CB MATIC LM 52×43 plasma TIG welding boom for pipes and tanks

Built by Air Liquide Welding in 2015, the welding station provides a complete solution to automate the process of TIG + Plasma welding of longitudinal and circumferential welds. The welding station is equipped with a CB MATIC LM 52×43 welding column boom and two NERTAMATIC 450 DC TIG – PLAZMA installations and a head for vertical welding. The installation is designed for welding rotating parts, tanks, longitudinal or circumferential welds, pre-prepared with tack welds.

The AIR LIQUIDE robotic welding station consists of the following components:
– welding column and boom: CB-MATIC LM 52X43
– NERTAMATIC 450 DC TIG-PLASMA power source with control panel
– SP7 torch (plasma)
– MEC4 torch (TIG)
– connection device between power source and torch
– specially designed torch support head with accessories
– PLC controller: SIEMENS
– rotary table 30t with arms
– ROTAMATIC ST 30 W; ROTAMATIC ST 30 F rotator
– ROTAMATIC ST 2 W; ROTAMATIC ST 2 F rotator
– magnetic arc oscillator
– AVC system (Arc Voltage Control) for the adjustment of the arc length between torch and workpiece
– “antidrift” system to prevent movement of the workpiece rotated on the rotator
– wire guide system
– cooling system: FRIOJET 3000
– gas control system
– CCD camera for process observation

All components of the welding station involved in the machining process, i.e. torches and power source, were mounted on a CB-MATIC LM 42X43 D2C column and boom. The welding column and boom is a multi-process device, manufactured in accordance with CE machine directives, which is responsible for the position of the welding head in relation to the workpiece. It features, among others, guards for the moving parts and an electrical safety box, which controls the welding system and power source. Movement control, as well as the programming of the boom’s operation, is performed via an intuitive SIEMENS PLC control.

The torches are supplied with high-quality current generated by a NERTAMATIC 450 DC power source. The device, based on thyristor technology, enables TIG AC, plasma DC or TIG DC flat or plus welding. Its use in the process ensures the highest quality plasma welding in the thickness range from 2.5 to 8 mm, without bevelling, and below 2.5 mm in the TIG process. The integrated control panel, connected directly to the power unit via a fibre-optic cable, additionally enables comprehensive control of the welding process, i.e. cycle programming, cycle modification and display of welding parameters.

The torches are connected to the power source via a special device with a cooling valve and an HF system. The HF system is responsible for initiating the pilot arc in the plasma method and the main arc in the TIG method. The SP7 torch is designed for automatic plasma, standard TIG or dual flow installations, which is a combination of high accuracy and ease of use. Its special design provides excellent gas protection, resulting in a high quality weld appearance. The unit also features self-centring electrodes and an indexable nozzle with high-performance cooling.

A precision rotary table with a maximum load capacity of 30 tonnes or ROTAMATIC rotators are used to rotate the workpiece during welding, depending on the diameter and weight of the workpiece. Each rotator has driven or thrust rollers, mounted on a steel frame. The distance between the rollers is continuously adjustable by means of a screw. The driven version (ST 30 W and ST 2 W) also has an electrical cabinet and remote control with a choice of two directions of rotation and speed control via a potentiometer. In addition, a special ‘antifdrit’ system prevents the workpiece from moving during the performed rotation.

Due to its small size and high power density, the electric arc is difficult to observe with the naked eye, even through special screens. The solution comes in the form of a colour CCD camera for observing the machining process, with 5x zoom, thanks to which the operator can accurately see the behaviour of the arc, the wire feed or the workpiece being welded in real time. All this makes the offered AIR LIQUIDE robotic welding station the perfect solution for the precise welding of oversized rotary workpieces.

Technical specifications of individual components of the longitudinal and circumferential welding machine for tanks and pipes CB MATIC LM 52×43

AIR LIQUIDE welding robot for pipes and tanks

• maximum workpiece diameter (rotary table): 4500 mm
• maximum workpiece diameter (ST 30 rotator): 4000 mm
• minimum workpiece diameter (rotary table): 1000 mm
• minimum workpiece diameter ( ST 30 rotator): 350 mm
• maximum workpiece thickness: 8 mm (without bevelling) or 12 mm (with Y-bevelling)
• minimum workpiece thickness: 1 mm
• maximum workpiece length: 4000 mm
• working length (maximum travel distance on track): 15 m
• vertical arm reach: 4200 mm
• horizontal arm reach: 4300 mm
• variable arm lifting speed: 50-1100 mm/min
• variable arm speed: 200-5000 mm/min
• manual rotation of column (indexing of column position every 90°)
• platform for mounting 3 gas cylinders directly on the base of the boom
• platform for mounting the power source
• total machine height: 6550 mm

NERTAMATIC 450 DC power source

• main welding source (450 A)
• pilot auxiliary arc source (25 A)
• welding current: 3-450 A
• welding cycle: 450 A 100%-40°C
• pulse frequency: 1-1000 Hz
• idle voltage: 110 V
• internal power control 42 V; 30 A
• supplementary power supply for burner cooling unit 230 V; 6 A
• pilot arc: 7-25 A/100 %
• power supply: 3x 230/ 400/ 415/ 440 V; 50/60 Hz

Wire feeding system

• maximum wire diameter: 1.2 mm
• minimum wire diameter: 1 mm
• programmable wire feeding speed: 0.15-10 m/min
• wire feeding accuracy: ۫±1%
• maximum weight of wire spool: 15 kg
• maximum wire spool diameter: 300 mm
• gear motor
• mechanical system for inserting and positioning wire in arc
• bracket and reel for wire spool

Cooling system

• maximum flow: 6 l/min
• flow pressure: 9 bar
• coolant tank capacity: 20 l
• cooling and pumping unit with temperature sensor and heat sinks
• device for controlling and regulating the coolant flow
• heat exchange (20°C increment): 2 kW
• current consumption: 11,6 A
• power supply: 230 V; 50 Hz
• noise level: 70 dB(A)

Rotary table

• maximum load: 30 t
• workpiece diameter (without tool): 2000-4500 mm
• workpiece diameter (with tool): 1000-2000 mm
• speed range: 0.004-0.204 rpm
• acceleration time: 0,6 s
• maximum torque: 1500 kgm
• table diameter (without tool): 1500 mm
• table height (without tool): 660 mm
• tool height: 300 mm
• centre bore: ⌀ 700 mm
• motor power: 1.1 kW
• power supply: 3x 400 V; 50/60 Hz
• weight of device (without tool): 1550 kg

ROTAMATIC ST 30 W rotator

• maximum driven load: 30 t
• maximum section load: 15 t
• workpiece diameter: 350-4500 mm
• ‘kit auto’ option to synchronise the automatic rotation of the rotator with the start of the welding process
• digital display
• rotational speed adjustment
• rotational speed: 120-1200 mm/min
• polyurethane rollers
• rollers diameter: 350 mm
• rollers width: 150 mm
• maximum distance between rollers axes: 1820 mm
• minimum distance between rollers axes: 460 mm
• power: 3.8 kVA
• maximum current consumption: 5,5 A
• power supply: 3x 400 V; 50/60 Hz
• device net weight: 442 kg
• device gross weight: 482 kg

ROTAMATIC ST 30 F rotator

• maximum section load: 15 t
• workpiece diameter: 350-4500 mm
• ‘kit auto’ option to synchronise the automatic rotation of the rotator with the start of the welding process
• digital display
• polyurethane rollers
• rollers diameter: 350 mm
• rollers width: 150 mm
• maximum distance between rollers axes: 1820 mm
• minimum distance between rollers axes: 460 mm
• device net weight: 282 kg
• device gross weight: 322 kg

ROTAMATIC ST 2 W rotator

• maximum driven load: 2 t
• maximum section load: 1 t
• workpiece diameter: 30-2500 mm
• ‘kit auto’ option to synchronise the automatic rotation of the rotator with the start of the welding process
• digital display
• rotational speed adjustment
• rotational speed: 120-1200 mm/min
• polyurethane rollers
• rollers diameter: 150 mm
• rollers width: 50 mm
• maximum distance between rollers axes: 690 mm
• minimum distance between rollers: 90 mm
• power: 1.7 kVA
• maximum current consumption: 2,5 A
• power supply: 3x 400 V; 50/60 Hz
• device net weight: 70 kg
• device gross weight: 95 kg

ROTAMATIC ST 2 F rotator

• maximum section load: 1 t
• workpiece diameter: 30-2500 mm
• ‘kit auto’ option to synchronise the automatic rotation of the rotator with the start of the welding process
• digital display
• polyamide rollers
• rollers diameter: 150 mm
• rollers width: 50 mm
• maximum distance between rollers axes: 690 mm
• minimum distance between rollers axes: 90 mm
• device net weight: 15 kg
• device gross weight: 25 kg