Welding Automats KA series

Transcription

1 Welding Automats KA series A manifold, modular system for increasing productivity and quality at welding

2 Kjellberg Welding Automats developed with 70 years experience Mechanization and automation of welding processes are the main demands of the industry, on which Kjellberg Finsterwalde has concentrated ist efforts since nearly 70 years. Starting with the mechanized meltingdown of stick welding electrodes in the early thirties Kjellberg Finsterwalde more and more was involved significantly in research and application of the submerged arc welding. Kjellberg automat (1938) Kjellberg automat, steerable (2004) The approved modular system of the sixties and seventies was the basis of various industrial solutions at home and abroad. The newly developed Kjellberg automat series KA follows this tradition, offering industries and shops an uptodate, flexible modular concept for different technological solutions. The wide range of application and the possibility to provide configurations suitable to the weld requirement, enabling the user to reduce fabrication costs and to increase weld quality, cover the following welding technologies: and MIG/MAG processes, butt joint and fillet welding, single and twin wire technique, single and double head welding. Advanced electronical controls simplifying the preparatory works and operations: parameter presetting, start and stop circuits, crater filling and burnback controls as well as tachometer controlled motors for wire feed and travel speed are based on advanced electronical components, making adjustments and use comfortable and safe for the operator. Welding automat KA 1UP, adapted for narrow gap welding at bridge construction members Different Kjellberg power sources are at disposal, completing the possibilities for various tailormade solutions to achieve highest effectiveness and productivity. 2

3 Various possibilities of application for the standard tractors of the KA series Welding applications Tbeam Double Tbeam Boxbeam Butt joint Container longitudinal beam Container circumferential seam (inside and outside) Hardfacing... performed with the automatic welders: Fig. 1: KA 1UP standard tractor applied for the submerged arc welding of double Tbeams in flat position (PA). The beam is fixed parallel to the truck way, ensuring a stable seam quality. Fig. 2: KA 2UP adapted to a column and boom for welding CrNicontainers. The visual seam tracing system consists of a laser pointer with camera monitoring. By means of a tactile sensor, the welding head always is kept in an optimum position to the welding seam. The central control board is provided with a monitor for the process control.. Fig. 3: KA 4UPDG tractor equipped with two fillet welding heads for the simultaneous welding of two fillets or HVseams in one run. Seam tracing is performed by guide wheels

4 Kjellberg welding automats for various welding systems Each Kjellberg automatic welder is offering the following features in general: 1 Highest welding quality through stable tachometercontrolled wire feed with 4roll drive for wires up to 3.0 mm ( and MIG/MAG) for wires 2.5 to 5 mm for single wire welding (KA 1UP), for parallel wire (KA 7UPP) 2x 1.6 2x 2.5 (2x 3.0) also adaptable to twin wire welding for doublehead fillet welding with wires up 2x 2,5 mm wire (KA 4UPDG) Use of the modules for complete solutions: The flexible modular concept of the automatic welders KA is the basis for different technological solutions under various conditions and numerous applications. In connection with Kjellberg power sources the optimum welding system for nearly all practical applications and highest productivity and efficiency can be configurated, e.g. welding portals and gantry equipment. Examples for application are shown on the Kjellbergwebsite / solutions for automation. 2 Flexible technological application through fixed welding head, adjustable in three planes for butt and fillet welding (KA 1UP) high lifetime of nozzles up to (KA 1UP, KA 7UPP) applicable to narrow gap welding with adapted nozzle attachment (KA 1UP) applicable as KA 7UPP (parallel wire) fillet welding head, springloaded mechanized guidance along the welding seam 3 cost saving, safe and reliable mechanicacal seam tracing (KA 3UPG, KA 4UPDG, KA 5MIG/MAG), avoiding costintensive electronical sensing systems Simple visual wire position control through laser pointer Easy to handle, comfortable controls (control voltage 42 V AC / 50 Hz) with Parameter presetting for: Safe transportation by lifting eye welding current arc voltage welding speed Preadjustable automatic sequence for arc start and crater filling and preadjustable welding programs (second service level) Wire reel capacity max. 30 kg Quick headtoseam positioning through cross slide (100 mm effective adjustment each) with dustprotected spindles 5 Stabilized balance with axle extensions for track gauge enlargement Flexible connection of supply cables with stress relief (front or aside tractor frame) Safe tractor guidance along construction members, profiles, welding seams, etc. through side rollers Minimizing of time consuming secondary operations through pneumatic flux recovery (injector principle); voluminous flux hopper (6 or 10 l) with fill check window Precise tractor drive because of tachometercontrolled 4wheel drive, travel speed 0.1 up to 2.0 m/min rubber rimmed or Vgrooved wheels with large diameter (160 mm) dust, protected, manual operated gear

5 Tractor models of the KA series Basic model KA 1UP Standard types Type KA 1UP KA 1UP (steerable type) Figure Technology Welding current (max.) Wire diameter (mm) Recomm. power source single wire tractor 800 A or GTH 522 GTH single wire tractor for container and pipe inside welding (e.g. wind power towers) 6

6 Type Figure Technology Welding current (max.) Wire diameter (mm) Recomm. power source KA 2UPP twin wire head (with controls, for adaptation to column and boom or other engineering devices, without undercarriage) 2x 1.6 up 2x 3.0 As well as single wire head available 800 A or GTH 802 KA 4 UPDG double fillet welding tractor (simultaneous welding of two fillet or butt seams) 600 A (per welding head) 1.6 to 2.5 (per welding head) 2x GTH 522 2x GTH 802 KA 7UPP parallel wire tractor 2x 1.6 to 2x 3.0 Also available with steering device 7

7 Technical data of power sources for Kjellberg automats of the KA series Welding rectifier 1) GTH 522 GTH 802 KH 600 Dynamic Article no a Application Characteristic Input voltage Input power, 100 % d.c. Fuse, slow Welding current range 40 % d.c. 60 % d.c. 80 % d.c. 100 % d.c. Protection class Weight Dimensions L x W x H (mm), MIG/MAG 3x 400 V, 10%/+10%, 50 Hz 25 kva 50 A 70 A / 18 V 500 A / 45 V 500 A 400 A IP kg 1130 x 665 x 865 (doubleaxle undercarriage), MIG/MAG 3x 400 V, 10%/+10%, 50 Hz 44 kva 63 A 80 A / 18 V 800 A / 44 V 800 A 720 A IP kg 980 x 720 x 1,000 (doubleaxle undercarriage) MIG/MAG pulse 3x 230/400 V, 10%/+10%, 50 Hz 22,8 kva 80/50 A 30 A / 15 V 600 A / 44 V 600 A 450 A IP kg 1,020 x 750 x 1,130 (with trolley) Welding rectifier Article no a a Application Characteristic Input voltage Input power, 100 % d.c. Fuse, slow Welding current range 100 % d.c. Protection class Weight Dimension L x W x H (mm) 78 kva 100 A / 19 V 1,000 A / 44 V 1,000 A 440 kg, MIG/MAG 3 x 400 V, 10 % / + 10 %, 50 Hz 82,5 kva 100 A / 19 V / 44 V 1200 A 440 kg Welding rectifier GTF 752 GTF 1002 GTF 1402 Article no Application Characteristic Input voltage Input power at 100 % d.c. Fuse, slow Welding current range 60 % d.c. 80 % d.c. 100 % d.c. Protection class Weight Dimension L x W x H (mm) (gouging) 49 kva 60 A/22,4 V 750 A/44 V 750 A 630 A IP kg 980 x 720 x 1,000 (doubleaxle undercarriage) (MMA, gouging) drooping (cc) 3 x 400 V, 10 % / +10 %, 50 Hz 78 kva 200 A/28 V 1,000 A/44 V 1,000 A 438 kg (MMA, gouging) 82,5 kva 200 A/28 V /44 V 1,200 A 438 kg 1) with integrated water cooling; without water cooling possible Our products are produced according to the latest technical development. We reserve the rights for changes during production. Therefore claims of whatever kind can t derived from prospectus Kjellberg Finsterwalde Elektroden und Maschinen GmbH Germany D Finsterwalde Leipziger Str. 82 Tel.: Fax: kjellberg@kjellberg.de Internet: