2015 RONZANI Pillow plate welding machine

Pillow plate welding machine 

I.No. 1 CNC CONTROL DEVICE FOR WELDING STAINLESS STEEL PLATES WITH PLASMA AND TIG AUTOMATIC SYSTEM,                        

for the production of heat exchangers from steel sheet of up to 2000mm width, with the following characteristics: reference Your drawing PUNTA20R6_L7, without Roller Conveyors and Applying Protection Film.

a. The plant positions the spot-welding units and the sheets to be both spot and edge welded. The welding units are carried on pneumatic driven slides for vertical travel and on two independent motorized axes for transversal-travel. Each axis carries two torches, one for spot and transversal seam weld, and the other for longitudinal seam weld.

The sheets are transferred by two couples of motorized rollers that allow sheets of considerable length to be processed, with a minimum of 1600 mm.

b. An electronic device (PLC) controls the machine, governing via the program the logical sequence of the processing cycle. The PLC is connected to a touch sensitive display terminal (Touch Screen), that allows the variable parameters for the single processes, times and positions for welding to be input and memorized in the resident programs.

c. Two spot-welding and two continuous-welding units are provided each with a welding generator, made up of a torch carriage, with a special patented sheet holder, for longitudinal, transverse and spot welds.

d.  N° 1 SCOTCH BRITE BRUSHING UNIT to clean the bottom side of dimple jacket from the welding’s oxide, it is made the brushing unit inside of welding machine; between the torch’s crossbeam and the output rubber roller. The unit moves transversely on carriage by pinion rack system; to the vertical position controlling, a pneumatic actuator rotates the brushing unit’s arm. The brushing is made by a scotch-brite dish.

e.  N° 2 FRONIUS TT3000 JOB TIG generators for seam welds

f.  N° 2 SBI PLASMA SPOT WELDER PSW-500 V2.1 generators for spot welds.

g. Spot welding, which employ two spot-welding units, are carried out on a copper bar with cooling.

h. The longitudinal weld, using two spot-welding units, is effected on a copper roller.

i. The transversal weld will be done with one of two longitudinal torches 90° rotate.

j. The welding devices, and accessories are carried at the side of the machine, while the respective controls and electrical components will be installed in the electric panel:

k. The electrical energy supply rating is approximately 40 kW, including the welding generators, supplied at 400 Volt, 3 phase, 50 Hz, plus neutral and ground.

l. No. 2 Remote Weld Monitoring Camera System, with manual control for longitudinal and transverse seam weld on the edges of the jacket sheets.

m. The machine will be equipped with applications:

1. No. 2 Application “Cold Wire System”, for longitudinal and transverse seam welds.

2. PUNTACAM APPLICATION. CAD-CAM software that allows to create the work program from a drawing file. With this application the machine is added of an industrial computer to work with Ronzani Puntacam software.

3. ARCAM APPLICATION. Added to Puntacam software and special rotating equipment, allows to make arcs and diagonal seam welds.

With this application the transversal seam weld will be done with one of two longitudinal torches 180° rotate.

All communication in panel will be prepared in Polish language.

GENERAL DESCRIPTION

THE AUTOMATIC SYSTEM OF DIMPLE JACKET WELDING is suitable for working sheets up to 2000 mm, wide and 6000 mm long, with overall dimensions The machine has the following characteristics:

• The automatic system of welding executes the positioning of the torches for the spot and seam weld around the border so as to form the dimple jacket structure. The torches are fixed on a pneumatic slide with pneumatic cylinders for vertical movement and on two motorized independent pneumatic slides for transversal movement. The sheets are moved by two pairs of motorized rolls which allow the processing of sheets of remarkable length. The minimal length is of 1600 mm.

• The welding parameters are controlled by the PLC with a specific software that controls the operation schedule. The interface of communication between the operator and the machine consists of a touch screen control panel from which it is possible to select the position and the welding time programmable in a residential memory – copy to hard disc.

• There are 2 working units with 2 generators. Two units are made up by 2 slides hold-torch with special equipment pressing sheet . The TIG torches groups can be turned by 180° to permit the transversal and longitudinal seam welding, or diagonal and arc seam welding.

• The Plasma spot welding is done on an inferior crosspiece that supports a branch bar, with connection to ground and distribution of the protecting gas by cooling system. This crosspiece is lowered during the movement of the sheet to prevent damages on the inferior surface.

• The continuous welding is done on a Copper and Aluminium roller, with connection to ground; the TIG torches can be turned by 180° on the roller to permit the transversal and longitudinal seam welding, or diagonal and arc seam welding.

• The components of welding are assembled under the roller conveyor.

• The machine is provided by a monitoring system for the longitudinal and transversal welds, this system has 3 cameras fixed on its support with optical screen photosensitive and two monitors located on the control board. The position of every single torch can be adjusted manually by 3 joysticks situated on the control pulpit.

• Longitudinal and transversal seam welds can be realized on the edge of the sheet thanks to a monitoring system. The position of every single torch can be adjusted manually by 3 joysticks on the control pulpit.

System is working under control procedure and will switched off machine in below circumstances:

- no power or any medium needed for process : electricity, water cooling, gas for TIG and PLASMA welding system.

II. TECHNICAL DATA OF MACHINE

Machine is prepared for welding steels according group 8, 9, 10.

- Dimple jacket machine RONZANI

Max sheet width 2000 mm

Min sheet length 1600 mm

Pillow plate thickness min 0.6 mm max 2.0 mm

Base plate thickness min 1.0 mm max 20.0 mm

Longitudinal Feeding sheet by 2 couples of rubber rollers

Longitudinal Feeding sheet speed max 8 m/min

Longitudinal Feeding Engine OMRON Sigma II 220 V 400W 1.27 Nm 3000 RPM

N° Torch’s transversal carriage 2 (each carriage has 1 Plasma + 1 TIG)

N° Plasma torches 2

N° Tig torches 2

Max transversal stroke for each carriage 1800 mm

Transversal carriage speed max 8 m/min

Transversal Feeding Engine OMRON Sigma II 220V 200W 0,637Nm 3000 RPM

Lower side cooling bar: the copper bar has two different circuits, the first with

water-cooling circuit used to refrigerate the bar itself, and the second with

protection gas used to protect the dimple jacket during welding.

Water chiller HITEMA model ECA 001

Gas cooler generally mix Ar + CO2

copper bar length 2050 mm

- SBI PLASMA SOURCE DC PSW – 500

Supply voltage: 3x400V+N/50Hz

Power connection: 5x32A CEE plug, 6mm²

Max. power consumption (50% on-time): 15kVA

Cos ϕ : 0.99

Max. impulse current: 510A

Degree of protection: IP23

dimensions (L x B x H): 1050x360x750mm

weight: ca. 70kg

Control range plasma gas 0.2 – 5 l/min

Control range protective gas 0.2 – 20 l/min

- FRONIUS TIG SOURCE TransTig 3000 Job

Main voltage 50 -60 Hz 3 x 400 V

Main voltage tolerance +/- 15 %

Main fuse protection (slow) 3 x 400 V 16 A

Primary cont. power 3 x 400 V -100 % d.c. 6,1 kVA

Cos phi 1 0.99

Welding current three-phase TIG 3 -300

Welding current three-phase MMA 10 -300 A

Welding current single-phase TIG 3 -300 A

Welding current single-phase MMA 10 -180 A

Welding current at 10 min / 40 °C 50 % d.c. at 300 A

Open-circuit voltage 85 V

Standard working voltage TIG 10,1 -22,0 V

Standard working voltage MMA 20,4 -32,0 V

Ignition voltage (Up)* 10 kV

Type of cooling / insulation class AF / B

Dimensions l/w/h (mm) 560/250/435

Dimensions l/w/h (inches) 22.0/9.8/17.1

Weight 24,2 kg

Marks of conformity CE

Protection IP 23

- Lower brushing unit

Travel length: 2100 mm

Max work length: 2000 mm

Feeding speed : min 2 max 9 m/min completely variable

Pneumatic Slewing function; max work pressure: 0,6 MPa

Diameter of wheel: 250 mm

Width of wheel: 100 mm

Wheel rotation completely variable up to 3000 RPM

Hood for dust suction

Power of grinding motor: 3 kW 2poles 400V/50Hz 3 Phases.

Power of carriage motor: 1,1kW 4poles 400V/50Hz 3 Phases.

- Control panel PLC programmable controller. All functions can be controlled

separately.

Dimension: 1200 mm x 1100 mm x 1615 mm

Remote assistance by Ethernet connection

Computer Dell OptiPlex 780 or similar

Software Cad/CAM EdgeCAM Milling Base

- Electrical features

Operating Voltage and frequency 3 x 400Volt + N + PE- 50 Hz

Installed power  35,0 kW

Main switch 4 x 63A

Electric line 5x16 mm2

Compressed Air Supply Pressure. 0.6 MPa (6 bar).

- Machine dimension

Length:  2200 mm

Width:  3100 mm

Height: 2200 mm

Pass line:  915 mm

Machine Weight 2,5 tons

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