SEAM-MATIC EX IT 32 plasma TIG longitudinal tank welding automat

The welding station built by Air Liquide Welding in 2015 provides a complete solution for automating the plasma and TIG welding process. The longitudinal welding station is equipped with an EXINTER 32 welding bench and a NERTAMATIC 450 DC TIG-PLAZMA welding installation. The installation is designed for the longitudinal welding of tank components (cargs), pre-prepared with or without bonding welds (in the range of sheet thicknesses 1-5mm).

The SEAM-MATIC EX IT 32 D2C longitudinal welding machine consists of the following components:
– PLC control: SIEMENS
– NERTAMATIC 450 DC TIG-PLAZMA power source with control panel
– connection device between power source and torch
– SP7 torch (plasma)
– MEC4 torch (TIG)
– AVC system (Arc Voltage Control) for changing the arc length between torch and workpiece
– cooling system: FRIOJET 3000
– double jaws
– gas control system
– foot switch
– CCD camera for process observation
– water-cooled copper pad

The machining process is performed using torches with self-centring electrodes and an indexable nozzle with high-efficiency cooling, using the TIG+plasma method. During machining, workpieces with a maximum thickness of 10 mm are held securely by 100 mm long jaws, which are controlled via foot switches. The special torch design provides excellent gas protection, resulting in a high quality weld appearance. Both torches are connected to the power source via a special device with an HF system. This system is responsible for initiating the pilot arc in the plasma method and the main arc in the TIG method.

The torches, in turn, are supplied with high-quality current generated by a NERTAMATIC 450 DC power source. The unit, which is based on thyristor technology, allows welding with TIG AC, plasma DC or TIG DC flat or plus methods. The control panel, connected to the unit via a fibre-optic cable, also provides additional process management options in the form of e.g. cycle programming or its modification. This is complemented by a colour CCD camera with 5x zoom, which allows the operator to see the exact behaviour of the arc, the wire feed or the welded workpiece in real time. The EXINTER 32 welding seamer weighs 6000 kg.

Technical specifications of the AIR LIQUIDE SEAM-MATIC EX IT 32 longitudinal welding machine

• welding length: 3250 mm
• maximum workpiece diameter (internal weld): unlimited
• maximum workpiece diameter (external weld): 1450 mm
• minimum workpiece diameter (internal weld): 1450 mm
• minimum workpiece diameter (external weld): 380 mm
• maximum workpiece thickness (with bonding seam): 10 mm
• minimum workpiece thickness (with bonding seam): 6 mm
• maximum workpiece thickness (without bonding seam): 5 mm
• minimum workpiece thickness (without bonding seam): 1 mm
• jaw length: 100 mm
• power supply: 400 V; 50 Hz
• dimensions (L x W x H): 5665 x 1965 x 1650 mm
• weight of machine: 6000 kg

Technical specifications of the individual components of the welding seamer bench

NERTAMATIC 450 DC power source

• main welding source (450 A)
• auxiliary pilot 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
• auxiliary power supply for torch cooling unit: 230 V; 6 A
• pilot arc: 7-25 A/100 %
• supply: 3x 230/ 400/ 415/ 440 V; 50/60 Hz

Cooling system

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