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Roll-Arc™
System - Model
WRA-001 |
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Introduction
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VIDEO
LINKS:
INTRODUCTION (For
Dial-Up Click Here)
APPLICATION (For
Dial-Up Click Here)
To
view an introduction of the Roll™ Arc System or the WRA-001 in
operation in the field click on the video links above
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The
WRA-001 is a fully automated Roller-Arcing System for the hard
facing of Sugar Mill Rollers. This system enables a continuous arcing of
the roller to occur to pre-set requirements, allowing one operator to
attend to several machines at once. This saves both time and money as well
as eliminating the stifling work environment of heat and fumes
associated with the traditional method of roller arcing.
The
system is easily installed in almost any environment and provides a fast,
reliable and accurate method of arcing.
The
WRA-001 comes as a complete kit, ready to plug in and operate.
Only 20 minutes of instruction are required for an operator to be fully
qualified to operate the system, ensuring your investment returns are
immediate.
The
components of the kit are outlined at right and explained in greater
detail below.
To
view an introduction of the Roll™ Arc System, click on the
INTRODUCTION Video above left or click
here.
To
view the WRA-001 in operation in the field,
click on the APPLICATION Video
above
left or click here.
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Complete kit for
Roll-Arc™ System
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Components
of the Roll™Arc System - Model
WRA-001
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Weldalloy
Pty Ltd ROLL-ARC™ System for Automatic Arcing of Mill Rolls has been
developed after extensive consultation with many mills to assess their
requirements.
VIDEO
LINK: SAFETY
(For
Dial-Up Click Here)
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1.
Main Control Box |
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The
Main control box contains the controls necessary to operate the ROLL-ARC™
System in one compact (400 x 350 x 175 mm) light weight (10kg) box,
which is manufactured from high strength, light weight
thermoplastic and is well sealed against moisture. These features allow
flexibility in location of the control box ie. Inside or outside the
crusher and extremely simple and repeatable control of all functions. A
new indexing controller will allow programming flexibility resulting in
the system being capable of arcing in 1, 3, 5, 7 (or more) locations on
each tooth of the roll. This means that any combination of arcing runs
can be completed in a single traverse thus eliminating the time required
for the physical movement of the carriage from one end of the beam to
the other in subsequent passes. This capability will allow the complete
face of each tooth to be arced in one traverse of the beam if required. |
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The
system has been "purpose-built" and features proven components resulting
in:
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2.
Remote Pendant
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Pendant
control is provided in a compact and light (2kg), scaled box (in
addition to main control box) to allow operator remote and close-up
adjustment of the weld centering, inching, weld direction, carriage
speed, wire speed (current) and weld voltage on electronically
controlled power supplies.
All
of the above functions may be adjusted during operation. Also
incorporated as a standard feature is the automatic operation of the
welding power supply contactor with electronically controlled power
sources. This ensures that all voltage is off the system when Shutdown
Switch is activated. These features ensure ease of operation, adjustment
and repeatability from arc to arc.
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VIDEO
LINKS:
PENDANT
(For
Dial Up
Click
Here)
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A
great deal of time has been spent in catering for the different
applications by engineering "flexibility" into the system.
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3.
Main Beam
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High
strength main beam with precision engineered drive rack, fully
galvanised internally and externally for corrosion protection. Beam
mounting is by U-Shaped brackets to customer supplied mounting points.
Beams are inexpensive and are designed to be permanently fixed in
position at each arcing location to reduce set-up times. Weight:
Approximately 20 kg.
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4.
Traversing Carriage
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Use
of this system will result in greatly increased efficiency of arcing
with the additional benefits of longer roll life and improved crushing
efficiency.
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The
main carriage is fitted with fully sealed, ducted, variable speed DC
drive motor and gearbox driving through a positive rack and pinion.
Motor is fitted with robot style encoder to give infinitely adjustable
pitch settings with precision and repeatability. Motor and encoder are
fitted with an additional cover giving extra mechanical protection and
water proofing. Main carriage has been designed to open rather than
slide onto beam so it can be fitted to beam at any location quickly and
easily and once fitted, with the use of the quick release coupling, can
be freely and quickly moved along the beam to any location.
Weight:
Approximately 18kg.
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Features
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Simplicity
- Ease
of operation, training and maintenance
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Repeatability
& Accuracy - Encoded motor as used in robots for accuracy
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Versatility-
Can be used for straight line welding and roll rebuilding in
workshop as well as arcing during crushing.
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Reliability
- Proven components designed for on-site maintenance applications
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Compact-
System can be quickly broken down into individual components with
largest component fitting through a 600 x 600 mm (24"x
24") opening. System can be easily relocated from one location
to another by one person in 10-15 minutes
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Lightweight
& Portable - Total System Weight: Approximately 70kg
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Heaviest
Individual Component: 20 kg
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5.
Weld Arm
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The
weld arm is fully automatic with in-out axis of 800 mm plus pivot axis
through 600, all controlled electronically from the pendant. Special
attention has been paid to weld arm fitup and clamping to ensure even
better rigidity of welding torch.
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VIDEO
LINK: WELD
ARM MOVEMENT
(For
Dial-Up Click Here)
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6.
Welding Torch
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Welding
torch is heavy duty, open arc type requiring no shielding gas and no
water cooling. These features overcome the problems associated with
auxiliary water cooling. Torch is rated for continuous welding at 600
aznps, thus, ensuring long and reliable service life.
Torch
Adjustments
Torch
can be adjusted in three planes to cater for any welding position. A
vertical height adjustor providing +75mm (3") of travel is included
- The torch can also be adjusted in the forward plane from vertical down
to 100 below horizontal and rotated to +450 to allow for welding on the
sides of the roll teeth. Torch feeds forward and reverse automatically
for ease of contact tip change. Torch is fitted with quick disconnect
power cable for ease of operation.
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7.
Wire Feeder
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Wire
feeder is PA-6 extra heavy duty constant potential type with 4 drive
rolls to allow continuous, positive feeding of arcing wire. Drive rolls
are covered for protection from moisture, and crushing residue during
operation. The Feeder can be fitted on the top of the main carriage
assembly to overcome the need to drive wire long distances. (Maximum
length to torch tip 900 mm (3').
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VIDEO
LINK: WIRE
FEEDER
(For
Dial Up Click Here)
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8.
Wire Location and Type
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The
ROLL-ARC™ System has been designed to operate with Crushalloy-FC wire
in any of the following modes:
(i)
25 kg (60 lb) coils mounted on wire feeder on carriage.
(ii)
25 kg (60 lb) coils mounted on dispenser remote from feeder.
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Benefits
Improved
Efficiency through:
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Lower
consumable consumption by as much as 75%
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Reduced
time (Properly arc a roll on three faces in as little as 2 hours)
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One
operator can operate two (2) Systems with time to spare
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Reproductibility
- weld each roll the same way each time. No manual input.
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Greater
Health and safety - remove operator out of hazard area of fumes
etc.
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Automate
welding tasks in workshop
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9.
Additional Features
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A.
Water Proofing
Improved
waterproofing including the use of waterproof connectors and switches.
This feature will allow the system to be operated in almost any roll
location under almost any conditions.
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B.
Cable Protection
Fitting
of cable-protectors will result in improved mechanical protection on
interconnecting cables and hard wiring and waterproof plugs (where
fitted) will ensure the sealing of the electrical system.
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VIDEO
LINK: LOSS
OF MOTION
(For
Dial Up Click Here)
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C.
System Shutdown on AULL Stoppage
This
facility is supplied during production as standard and will ensure that
the Roll™ Arc System will shut
down if there are any unexpected mill stoppages. A switch to activate
this facility is fitted to the main control box and an adjustable
potentiometer is provided to allow settings for shutdown point to be
changed.
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D.
Shutdown on Loss of Weld Current
To
ensure the wire feeder does not continue to feed if there is a loss of
welding current, a current sensing circuit has been added to the system
which will stop the system operation completely upon weld current
failure.
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FURTHER
INFORMATION
For
further information on Roll- Arc™ System,
Model
WRA-001
contact
Andy
or Scott on
+61
7 3255 8660
or
click here |
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E.
Operation and Shutdown Indication
Flashing
indicator lights have been fitted to indicate remotely to the operator
the state of readiness or emergency shutdown of the system thus allowing
the operator to be setting up or moving another system while being aware
of the operating state of the first system.
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VIDEO LINKS: NEW
ROLLER
(For Dial Up Click Here)
USED ROLLER
(For Dial Up Click Here)
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10.
Additional Facilities
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In
addition to the capability of roller arcing, the system can also be used
in the workshop environment when not in use in the mill for:
Mode
1. Straight line welding eg. fabrication, striping etc.
Mode
3. Continuous circumferential build-up of rolls, journals, piston rods,
pump sleeves etc.
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