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Pipe Fit Up Turning Rolls

Fit up welding rotator(Also called:Hydraulic Turning Rolls) is one of welding auxiliary devices, which has similar but advanced technology comparing to conventional welding rotator. Comparing with conventional welding rotators, the fit up welding rotator developed by Fengwei Machinery is composed of one driver, one idler, hydraulic cylinder and hydraulic control system etc.. The main function of fit up welding rotator is to rotate cylinder objects in 360 degree, automatically or manually move along with rails, and automatic elevation to reach horizontal level and the welding joints.

Application

Description

With the progress of production automation, especially in the welding processing of large tanks, such as pressure vessels, wind towers, etc., Fit up welding rotator is an essential welding assistance.

The center angle of the workpiece should be maintained within 45 and 110 degrees. When the center angle exceeds this range, it can be adjusted by adjusting the center distance of the rotator seat. The center distance of the rotator seat is adjusted through the screw hole grading.

What is mechanism of Fit Up Welding Rotator?

The hydraulic welding rotator comprises two hydraulic roller housings, in which hydraulic roller systems are installed respectively. Each hydraulic roller system includes a hydraulic roller. The outer walls on both sides of the hydraulic roller are sleeved with ball bearings through the roller shaft. The upper and lower parts of the spherical hydraulic roller are gap matched with the upper and lower grooves set in the hydraulic roller housing, The outer sleeve of each ball bearing is provided with a fixed bearing, an oil supply channel connected with the oil supply hydraulic system is opened in the middle of the bottom of the lower groove in the hydraulic roller housing, and an oil return channel connected with the oil return tank is symmetrically opened on the bottom wall of the hydraulic roller housing supporting the ball bearing, The roller shafts on the adjacent sides of the two hydraulic rollers are connected as a whole, and the roller is sleeved on the roller shaft connected as a whole through a bearing. The friction between the upper and lower hydraulic rollers of the device is almost zero due to the existence of oil film, so as to reduce the rotating energy consumption of welded pipe fittings.

The roller of fit up welding rotator is made of 35# cast steel wheel. If the material type of cylinder is stainless steel or non-metallurgic, PU roller is recommended to prevent the surface from being abraded while welding or sand blasting.

Why need a Fit Up Welding Rotator?

Comparing with conventional welding rotators, the fit up welding rotator can similarly rotate tanks in 360 degrees. More technically, the fit up welding rotator is highly advanced to move tanks once completed joints, automatic elevation to reach the circumferential seam joints, in the process of welding or blasting.

Comparing with traditional way of tank fabrication,the fit up welding rotator significantly reduce 50% man hours and boost at least 70% efficiency with better precision. As you can imagine all actions of moving around tanks by crane is replaced by fit up welding rotator with safety guarantee. 3-5 labours are reduced to 1-2 man with better completion rates.  

The main function of the fit up welding rotator is to help group joints between tanks and form a completed pipeline int he field of pressure vessel or wind tower production line. It helps to elevate and drop cylinder objects to meet the circumferential welding seam, and make two tanks join together. Tanks are used to be moved around by crane, now fit up welding rotators can automatically move up and down cylinders to reach the seam position. Tanks are used to move away by crane if adding more joints, now fit up welding rotators can horizontally move along with rails and bring away completed cylinders.

Merits of Fit Up Welding Rotator

Ø Ready-to-use status once received

Ø Robust structure

Ø Fully automatic

Ø Horizontally or vertically adjust with adjacent vessels

Ø 50% man cost reduction

Ø 70% efficient boost

Ø Options of Fit Up Welding Rotator

Ø Manual or motorized walking

Ø Metal or PU roller

Ø Synchronization or not

Ø Equip with welding manipulator

Fit up welding rotator is newly designed and manufactured by Fengwei Machinery with patented certificate. With experienced technical team, we specially researched and developed fit up welding rotator to significantly improve the working environment, and well-known by its features of “high efficiency, low labour cost and high safety”.

Fengwei Machinery is the first to apply for such patent, with options from 10 tons up to 500 plus tons. So if you are looking for a rotator that could automate the existing welding rotator production line, as well as boost the weldment efficiency, reduce man hours and improve safety while grouping long pipelines, fit up welding rotator is an ideal welding auxiliary and your first choice.

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Application Field

  • Petrochemical Industry

  • Environmental Protection

  • Steel Structure

  • Power Tower

  • Hot Water Container

  • The petrochemical industry plays a crucial role in enhancing the growth and economy of the world. Additionally, petroleum products produced in offshore and onshore exploration, refining, and oil production have also increased, resulting in increasingly complex waste production. This industry is a vital source of inorganic toxic and organic materials. 

    For the run of the industries present worldwide the top-quality equipment is mandatory. Several types of machinery producing industries are present worldwide but choosing the right one is a little confusing. Don't worry; we are here for your help. Giving the right solutions and shipments to your industry is our duty.

    Here are 3 must haves of welding automations for the fabrication process in the petrochemical industry:

    1) Conventional welding rotators

    2) fit up welding rotators

    3) welding manipulator.

  • Wind towers have saved 30% of nonrenewable energy while producing electricity. Today, there are hundreds of wind farms and sea areas are having thousands of wind towers. They hold the generator or dynamo blades, which are tones of weight. These wind power infrastructures are standing strong due to the use of welding rotators, welding manipulator, and welding positioners to be a tank assembly line. Experts in technology and engineering make them.

  • Steel structure has become an indispensable material type used in modern construction industry. Due to the feature of environmental friendly, it has been widely used in construction, such as steel structure factory building, ordinary steel construction building, boiler, pressure vessel, shipbuilding, electric power, petrochemical, petroleum engineering machinery, bridge construction, metallurgical machinery industry, wind power and power tower etc. The bird's Nest building in Beijing, China, is a classic masterpiece of steel structure architecture.

    The h-beam steel production line made by Fengwei Machinery is a highly automated steel structure production line which composes of CNC flame cutting machine, h beam assembly machine, h beam welding machine, and h beam straightening machine. It greatly reduces labor intensity and production costs, improves production efficiency.

     

  • The application of automatic welding and cutting equipment in the manufacturing process of steel tube tower can thoroughly optimize and upgrade the original production process. The traditional production mode adopts the operation of lifting semi-finished products, which requires a special person to be responsible for the lifting and operation of semi-finished products. It has high requirements on the environment and working space, which not only requires a lot of manpower and material input, but also has high labor intensity with low production efficiency. Different from the traditional production mode, the automatic cutting equipment integrates online monitoring, automatic upload and offload raw materials and other automatic functions, can reduce the workload of workers and work intensity, thus greatly improving the production efficiency. The production lines of cutting, pairing and welding can cover each area of the workshop, which can be operated as a whole or independently in each area.

Technical Parameter

Fit Up Turning Rolls

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