladding Technology
10
Cable management )HDWXUHV DQ HQHUJ\ FKDLQ PDQDJHPHQW V\VWHP 6DIHO\ LQFRUSRUDWHV DOO FDEOHV ZLWKLQ RQH DVVHPEO\ (QVXUHV ORRVH FDEOHV GRQ¶W DIIHFW PRYLQJ SDUWV RI WKH machine 5HGXFHV QRLVH LQWHUIHUHQFH
Machines under the spotlight Wirefeeder angle unit and position adjuster Beta $ngle GearEo[ Beta +andle
Į
ȕ $OSKD +andle $lpha $ngle GearEo[ Oscillator
Y
< $[LV +DQGOH
$QJOHRPHWHU
Wirefeeder
:HOG +HDG +HDW 6KLHOG
Water Cooled Welding Gun
Like all the other aspects of our roll cladding machines, the wire feeders and welding guns perfor perform rm in unison with the highest quality wire feeder angle e unit and position n adjuster.
:$ 8QLYHUVDO 7LS $GDSWHU
)XOO 5DQJH RI :$ :HOGLQJ 7LSV
General features include:
$FFXUDWH ZHOGLQJ JXQ DQJOH SRVLWLRQ LQ WZR D[HV Į DQG ȕ D[LV
7RS GHDG FHQWUH DGMXVWPHQW )XOO\ VHDOHG KHDY\ GXW\ RVFLOODWRU
Wire Feeder features:
10 11
8QLYHUVDOO\ VXLWDEOH IRU IOX[ FRUHG DQG VROLG ZLUH +HDY\ GXW\ DQG UREXVW GHVLJQ 4XLFN WR VHW XS 7UXH ZLUH VSHHG PRQLWRULQJ DQG IHHGEDFN (DVH LQ UHSURGXFLELOLW\ LQ ZLUH WHQVLRQ DGMXVWPHQW (QG RI ZLUH VHQVRU
X2
Welding Processes Flexibility is a key feature in the MultiSurfacerTM range of machines. All MultiSurfacerTM machines are adaptable to operate with open arc, submerged arc or gas shielded welding processes. These machines can be used with single of multiple heads and operate with single or twin wire for maximum productivity.
Submerged Arc Welding
Submerged arc welding
Best suited for large diameter rolls which require higher weld deposition rates. Automatic flux recovery is designed to recirculate the flux back through a series of filters into the weld reducing waste and flux replenishment time.
Open Arc Welding Open arc welding technology is normally applicable to cladding continuous casting rolls and small diameter rolls.
Gas Shielded Welding Gas shielded welding is applied when a high quality defect free weld is required. Bearing areas of rolls are commonly clad with shielded processes.
WA Flux recovery and slag separation
Additional product features providing added health & safety protection in a welding environment are available, these are as follows: Protective shields - Protects the operator from the welding arc and offers protective viewing Fume Extraction - Safely extracts welding fumes from the weld head
Technical Support WA Engineering The engineering department at Welding Alloys utilises the latest in mechanical, electrical and software capabilities in order to deliver a comprehensive welding solution. We undertake thorough analysis of our customers’ needs, both visible and hidden, to provide a machine designed for the customer, with the customer.
WA Training In addition to delivering a welding solution, WA are able to provide optional multi-level training to operators and managers alike from our dedicated team of application specialists.
WA Reliability At WA we know the importance of reliable machines and appreciate how expensive machine downtime can be. We provide a variety of maintenance and upgrade packages to maximise productivity, reduce operating costs and extend the overall operational lifespan of your production line. Each machine which leaves WA is covered by our guarantee, giving you the confidence in knowing we provide a quality product which meets the specified needs of your production.
Automated Roll Cladding Technology
A perfectly controlled technology
WA Cored WiresTM
WA MultiSurfacerTM
WA IntegraTM Services
Design and manufacture all types of cored welding wires
Design and manufacture automated welding equipment for hardfacing and rebuilding applications
Innovative hardfacing and rebuilding solutions by welding
A worldwide presence United Kingdom
India
South Korea
(Head Office) Welding Alloys Ltd
Welding Alloys South Asia Pvt Ltd
Welding Alloys Korea Ltd
Argentina
Italy
Spain
Welding Alloys Argentina S.A.
Welding Alloys Italiana s.r.l.
Welding Alloys España
Australia (Trading Partner)
Japan
Sweden
Specialised Welding Products Pty Ltd
Welding Alloys Japan
Welding Alloys Sweden
Brazil
Malaysia
Taiwan
Welding Alloys Brazil Ltda
Welding Alloys (Far East) Sdn. Bhd.
Welding Alloys Taiwan Co.
China
Mexico
Thailand
Welding Alloys China Ltd
Welding Alloys Panamericana S.A. de C.V.
Welding Alloys (Thailand) Co. Ltd
Egypt
Morocco
Welding Alloys Egypt
Welding Alloys Maroc Sàrl
Turkey
Finland
Poland
Ukraine
Welding Alloys Finland Oy
Welding Alloys Polska Sp. z o.o.
Welding Alloys Ukraine
:HOGLQJ $OOR\V /LPLWHG ùLUNHWL
France
Russia
United Arab Emirates
Welding Alloys France SAS
ZAO Welding Alloys
Welding Alloys Middle East FZC
Germany
South Africa
USA
Welding Alloys Deutschland GmbH
WASA (PTY) Ltd
Welding Alloys (USA) Inc.
Greece
Vietnam
Welding Alloys Hellas EPE
Welding Alloys Vietnam Co. Ltd
www.welding-alloys.com
Welding Alloys Group 2012. WA Cored Wire, WA Integra, WA MultiSurfacer, Hardlite, Tuffplate, and 3-DCarb trade and registered marks and logos are the property of the Welding Alloys Group. v1.0