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.
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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The whole welding rotator has strong rigidity and stability, beautiful appearance, reliable performance, simple maintenance and long service life. Learn more about the details and types of welding rotators.
Fengwei has 20 years of experience in the design and development of welding rotators, among which the self-adjusting welding rotator has been recognized by partners from all over the world.self-adjusting welding rotator
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