WA MultiSurfacer™ Roll Cladding

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