Plasma Cutting Products

Transcription

1 F INE F OCUS Plasma Cutting Products for each task the optimum system PA-S Focus Fine CutFire FineMarker Pioneers in Plasma Cutting since 1959 made in Germany

2 F INE F OCUS Application oriented Plasma Cutting Technology For the mechanised and the CNC-controlled cutting of electrically conductive materials Kjellberg Finsterwalde offers a wide range of plasma cutting technique, matching different requirements and demands. That expresses our continuous efforts for the advancement of the plasma cutting technique and technology. Besides the FineMarker, suitable for marking purposes, the following series of cutting installations are at disposal: CutFire PA-S FineFocus HiFocus Plasma cutting inverter - easy to handle, for plasma gas air, therefore preferred for cutting of mild steel, torch air cooled Step-switched power source for cutting of all metallic materials with multi-gas regime and water cooled Fine-Focus plasma torches Power sources for heavy load and excellent cutting quality in a material range from 5 to 160 mm in connection with swirl-gas technology HiFocus-technology for highest demands by using primary-switched inverters, suitable for thicknesses from 0.5 to 120 mm, marking function because of optimal process control included This latest plasma Fine-Focus technology, characterised by largely dross-free cuts, low rawnes, less straightness and inclination tolerances as well as repeatable precision is embodied by the HiFocus installations. Especially the HiFocus series is designated by a constant improvement of the inverter technique. Optimised parameters for best cutting results at different materials and thicknesses are available for various technological parameters. Kjellbergs HiFocus technology achieves laserlike cuts according to quality range 2 to 4 as per DIN EN ISO 9013 and furthermore contrary to laser up to thicknesses of 80 mm. Conventional plasma cutting just attains quality range 5 as per DIN. - Technique enables high Flexibility in Fabrication Precondition for such results are an ingenious process control, the gas control FlowControl and an outstanding torch technique. HiFocus plasma torches of the PerCut series are offered with quick-change heads and in different versions for cutting application at 3D parts in connection with cutting tables or with robots. Beside straight line, contoured and bevel cutting up to 50 the plasma cutting units HiFocus 130, HiFocus 161i, HiFocus 280i, HiFocus 360i and HiFocus 440i are applicable for marking, notching and punch marking as well.

3 F INE F OCUS Range of Application Max. cutting current Material thickness in mm A 130 A 160 A HiFocus 80i HiFocus 130 HiFocus 161i 280 A 360 A 440 A HiFocus 280i HiFocus 360i HiFocus 440i mild steel stainless steel Recommended Maximum cutting range 1) cutting range 1) Piercing 1)2) Technical Data 1) These data are depending on the materials to be cut and their composition. 2) Attend piercing technology! HiFocus 80i HiFocus 130 HiFocus 161i HiFocus 280i HiFocus 360i HiFocus 440i 3) Mains voltage Fuse, slow Connected load Cutting current at 100 % d.c. Cutting gases Marking gas Swirl gases Dimensions (L x W x H) Weight 25 A 17 kva 80 A O 2, N2 - O 2, N 2, Air, F5* 1,000 x 510 x 1,020 mm 161 kg 50 A 32 kva 130 A O 2, Ar/H 2, N2 Ar O 2, N 2, Air, F5* 960 x 540 x 1,050 mm 251 kg 50 A 28 kva 160 A O 2, Ar/H 2, N2 Ar O 2, N 2, Air, F5* 985 x 570 1,140 mm 206 kg 3~, 400 V, 50 Hz 100 A 67 kva 280 A O 2, Ar/H 2, F5* Ar O,N, Air kg 125 A 87 kva 360 A O 2, Ar/H 2, F5* Ar O,N, Air 2 2 1,030 x 680 x 1,450 mm 517 kg 3) Other voltages and frequencies on request. *) Forming gas F5 (95 % N 2/5 % H 2) FlowControl - the most advanced Plasma Gas Control 200 A 127 kva 440 A O 2, Ar/H 2, F5* Ar O,N, Air kg For getting high quality cuts gas mixtures and flow rates have to be adapted carefully to the respective workpiece to be cut. Conventional gas mixing devices are keeping only the gas pressure constant and operate mainly with pre-mixed gases, preventing therefore the possibility of a job-related optimisation of the process. That makes it difficult to achieve a high cutting quality. The patented FlowControl of Kjellberg Finsterwalde enables an unique automatic and flow-controlled plasma gas supply. The data are stored in a data bank and at any time reproducible. This high-class technique stands for: customised, safe reproducible gas mixtures exact dosage of different gas amounts and compositions constancy of gas parameters and precise reproducibility by microprocessor control and monitoring compensation of pressure fluctuations in the system use of cutting data from the included data bank for different materials and thicknesses storage of customer specific cutting data and materials in the data bank The gas supply units of the FlowControl series are suitable for all HiFocus installations, with exception of the HiFocus 80i. Also for marking operations an optimal gas supply is warranted. The gas consoles are controllable by a serial interface and can be upgraded on demand.

4 With FineFocus F INE F Plasma Cutting up to 160 mm Plate Thickness These well-proven plasma cutting systems with thyristor-controlled power sources for cutting thicker plates are available with further improved parameters and at an attractive price-performance ratio. The extremely robust machines of the FineFocus series offer a very high capability even under difficult conditions of use. In addition to using manufactured gases for highest cutting quality, it is also possible to cut with air as plasma gas which is a very cost-effective option. Moreover, the FineFocus 600, FineFocus 800 and FineFocus 1600 can be used for underwater cutting. The FineFocus 1600 consisting of two FineFocus 800 allows cutting of materials with a thickness of up to 160 mm. OCUS Range of Application Max. cutting current 130 A 200 A 300 A 300 A 600 A Material thickness in mm FineFocus 450 Dry Plasma FineFocus 600 Dry Plasma FineFocus 800 Dry Plasma FineFocus 800 Underwater Plasma 2) FineFocus 1600 Dry Plasma 2) FineFocus 1600 Underwater Plasma 600 A 3) Technical data Recommended cutting range 1) Maximum cutting range 1) Piercing1)3) 1) These data are depending on the materials to be cut and their compositions. 2) Two pieces FineFocus 800 parallel connected. 3) Attend piercing technology! 4) Mains voltage Fuse, slow Connected load Cutting current at 100 % d.c. Cutting gases Swirl gases Dimensions (L x B x H) Weight FineFocus A 34 kva 100 A (130 A / 75 % d.c.) O 2, Air, Ar/H2 Air, N2 960 x 540 x 1,050 mm 251 kg FineFocus A 62 kva 200 A O 2, Air, Ar/H2 Air, N2 1,040 x 645 x 1,330 mm 370 kg FineFocus ~, 400 V, 50 Hz 125 A 83 kva 300 A O 2, Air, Ar/H2 Air, N2 1,370 x 875 x 1,505 mm 556 kg FineFocus 800 UWP 5) 145 A 102 kva 300 A O 2, Air, Ar/H2 Air, N2 1,370 x 875 x 1,505 mm 564 kg FineFocus x 125 A 168 kva 600 A Ar/H 2-2x 1370 x 875 x 1,505 mm 2x 556 kg 4) Other voltages and frequencies on request. 5) UWP = Underwater plasma

5 F INE F OCUS PA-S series - an approved Plasma Fine-Focus Technology With its conventional step-switched power sources these units have got world wide recognition, because they are offering various technical and economical advantages, as there are: longevity of consumables because of the application of direct water cooled, easy to handle Fine-Focus torches outstanding cutting results, also at stainless steels and aluminium, due to the alternative use of technical gases or compressed air mechanised gouging applicable contour cutting, straight line cutting and bevel cutting up to 60 can be performed, as well as interrupted cutting, and that at all 2D and 3D positions attractive price-performance ratio The units of the PA-S series are suitable for cutting and gouging operations in connection with Fine-Focus hand torches too. Range of Application Max. cutting current 70 A Material thickness in mm PA-S25 W 130 A PA-S45 W 240 A PA-S70 W Recommended cutting range 1) Technical Data Maximum cutting range 1) Piercing1)2) 1) These data are depending on the materials to be cut and their composition. 2) Attend piercing technology! PA-S25 W PA-S45 W PA-S70 W 3) Mains voltage Fuse, slow Connected load, max.cutting current at d.c. Plasma gases Dimensions (L x W x H) Weight 3~, 230/400 V, 50 Hz 50 / 32 A 21 kva 25 A / 100 % 45 A / 100 % 70 A / 75 % Air (O 2, Ar/H 2) 920 x 630 x 960 mm 168 kg 3~, 400 V, 50 Hz 63 A 38 kva 45 A / 100 % 85 A / 100 % 130 A / 60 % Air (O 2, Ar/H 2) 1,040 x 710 x 990 mm 240 kg 3~, 400 V, 50 Hz 125 A 75 kva 80 A / 100 % 160 A / 100 % 240 A / 80 % Air, H35 (35 % H 2/ 65 % Ar) 1,380 x 870 x 1,080 mm 460 kg 3) Other voltages and frequencies on request.

6 F INE F OCUS CutFire 100i - Inverter Technique for Professionals in Metal Working With the inverter power source CutFire 100i Kjellberg Finsterwalde offers an easy to handle plasma cutting system. Designed for simple thin sheet cutting application in combination with any kind of mechanized guiding systems, CNC cutting machines and robots. Perfect for handicraft and industry, manufacturer of exhausting systems and control cabinets. CutFire 100i represents the latest inverter technology equipped with the well established air cooled plasma machine torch Flash 100 High reliability with soft-switch-inverter module made in Germany 100 % duty cycle With high efficiency of 92 % Low investment costs Dust protection through inbuilt filters CNC interface Low weight Functional operation panel: Digital current meter Current pre-setting function LED display for process monitoring Emergency stop, safety key switch Range of Application Cutting current Material thickness in mm max A CutFire 100i Recommended Maximum Piercing 1)2) cutting range 1) cutting range 1) Technical Data 1) These data are depending on the materials to be cut and their composition. 2) Attend piercing technology! Power source Mains voltage Connected load Fuse, slow Open circuit voltage Cutting current at 100 % d.c. Cutting voltage Cutting power Protection class Dimensions (L x W x H) Weight Plasma torch Plasma gas CutFire 100i 3x 400 V, 50 Hz 16.6 kva 25 A 330 V A max. 130 V 13 kw IP x 280 x 590 mm 50 kg Flash 100 Air

7 F INE F OCUS FineMarker - a Plasma System for Marking, Notching and Punch Marking Supplementary to existing oxyacetylene or plasma cutting installations Kjellberg Finsterwalde offers as an accessory a marking system that is controllable through an interface from the guiding machine. Mild steels, stainless steels and primered plates, even with wet or oily surface, can be furnished with markings at a speed up to 12 m/min. The stepless control of the marking current in the range of 4 to 25 A allows marking of plates or profiles durably or temporarily. When choosing deep notches the markings remain readable also after coating the surface. Punctual notchings are possible with according programming of the CNC. The outstanding feature of the FineMarker represents the water cooled plasma torch and outperforms all competitors. By that all the necessary and unalterable requirements for an automated process, like longevity of consumables, heavy duty operating cycles, continuous workflow, etc. are assured. Technical Data Mains voltage 1) Fuse, slow Marking current Duty cycle Marking gases Speed Flow rate Dimensions (L x W x H) Weight 3~, 400 V, 50 Hz 16 A 4-25 A 100 % Ar m/min 7.0 l/min 710 x 400 x 440 mm 30 kg 1) Other voltages and frequencies on request. Arc Voltage depending Height Controls ensure safe Plasma Process A safe plasma process and a high cutting quality can be achieved only, if the torch distance to the workpiece surface always is constant, and if the torch is lifted up when piercing starts. The arc voltage depending height controls ensure process stability and constant good cutting quality, and furthermore they are offering a number of cost-saving effects (increase of lifetime of consumables, material saving by better plate utilization, accuracy of the cut, collision protection, etc.). Kjellberg offers two different height control systems, KHC 4 PCS and KHC 1. Kjellberg-plasma cutting units are CE-conform and correspond with the valid guidelines and instructions of the European Union. They are developed and fabricated on basis of following standards and instructions: EN (VDE 0544). The plasma cutting units are labelled with the S-sign and therefore applicable to environments with increased hazard of electric shock. The fabrication takes place according to DIN EN ISO The factory-owned quality assurance comprises piece and cutting performance tests, documented by test certificate. Our products represent a high level of quality and reliability. We reserve the rights to change design and/or technical specification during the series fabrication. Claims of any kind cannot be derived from this brochure.

8 Tradition gives an Enterprise Identity, Character and Profile Europe's biggest factory for arc welding machines and welding electrodes Foundation of the Kjellberg Finsterwalde Elektro-Maschinen GmbH First automatic welder from Finsterwalde Kjellberg becomes largest producer of arc welding equipment in Europe With 5,000 employees Kjellberg is the largest manufacturer of arc welding equipment in the world Year of birth of the plasma technology at Kjellberg Finsterwalde First successful industrial application of a plasma cutting unit with 50 kw Patent application is field for Fine- Focus Plasma Cutting together with the research institute Manfred von Ardenne in Dresden First application of air as plasma gas worldwide Kjellberg-Plasma dominates the Japanese shipyards Technology of the under water plasma launched First primary switched inverter with Plasma Cutting Unit PA 12i Innovative novelties in the manufacturing program and renewed sales network are basis for the reconstruction of the enterprise The heavy duty life time system XL -Life enables the breakthrough of the Oxygen-cutting technology Adaptation of the Swirl Gas Technology to the Fine Focus Cutting HiFocus - a new technology with laserlike cutting quality enters the market First Soft-Switch-Inverter Module with microprocessor control applied Flow-controlled Automatic Plasmagas Supply - a step into a new dimension of quality and reproducibility - a worldwide novelty PLUS HiFocus - the no. 1 of the Fine Focus Plasma Technology dominates the quality level of plasma cutting HiFocus 80i / 160i / 280i / 360i - the first complete series of primary switched inverter technology Launching of new generation of consumables - YellowXLife Unmatched flexibility with the new HiFocus 440i - the worldwide strongest high precision plasma cutting machine Kjellberg develops plasma cutting technology for 50 years and is one of the longest established manufacturers on the market. PA 20 - first unit with Plasma Fine Focus Technology Kjellberg Finsterwalde Plasma und Maschinen GmbH Germany D Finsterwalde Leipziger Str. 82 Phone: Fax: plasma@kjellberg.de Internet: F F, INE OCUS,, YellowXLife, XL, HiFocus, PGC and GreenLine are trademarks of the Kjellberg Foundation/Kjellberg Finsterwalde Plasma und Maschinen GmbH and may be registered in Germany and/or other countries. Copyright 2011 Kjellberg Finsterwalde Plasma und Maschinen GmbH All rights reserved.

9 Precision in Detail Small holes, fine inner and outer contours: the precision of Contour Cut revolutionises the plasma cutting of mild steel.

10 F INE F OCUS Contour Cut for Highest Quality Standards Until now it has been difficult to cut small holes with a diameter equal to the material thickness. Being the technology leader in plasma cutting, Kjellberg Finsterwalde offers an optimum solution for this problem. HiFocus systems with Contour Cut determine the state of the art. The result is an excellent quality without time-consuming after-treatment at low costs. Precision in Detail Contour Cut is the further development of the HiFocus technology which has been in use successfully for a long time, for cutting contours in mild steel, in particular small holes as well as fine inner and outer contours. This newest development ensures the further improvement of the quality with respect to contour accuracy, perpendicularity and surface quality. Contour Cut is standard in all machines of the HiFocus range with the plasma torches PerCut 200/210 and PerCut 440/450. Customers with an existing HiFocus system can use this new technology as retrofit. Results When cutting small contours, i.e. holes, slotted holes, squares and hexagons, convincing cut qualities can be achieved: Holes with angular deviations ranging between 2 and 4 according to DIN EN ISO 9013 Further reduction of perpendicularity tolerances at inner and outer contours Reduced difference of angular deviations on all sides of outer contour Competitior Kjellberg Finsterwalde Plasma und Maschinen GmbH Leipziger Straße Finsterwalde Phone: Fax: Mail: plasma@kjellberg.de

11 F INE F OCUS Plasma Cutting with Contour Cut Contour Cut is the latest patented plasma cutting technology for mild steel. The following points should be considered to achieve good results when cutting holes with a diameter to thickness ratio of 1:1: Workpiece must be aligned horizontally to the plasma torch that is in absolutely vertical position Adjust correct torch height Freeze the height control for hole diameters of up to 25 mm Select speed in correspondence with the cutting parameters for Contour Cut Program contours according to the following drawings time the cutting kerf 1 time the cutting kerf times the cutting kerf Sequence for 1-6 mm material thickness minimum hole diameter 4 mm Sequence for 6-25 mm material thickness Sequence for material thickness from 25 mm Advantages at a Glance High cut quality and contour accuracy on inner and outer contours Reduced angular deviations and improved quality of cut surfaces Very high repeatability and dimension accuracy High productivity at low costs No further equipment or software required No new consumables required Standard for all HiFocus systems with the new plasma torches 10 mm Mild Steel with 264 holes à 10 mm Our products represent a high level of quality and reliability. We reserve the right to change design and/or technical specification during the series fabrication. Claims of any kind can not be derived from this brochure. Copyright 2011 Kjellberg Finsterwalde Plasma und Maschinen GmbH All rights reserved

12 Kjellberg Finsterwalde Schweißtechnik und Verschleißschutzsysteme GmbH Automation Solutions Basis for your success

13 85 years of experience the basis of our expertise Tradition our commitment to innovation With more than 85 years of experience in the welding industry, KSV has a high level of expertise in delivering customised automation solutions. Beginning with the mechanisation of stick welding processes in 1934, Kjellberg Finsterwalde played a major part in the development of submerged arc welding (SAW). Since that time Kjellberg welding systems have formed the basis for successful solutions in the metal industry and in trade. Kjellberg automat (1938) For more than 70 years, KSV welding machines have laid the optimum foundation for a wide variety of rationalisation solutions in metalworking worldwide. As the basis for customised machines, the innovative Kjellberg KA series follows the tradition of a modern and flexible modular concept for customised industrial solutions. The breadth of technical and technological application and the modular system guarantee the user maximum performance and top quality automation technology geared to customer specifications. Kjellberg KA automat (2008) - 2 -

14 Customised Kjellberg system solutions The outstanding features of KSV automation solutions include their optimised mechanical assemblies and the use of modern electronics for simple control and presetting. Automatic and preset parameters for start/stop, crater filler and burn-back as well as speedometercontrolled drives for tractor and wire feeder are par for the course, as are the robustness and user-friendliness of the control unit and the mechanical system. The range is enhanced by other available modifications, such as flux recovery unit, documentation of welding parameters, sensor systems and wire to seam controller. The modern Kjellberg concept reduces demands on operating personnel and ensures consistently high standards of production quality for the following: Variations: SAW and GMAW Range of operations: butt welds, fillet welds, cladding Single, double or multiple wire technology (parallel or tandem) Welding with one or two welding heads Combined with approved Kjellberg DC power sources (400 to 1,200 A with a duty cycle of 100% CV / CC characteristic), the result is a wealth of options in terms of made-to-measure solutions with maximum economic benefit for a faster return on capital employed. Our catalogue contains various ideas as to how you might mechanise or automate your welding jobs, with examples of Kjellberg applications for frequently recurring production processes customised as system solutions for the following: Fillet welds from page 4 Butt welds from page 14 Longitudinal and round seam welds (inside and outside) from page 24 Surfacing (cladding, buttering, hardsurfacing, regeneration) from page

15 Profile and beam welding system Automatic SAW welding gantry type KU Application Box beam welding with max. 300 mm component preload SAW welding Fillet welds Thicknesses from 10 to 20 mm Maximum component dimensions 60,000 x 1,500 x 2,500 mm Materials: S235, S

16 Features Production of box beams up to 2,500 mm in height On-board operation platform with all control elements for each working section and camera system Target 50% reduction in secondary time gained through single turn-over of workpiece. The gantry enables the welding of all seams in horizontal position Set-up times minimised by automatic balancing of location deviations up to 750 mm High flexibility as regards profile component due to custom portal construction, leading to high potential savings through versatility of application System components 2 DC welding power sources type GTH motorised flux recovery units Inductive seam tracking system Performance range 100A/19V up to 1,000A /44V at 100% duty cycle Welding speeds of up to 80 cm/min Diameter of welding wire of up to 5 mm Fillet welds in PB position (horizontal vertical) Applied benefits High productivity due to fully automatic beam welding approx. 70% reduction in working time Simultaneous welding of both fillet welds including automatic balancing of the direction deviations Set-up time minimised by closed flux recovery Entire welding process overseen and controlled from an operating platform - 5 -

17 Beam welding system Fully automated SAW welding gantry type VWS Application Joint welding of steel plates into carrier sections with boundary fillet welds SAW welding Fillet welds Thicknesses from 8 16 mm Maximum dimensions: 22,000 x 1,400 mm (base height) Materials: S235, S355, shipbuilding steel - 6 -

18 Features SAW gantry for welding of components in longitudinal direction Internal heavy-duty tractor for complete welding assembly support Target Productivity boosted to approx. 130% through automatic carrier section welding Enhanced process reliability through elimination of human error in manual welding High production efficiency and considerable reduction in workload through appropriate workpiece handling High-grade and robust process technology for optimum welding results combined with longevity of systems engineering System components 2 power sources type GTH SAW single wire welding heads Mechanical seam tracking system using hinged arm technology Motorised flux recovery system Main control console for welding and on-board peripherals in the welding area Performance range 80A/18V up to 720A/44V at 100% duty cycle Welding speeds of up to 70 cm / min Diameter of welding wire max. 2.5 mm Fillet welds in PB position (horizontal vertical) Applied benefits Component warpage minimised by simultaneous fillet welding Secondary processing time reduced thanks to two side by side workpiece supports Hinged arm technology for perfect seam tracking even with nonlinear welding seams - 7 -

19 Beam welding system Fully mechanised GMAW welding gantry type HUE Application Joint welding of plates to longitudinal beams with required angle deviations of up to 13 GMAW welding Fillet welds Material thicknesses of 8 to 16 mm Maximum workpiece dimensions 9,500 x 500 x 200 mm Materials: S235, S

20 Features Target Automation of beam welding for increased productivity compared to semi-mechanised welding process used hitherto Productivity boosted by around 70% through automatic welding of the beams including torch control in angular range Time saved on stitch process by using separate fixture elements Reduced set-up time through simultaneous feeding of two parallel workpiece tables System components 2 GTH 522W power sources with separate wire feeder 2 water-cooled GMAW machine torches with double cooling system and angularity of 45 Tactile seam tracking straight in front of the welding arc Performance range 70A/18V to 400A/34V at 100% duty cycle Welding speeds of 70 cm/min Diameter of welding wire 1.2 mm Fillet welds in PB position (horizontal vertical) Applied benefits Time saved by automated beam welding with cut-off system component-oriented welding limit stop Simultaneous welding of both fillet welds, including tracking of existing angle deviations Considerable reduction in secondary process time through automation, elimination of stitch process and positioning of both beams in a narrow gap Workpiece warpage minimised by simultaneous welding of both fillet welds - 9 -

21 Beam welding system Fully mechanised heavy-duty GMAW welding tractor Application Construction welding of plates to carrier sections GMAW welding Fillet welds Thicknesses from 8 25 mm Maximum dimensions 25,000 x 500 x 1,200 mm Materials: S235, S

22 Features Mechanised longitudinal carrier section welding deploying heavyduty tractor on roadway Target Significant cost reduction through the use of heavy-duty machine technology compared to the originally planned construction portal High flexibility through applicability for different carrier sections due to the long boom and by using hinged arm technology Secondary process time minimised by bilateral workpiece feeding along roadway positioning on a swivel joint on the rail carriers System components 2 power sources type GTH 522W 2 water-cooled GMAW machine torches capable of withstanding 500A 2 DV 4W-1 wire feeders Four-wheel heavy-duty tractor, track width 540 mm, with swivel joint for welding equipment Mechanical seam tracking through guided rolls on GMAW hinged brackets Plant-floor control panel with all display and functional elements Performance range 70A/18V to 400A/34V at 100% duty cycle Welding speeds of up to 100 cm/min Diameter of welding wire max. 1.6 mm Fillet welds in PB position (horizontal vertical) Applied benefits Productivity increased by about 40% and process reliability enhanced by mechanised welding process Workpiece warpage minimised by simultaneous welding of both fillet welds Approx. 30% reduction in secondary process time thanks to second workpiece table at opposite side of roadway

23 Beam welding system Fully mechanised double hinged joint arm automat type KA 4-UPDG Application Joint welding of sheet metal, plates and rolled sections to box sections SAW welding Fillet welds and butt welds Thicknesses of up to 30 mm Max. dimensions 30,000 x 1,500 x 800 mm Material: S

24 Features Modified welding machine for simultaneous welding of opposite fillet welds Seam tracking through guided rolls and hinged arm Welding of components preheated to 200 C Target Installation costs reduced to approx. 35% by using machine technology as opposed to portal construction Major reduction in set-up time through flexibility and easy tractor handling Cost reduction through added versatility of optional equipment with plasma cutting torches for gouging the sealing run Integrated hinged arm technology for versatility of application with regard to workpiece geometry and seam type and position Option of fitting oxyfuel torches on hinged brackets for preheating System components Modified double joint arm automat 2 power sources type GTH pneumatic flux recovery units Performance range 80A/18V to 720A/44V at 100% duty cycle Welding speeds up to 60 cm/min Diameter of welding wire up to 2.5 mm Fillet welds and butt welds in PA position (flat) and PB position (horizontal vertical) Applied benefits Significant increase in productivity and reduction in workload through high degree of mechanisation Significant improvement in quality error rate for ultrasound and X- ray examinations down to 0.5% Maximum processing route dependent only on media supply

25 Beam welding system Fully mechanised SAW tandem welding gantry type TE Application Joint welding of plates to various types of heavy-duty beams SAW tandem welding Fillet welds and butt welds Plate thicknesses from 50 to 180 mm Max. workpiece dimensions 15,000 x 1,600 x 1,400 mm Material: S

26 Features Existing portal with double-wire equipment has been converted to Kjellberg tandem technology Target Considerable boost in productivity to 150% through automation of beam manufacturing Major increase in welding productivity thanks to the use of tandem technology Quality guaranteed by high level of automation plus powerful and reliable welding processes System components 1 DC power source type GTH AC power source type TTH SAW tandem welding head, tilt adjustable left/right Motorised flux recovery unit with pressure conveyor Performance range 100A/19V to 1,000A/44V at 100% duty cycle DC 200 A to 1,000A at 100% duty cycle AC Welding speeds of up to 80 cm/min Diameter of welding wire 3 4 mm Single-bevel butt weld Applied benefits 50% increase in performance through very high welding speed and excellent welding performance High-quality workmanship thanks to effective weld seam geometry with improved mechanical characteristics Workpiece warpage minimised by reduced energy input

27 Beam welding system Fully mechanised SAW welding gantry type DE Application SAW longitudinal welding of box girders, T beams and trapezoid cross sections SAW parallel welding Fillet welds, optional butt welds Thicknesses of 8 30 mm Max. workpiece dimensions 35,000 x 6,000 mm under preload, (separate clamping device), 35,000 x 10,000 mm without preload, box girder max. 35,000 x 1,500 x 1,000 mm Materials: S235, S

28 Features Mechanisation of longitudinal welding Facility for welding in all four directions thanks to rotating column Target Significant time saving by utilising entire portal width and full length of workpiece table Preset parameters guaranteeing seam quality, process reliability and easing the workload of operating staff System components 2 DC power sources type GTH modified parallel wire welding heads with continuous adjustable wire positioning Inductive seam tracking system Performance range 200A/28V to 1,000A/44V at 100% duty cycle Welding speed up to 100 cm/min Wire diameter for each welding head 2 x 3 mm Fillet welds in PB position (horizontal vertical), butt welds in PA position (flat) Applied benefits Significant reduction in secondary time through eliminating portal runtime using a 270 rotating column Workpiece warpage minimised by simultaneous welding of both fillet welds Set-up time reduced by automatic tracking with existing angle and plate thickness deviation

29 Beam welding system Fully mechanised SAW gantry type WI Application Joint welding of plates to profiles and panels SAW parallel welding Main specialisation in fillet welds, optional butt welds Thicknesses of 8 30 mm Max. workpiece dimensions 8,500 x 1,500 mm Materials: S235, S

30 Features Fully mechanised gantry with double wire technology for increased productivity in comparison to a semi-mechanised welding process with single wire technology Target High productivity thanks to time saved by automated welding of profiles, beams and panels Extreme flexibility regarding workpiece dimensions due to large span and potential action radius of portal Staff workload reduced by preset process parameters and ease of operation while maintaining excellent product quality System components 2 DC power sources type GTH modified parallel wire welding heads with continuous adjustable wire positioning, capable of withstanding 600 A Mechanical seam tracking system aided by role guides on hinged arms Motorised flux recovery unit, exhaust air filtering and visual level indicator Performance range 200A/28V to 1,000A/44V at 100% duty cycle Welding speed cm/min Wire diameter per welding head 2 x 2.5 mm Fillet welds from a = 6 mm in PB position (horizontal vertical), butt welds in PA position (flat) Applied benefits High production time savings, minimisation of workpiece warpage and reduction in amount of post-processing required by simultaneous welding of both fillet welds Set-up time reduced by automatic tracking with existing angle and plate thickness deviation Significant reduction of secondary process time thanks to ample working width and large workpiece support for multiple charging

31 Profile welding system Fully mechanised GMAW welding gantry type AK Application Joint welding of plates for assembly of ship sections GMAW welding Fillet welds and butt welds Thicknesses from 8 20 mm Max. range of operation 70,000 x 10,000 x 500 mm Materials: S235, S355, shipyard steel

32 Features Mechanisation of section production for increased productivity compared to the typical semi-mechanised welding process Gantry dimensions: 11,800 x 4,200 x 3,200 mm 270 swivel pillar for welding in four directions Target Production time shortened to 50% by vast work area and removal of portal return High weld quality and process reliability thanks to selectable program sequences Staff workload eased by simple operation while increasing product quality System components 2 DC power sources type GTH 802 with external cooling units 2 water-cooled GMAW push-pull machine torches IInductive seam tracking system Performance range 80A/18V to 720A/44V at 100% duty cycle Welding speeds of up to 100 cm/min Flux cored wire with a diameter of 1.4 mm Solid wire with a diameter of 1.2 mm Butt welds in PA position (flat) Fillet welds in PB position (horizontal vertical) Applied benefits High savings in production time and minimal component warpage thanks to simultaneous welding of both fillet welds Secondary process time reduced by simultaneous charging of work area with several workpieces Four possible welding directions thanks to rotating holder pillar

33 Butt welding system Fully mechanised SAW welding automat with a linear compensation axis Application Joint welding of plates to large panels SAW welding Butt welds Thicknesses from 8 20 mm Materials: S235, S

34 Features Modified standard SAW automat featuring a drive shift system for the machine drive in linear axis Target Significant saving in production time (approx. 40%) by welding full plates without interruption until the end of process Minimum investment costs through use of machines modified to customer specifications Huge increase in seam quality through elimination of discontinuities at the end of seams System components 1 DC power source type GTH 1002 SAW welding head for single wire Linear axis with mechanised switching Performance range 100A/19V to 1,000A/44V at 100% duty cycle Welding speeds of up to 60 cm/min Diameter of welding wire 3 5 mm Butt welds in PA position (flat) Applied benefits No post-processing required on seam ends thanks to use of fully mechanised welding system with run-out plates Increased productivity and process reliability due to customised machine modification Reduction in working time due to minimised set-up time through elimination of start and stop plates

35 Tank welding automat Fully mechanised SAW welding automat type SOL Application Joint welding of rolled steel sheets SAW welding Circular and longitudinal seams (2 separate installations) Thickness 3 mm Tank diameter max. 800 mm Tank length 1,800 2,300 mm Material: Structural steel and pressure vessel steel

36 Features Solid machinery base with two support combinations and tank rotary device for simultaneous circular welding Solid machinery base with fixing bolt, roller slideway and support combination for longitudinal welding Target Very high increase in productivity by more than 150% due to fully mechanised tank production Significant increase in quality through the elimination of human error in manual welding processes Flexible range of application thanks to suitability for production of tanks with various dimensions System components 3 DC welding power sources type GTH 522 G 3 SAW single wire welding heads, each with optical seam tracking system 3 operating consoles for welding process control 3 pneumatic flux recovery units Performance range 70A/18V to 400A/34V at 100% duty cycle Welding speeds of up to 75 cm/min Diameter of welding wire up to 2 mm Circular and longitudinal seams in PA position (flat) Applied benefits High production time saving and low-warpage welding due to high welding speeds with very good seam quality High process reliability thanks to centralised control of both circular welding systems Simultaneous welding of tank top and end to minimise workpiece deformation 2 separate units for all welding tasks for complete tank production

37 Tank welding automat Automatic SAW column and boom manipulator type DV Application Joint welding of rolled stainless steel plates SAW welding Circular and longitudinal seams Thicknesses of mm Max. pipe diameter 3,500 m Material: unalloyed, low-alloyed and high-alloyed steels

38 Features A rotating column and boom manipulator with longitudinal and height axis (X and Z) was equipped with Kjellberg SAW technology The positioning occurs by the roller bock turning device Motivation 4 degrees of freedom for the production of different tank sizes System components 1 DC power source type GTH 802 SAW single wire welding heads, separate for mild steel and stainless steel Manual positioning for X and Z axis Central operating console with joystick control of the axes Pneumatic flux recovery with pressure conveyor Performance range 80A/19V to 800A/44V at 80% duty cycle Welding speed of up to 80 cm/min Diameter of welding wire up to 3.0 mm for stainless steel Diameter of welding wire up to 5.0 mm for mild steel Circular, longitudinal and fillet welds in PA position (flat) and PB position (horizontal vertical) Applied benefits Less welding deformation thanks to fast welding speeds and accurate weld quality Process reliability through high-class technology and direct process monitoring by the user Multiple applications by high number of degrees of freedom

39 Pipe welding machine Fully mechanised steerable automat type KA1-UPP Application Joint welding of rolled plates to pipe sections SAW parallel wire welding Butt welds and fillet welds Thicknesses of up to 40 mm Minimum pipe diameter approx. 1,400 mm Materials: S235, S

40 Features Modified steerable SAW automat for cylinders and conical parts with parallel-wire technology High degree of stability thanks to serial axis prolongation Modified power sources for sufficient process reliability at long distances from the welding area Target Major reduction in production time thanks to huge increase in deposition rate assisted by the use of double-wire technology High productivity achieved through fully mechanised welding process for interior seams Savings in operating materials thanks to universal use of steerable automat for cylindrical and conical components (e.g. as wind turbine towers) System components Modified steerable automat for double-wire technology 1 DC power source type GTH 1402 Pneumatic flux recovery unit in a closed circuit design Performance range 100A/19V to 1,200A/44V at 100% duty cycle Welding speeds of up to 60 cm/min Diameter of welding wire 2 x 2 to 2 x 3 mm Butt welds in PA position (flat) Fillet welds in PB position (horizontal vertical) Hoses and cables up to 50,000 mm in length Applied benefits Optimised engineering systems for welding complete towers, resulting in approx. 30% less labour time Automat base frame retains high degree of stability despite highly conical geometry of tube sections Maximum processing roadway dependent only on the media supply

41 Surfacing automat Fully mechanised GMAW welding gantry type VT Application Surfacing of plates for the manufacturing of wear plates GMAW welding with flux cored wire Cladding Max. workpiece dimensions 3,500 x 2,000 x 200 mm Material: Independent of application

42 Features An existing portal has been equipped with special GMAW welding technology Local exhaustion for occupational safety and environmental protection Target Significant increase in productivity in the range of 130% through automation of the surfacing process High process reliability through elimination of negative influence of incorrect torch management and distance Time saving and cost efficiency through use of full scope of system with several torches System components 2 DC power sources type GTH water-cooled flux cored torches with a power rating of 500 A Central operating console for peripheral equipment and welding technology Performance range 100A/19V to 1,000A/44V at 100% duty cycle Welding speed depends on process Diameter of flux cored wire max. 3.2 mm Cladding in PA position (flat) Applied benefits High savings in production time as well as huge reductions in workload and improved quality Low workpiece warpage thanks to simultaneous surfacing with several welding torches

43 Surfacing automat Automatic GMAW welding gantry type TAK Application Surfacing on mining components, conveyor parts and heavy industry workpieces GMAW welding with flux cored wires Cladding and regeneration Max. component dimensions 3,000 x 600 x 500 mm Material: Depends on alloy of flux cored wire

44 Features Target Automation of surfacing for regeneration and wear protection purposes Significant increase in productivity (approx. 70%) and reduction in workload thanks to complete equipment mechanisation in comparison to "manual flux cored wire welding Low error rate due to automated surfacing with a recordable program sequence Substantial decrease in staff workload and reduction in set-up times through use of turntable for workpiece handling System components Power source type GTH 1002 Water-cooled flux cored machine torch with four-rolled wire feeder Oscillation support for surfacing Central operating console for peripheral components and welding technology with stored program control (SPC) Performance range 100A/19V to 1,000A/44V at 100% duty cycle Welding speeds of up to 50 cm/min Diameter of welding wire max. 3.2 mm Cladding in PA position (flat) and PB position (horizontal vertical) Applied benefits Increase in productivity by approx. 60% thanks to oscillation device and high degree of mechanisation Occupational safety and environmental protection through external process control and program flow High process reliability, reduced heat input and low crack origin due to fixed program sequences geared to the respective welding task

45 Surfacing automat Automatic SAW Surfacing Unit type SMS Application Surfacing on running wheels and guide wheels SAW single wire welding Regeneration Diameter of work-piece between 300 and 1000 mm Weight of work-piece between 150 and 450 kg Material: unalloyed and low-alloyed mild steel

46 Features Automated surfacing for regeneration purposes Surfacing of running surfaces and edges is made possible by integrating a pivoting work-piece support Very high flexibility and easy transport due to compact structure of the unit with optimum arrangement of the individual components within the overall system Target Regeneration of components which are prone to wear and tear in order to save regular investments Very high process liability due to automated process with monitoring of parameters Compact version for transport in sea freight containers System components 1 welding power source of the type GTH pressure powder conveyor with a capacity of 50l, heated and with minimum level indicator 1 KA 2-UP welding head 1 rotating-tilting table with a maximum load of 750kg on the face plate 1 machine frame with main column and motor supporting cross Performance range Max A/ 44V at 100% duty cycle, optimum working range starts at 450A Welding speed up to 90 cm/min depending on diameter of workpiece and weld pool movement Wire diameter 3.0 mm Surfacing in positions PA and PB Applied benefits Huge cost savings by regeneration of consumables High productivity and process reliability Flexible positioning of the unit because it can be transported with forklift

47 Surfacing automat Automatic SAW surfacing column and boom manipulator type RAD Application Surfacing on wheelsets SAW and GMAW welding Regeneration Workpiece diameter up to 1,300 mm Infeed depth up to 450 mm Material: Filling material depending on welding job

48 Features Automated surfacing of Deutsche Bahn wheelsets for regeneration SAW and GMAW welding technology Target Huge increase in productivity by approx. 45% thanks to coating process automation Significant degree of reliability achieved through preset programming and fixed processes High savings in equipment thanks to job-oriented technology applying selective use of SAW surfacing at the seat of the wheels and GMAW edge technology at the hub flank Staff workload reduced by mechanised workpiece handling on turntable System components 1 power source type GTH GMAW machine torch, water-cooled 1 SAW single wire welding head Combined gas and water cooling system with flow control Motorised flux recovery unit, exhaust air filtering and visual level indicator Performance range 100A/19V to 1,000A/44V at 100% duty cycle Welding speeds of up to 60 cm/min Diameters of welding wire: Max. 3 mm (SAW process) Max. 1.2 mm (GMAW process) SAW surfacing in PA position (flat) GMAW surfacing in PB position (horizontal vertical) and PC position (horizontal) Applied benefits Major production time saving, high process reliability, reduced heat input and low tendency to crack due to automated regeneration with adapted welding procedures

49 Surfacing automat Mobile GMAW welding sytem type KAB Application Surfacing on worn cylindrical components GMAW welding with Innershield wires Cladding and regeneration Max. workpiece diameter approx. 3,000 mm Workpiece height approx. 300 mm Materials: Depends on availability of filling materials

50 Features Mobile surfacing equipment for regeneration and wear protection purposes Target Significant increase in productivity by approx. 150% through automated surfacing High increase in quality compared to the manual method previously used Option of partial disassembly of system with a view to its deployment in customer's locality and to saving time on transportation of parts for welding System components 1 power source type GTH water-cooled flux cored machine torch with four-roller drive Central operating console for welding technologies and peripheral components Water-cooling unit with flow control Performance range 80A/18V to 720A/44V at 100% duty cycle Welding speeds of up to 80 cm/min Diameter of welding wire max. 2.8 mm Cladding in PA position (flat) and PB position (horizontal vertical) Applied benefits Significant increase in productivity and alleviation of workload compared to "manual welding" in the range of 200% Occupational safety thanks to external process and program control High degree of flexibility and mobility due to segmental construction

51 Surfacing system for railways Fully mechanised machine for surfacing onto rails Application Regeneration of grooved rails SAW welding Layer structure of vertical groove flanks Material: Railroad steel

52 Features Optional use of solid wire or flux cored wire Facility for adjustment to a maximum track width of 1,500 mm according to the type of rail Waterproofed wire feeder housing Target Significant reduction in working time thanks to regeneration of grooved rails in mobile on-site applications using fully mechanised welding technology High seam quality thanks to uniform layers in the area of straight tracks, curves and switches System components 1 DC power source type GTH 802 modified for operating in generator mode SAW single wire welding head with flexible hollow cables for wire diameters of up to 2.5 mm Pneumatic flux recovery unit Hoses and cable 35,000 mm in length Performance range 80A/18V to 720A/44V at 100% duty cycle Welding speeds of up to 70 cm/min Diameter of welding wire up to 2.5 mm Layer structure in PC position (horizontal) Applied benefits Decrease in operative time, secondary processing time and downtime Mechanised welding on left or right groove flank, no re-positioning of the welding system necessary Stable welding construction in six-wheel version Minimum flux loss and long distances achievable with pneumatic flux recovery unit Flexibility regarding work location thanks to rubber wheels for ease of positioning and their infeed by electrical lifting cylinders

53 Kjellberg KA series welding machines Good value standard technology for a range of engineering applications Based on a flexible modular system, the KA machine series offers cost-effective solutions for a range of technological applications with a view to streamlining operations and realising potential savings. In the stiff competition between metalworking enterprises, you can secure benefits for yourself by deploying this standard technology, achieving: Major reductions in labour time through mechanisation and reaching high welding speeds and high welding output. Reliable welding quality in SAW process thanks to optimum welding performance, high pore reliability, excellent seam quality, and tachometer-controlled wire feeder and tractor drives Strong decrease in secondary process times thanks to mechanised operations, various flux recovery units, optimum slag retracking quality, fast support positioning Cost reductions due to high durability of wear parts (nozzle, feed rollers), low-wear and dustproof support newels, retrofit options for additional technology (sensors) and variable guide roll application, elimination of glare shield and welding fume exhaust Savings on labour costs through the use of semi-skilled, rotating personnel made possible by user-friendly, ergonomic controls and high degree of process reliability due to parameter pre selection for current, voltage and welding speed (preset) allows automatic process for start options and crater filling at the end of welding or choice of separate welding programs at a second operating level High degree of occupational safety due to avoidance of glare thanks to covered arc (by flux) at the workplace and in the whole workshop environment, very low weld fumes (no exhaustion), increased stability through axis prolongations, etc. Basic version KA 1-UP with flux recovery unit approx without flux recovery unit approx