Rotary Welding Positioner by Cyclotron
Welding Positioner
Welding Positioner are mechanical devices that hold a work part and provides flexibility for the welder to rotate the workpiece as per the requirement of the welder. It allows the operator to work at a certain angle providing a consistent surface to weld. It is designed to reduce the fatigue of the welder by allowing him to stay in one position and perform the job. Once the workpiece to be welded is adjusted on the welding positioner, it can rotate up to 360 degrees.
What is a Welding Positioner?
Imagine you are performing a manual welding operation on a welding table. How difficult it would be for you to move around the table or keep rotating it for welding the workpiece. It consumes time and energy and the operator gets tired easily reducing the productivity and quality of the weld. Some arrangement is necessary to accommodate easy movement of the workpiece so that the welder’s job is eased and a lot of time is saved. This is where the welding positioners come into the picture.
Welding Positioner Manufacturer
We at Cyclotron Automations are manufacturers of Welding positioners, weld positioners, Welding turntables, Rotary tables for welding, robotic welding turntables.
We specialise in providing high-quality welding positioners to meet the needs of various industries. As a reliable manufacturer, exporter and supplier of welding turntables based in India, we take pride in our commitment to delivering innovative and effective solutions to our customers.
Get Best Welding Positioners
Cyclotron is the leading manufacturer of Welding Positioner in India.
Our Engineered weld positioners are designed to align the job to the best position for down hand welding, whether it is a non-circular job or a rotating circular job. The structure of our adjustable welding positioners is carefully configured to allow for rotation and angular tilting of the table, ensuring optimal results.
Significance of Welding Positioners
- Improve quality: The positioned parts look great and has a better quality because of the controlled welding and less manual stuff involved.
- Improved speed: By Using a welding positioner, it is possible to make welds in flat or downhand position which can improve the speed, it can be better as well as cheaper. When the posiioner is not used the welds are commonly deposited as relatively lower rate.
- Improved productivity: The use of positioner can eliminated the need for the operator to hold the arc manually, which increases the productivity of the process.
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Features of Cyclotron Welding Positioners
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Weight Capacity:
Cyclotron provides Welding positioners starting from as small as 25 kgs to upto 25 Tons in weight capacity (From 25 kgs to 25,000 Kgs). -
Adjustable rotation speed:
The speed of the positioner can be adjusted based on the requirement which goes upto 0.5 RPM. Digital Speed indicator to monitor the speed of the machine. -
Heavy Duty Structure:
Cyclotron provides a heavy duty structure for welding positioners and hence it provides stability for the complete structure.
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Imported Gearbox:
Cyclotron uses an imported gearbox of Bonvario for better quality of the product. Back-lash free gearbox for rotation and tilting -
Variable frequency drive:
Heavy duty Variable Frequency Drive (VFD) for continuous operation without overheating and tripping -
Ergonomically designed:
We create the most comfortable and safe products for humans to work around. - Rotation speed: 0.04-0.4, 0.05-0.5 rpm (Variable)
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Working Principle of Welding Positioner
The welding positioner forms a plane of rotation perpendicular to the floor. Multiple tooling sets can be arranged on these positioners. The type of materials that are to be held by welding positioners depends on the positioner’s ability to hold them. They include pipes and fittings, tanks and vessels, non-uniform workpieces etc.
Why use a Welding Positioner?
1. Welding Positioners improve Safety:
The traditional material handling equipment depend on cranes, chains, trucks, ad forks etc. They are used to pull, move, drag or position the heavy work parts and their fixtures in position for the welding operation. Their actions are uncontrolled and can be extremely dangerous to the operators and the welders if the equipment falls or swing due to any improper functioning of cranes or trucks. Extra costs are incurred due to the damage that occurred to the equipment and workplace. Sometimes human lives are in danger too. In the presence of welding positioners, such hazards are avoided as they eliminate the need for chains, hoists to lift and rotate the weldments. The positioners firmly position the weldment and can raise them or rotate up to a certain height
2. Welding Positioners improve throughput
They reduce the unproductive time while keeping the welders safe and also improving the quality and productivity of the welding. A considerable amount of time is consumed while working with cranes. It requires labour to control the movements of the crane and position it accurately. The positioner helps the operator to quickly orient the crane and positon it accurately saving the labours hours and increasing the arc time of the welder.
3. They improve weld quality and visibility
The work part is to be oriented in the best possible angle to produce optimal quality welding. The manufacturers suggest that a joint is to be placed in 1F (Flat welding) and 2F (Horizontal welding) positions for better penetration and deposition rate. In 1F position welding, the joint is held at 45 degrees inclination for best deposition rate. In 2F welding, the joint is held at 90 degrees for utmost penetration. The positioners ensure maximum weld quality as they firmly hold the joint in place at the comfortable reach of the welder with better visibility.
It provides a stable working surface at any desired angle to the operator. Hence the accuracy of welding is greatly improved.
They can be equipped in compact spaces where there is limited room on the production floor.
Once connected to a power source, a welding positioner act as a semi-automatic machine which enhances the welding speed and improves productivity.
They find a wider range of applications in industries where welding and fabrication are necessary. Some of them are Rotary Positioning, Rotation of parts for assembling, welding equipment mounting, Rotating workpieces with huge offset loads, welding of shafts, wheels and pipes etc
Need a Welding Positioner?
We at Cyclotron Robotics and Automation Pvt. Ltd. manufacture all types of welding positioners as per your requirement.
Things to remember while working on the Welding Positioners
1. Positioner to be placed on an even surface
Make sure that the welding positioner unit is mounted on an even flat surface. Any unevenness on the surface causes the workpiece to fall in the middle of the operation which could pose a severe threat to the welder.
2. The importance of Centre of Gravity
Picking up the right positioner for your work part should not only depend on the size and weight of the weldment but also the centre of gravity and its distance from the positioning device. The CG is the point on which all the weight of the weldment is concentrated. As the distance of CG increases from the positioning device, more torque is applied to the positioner. Also, adding parts to the positioner changes the centre of gravity which should be kept in mind by the welder while making changes.
3. Specifications of the positioner
The table revolves around a multi-speed electric motor that can be hand-controlled or foot-controlled. Thus the positioner motor and controller is to be selected based on the parameters with which the desired welding operation is performed. As the positioner specifications guide the motor and control choice, it is necessary for the welder to check the specifications for both vertical and horizontal loading to ensure that the positioner has the capacity to handle the maximum load without failure.
4. Ensure accurate attachment of the weldment
As the weldment is physically attached to the positioner, you should make sure that it is attached accurately without any misalignment or improper attachment. The latest positioners come with slots that allow the workpiece to be bolted to the face.
5. Ground current to be connected to the Positioner
During the operation, connect the ground current to the positioner. The ground current is transferred from the table and into the chassis thus eliminating the need to replace the welding clamp frequently. Also, improper grounding can damage the electrical parts and produce poor weld deposits. The positioner should be compatible with the current produced during the operation and ensure that all grounding cables are firmly secured.
Need a Welding Positioner?
We at Cyclotron Robotics and Automation Pvt. Ltd. manufacture all types of welding positioners as per your requirement.
Customers List
Types of Welding Positioners
1. Two-axis Positioners:
Also known as tilt/turn positioners, they provide flexibility in moving workpieces in horizontal and vertical axes directions. These are used in various pipe applications like flanges and elbows etc.
2. Welding Turntables:
The welding turntables are used in applications where the workpiece is required to rotate about a vertical axis. The rotary welding turntables provide accurate positioning in the flat or horizontal position. They are used for welding, flame cutting and other machining applications.
3. Turning Rolls:
They are used for positioning heavier cylindrical work parts like pressure vessels and multisided poles.
4. Headstock and Tailstock Positioners
A Headstock is used for rotating shorter workpieces horizontally whereas, for larger and heavier work parts, the support tailstock is required additionally. They offer maximum flexibility while lifting and rotating massive work parts like trailer frames etc.
5. Pipe Welding Positioners
Their presence is advantageous while welding pipes, shafts, and elbows etc. Besides the welding turntables, the pipe welding positioners are mainly used for positioning and orienting the workpieces with large offset loads. From pipe spooling to chassis components, they are useful in positioning complex work parts too
6. Rotary Welding Positioners
With the rotary welding positioners, welding of round objects has never been this easy and efficient. A variable speed control box lets you choose between different speeds suitable for the operation. These positioners are mainly used in precision welding applications.
7. Gripper welding chucks:
It is used to hold the complex shaped metal parts between the headstock and tailstocks to allow welding operation. They are designed to withstand the adverse conditions of the industry.
Conclusion
The welding positioners find their use in many industrial applications. But these are most commonly used for mounting welding equipment, rotary positioning, mounting of various parts of assemblies etc. Study your requirements thoroughly. Based on this, you can choose between a variety of welding positioners. Both new and used welding positioners are available in the market. You can also rent a welding positioner as per your necessity.
Need a Welding Positioner?
We at Cyclotron Robotics and Automation Pvt. Ltd. manufacture all types of welding positioners as per your requirement.