Spectrum Welding longitudinal seam welder with new retrofit design drive system installation

Our customer had a seam welder production line welder in place that MIG welded all day, all night continuously. This was an old seam welder system with cables everywhere, an antiquated motor gearbox, that ended up cutting out and came to grinding halt in a puff of smoke.

We were then approached as a matter of urgency to get our customer’s longitudinal seam welder production line back up and running in the shortest amount of time possible. Our solution was to rip out all the old bogie carriage drive system and replace all of it with brand new the mechanical and electrical 415V motor gearbox components, including much tidier energy drag chain cable carriers for the pendants controllers and LEV fume extraction.

The customer also needed to control the tandem head MIG seam welder from both sides, so we designed a twin pendant system that allow 2 pendants to be attached to the both sides of the seam welder carriage, so the operators could independently control both MIG heads that we setup for 1.0mm solid wire longitudinal seam welds, and the other side with 1.2mm wire seam welds.

Additional safety systems were also needed including forward & reverse traverse limit switches, emergency stops on the control panel and both pendant controllers, and fume extraction ducting connected to powerful fans with fixed nozzles at the welding source.

We also fitted the new 3-phase 415V 32amp MCB D-rated trip dedicated socket and conduit, so the system had a fresh uninterrupted power supply feed.

By being able to offer our customer this automation retrofit repair and upgrade service, we saved them a lot of money replacing this with a new machine with 12 weeks of downtime.

Refurbished and Retrofit Schedule
New 3-phase AC inverter frequency control system
New control panel stand
Panel built in accordance with BS EN 7671 18th Edition
Brand new electronics inc. all new cabling and new limit switches
New protective conduit
New mounting blocked for limit switches
Drag chain cable carriers fitted to prevent trip hazards (and much neater)
Fume extraction ducting and system built into design for HSE legislation
New long cable twin pendant controllers off the same control panel
Forward / reverse / stop / variable / emergency stop pendant features
New upgraded more powerful force-cooled AC motor gearbox
Gearbox ratio, RPM, and torque calculated to meet weld travel speeds
Motor gearbox 24 hour duty rating efficiency calculated to prevent burnout
New upgraded and uprated mechanical drive systems
New wire rope design with pulleys and tensioners
Pre-existing tandem bogie carriage repaired
All re-drilled and tapped
New EN24T machined parts inc. shafts, keyways, and gears
New CAD drawings with component kN load tolerance calculations
Shear force calculations
New tensioner plate and locking system
New phosphor bronze wear bush sleeves
New belts
New pulleys
New couplers
New taper locks
New moving parts cover guards and vents fitted
2 coats of special primer paint
2 coats of high quality olive green paint (as requested)
Build, deliver, install, commission, tested. PASS

Видео Spectrum Welding longitudinal seam welder with new retrofit design drive system installation канала Spectrum Welding Supplies Ltd