Automatic MIG/MAG Pipe Flange Seam Or Overlay Welding Machine

 

 

The dual-torch flange circumferential weld/surfacing welding machine is an automated welding device specifically designed for welding circumferential welds between round flanges and components such as pipes and cylinders, or for surfacing (e.g., surfacing stainless steel or alloy layers) on flange sealing surfaces and ends. Its core feature is the use of dual welding heads (dual torches), enabling symmetrical and synchronous welding, which greatly improves production efficiency and welding quality.

 

 

1.Mechanical Body and Positioning System

• Head and Tailstock Positioner: This is the core of the specialized machine. The headstock is typically driven by a servo motor, allowing precise control of the workpiece's rotational speed (welding speed) and position. The tailstock is a driven clamping mechanism, ensuring stable workpiece clamping.

 

• Chuck and Fixtures(customised): Specially designed for rapid clamping of flange-type workpieces, ensuring that their rotation center coincides with the positioner's rotation axis. This is crucial for ensuring the quality of circumferential welds. 

2.Dual Welding System

• Two independent welding heads: Typically equipped with high-precision cross carriages, each head can be independently adjusted up/down, left/right, and forward/backward.
• Wire feeding mechanism: If using MIG/MAG, each head is equipped with an independent wire feeder, wire spool, and wire feeding hose.

• Welding torch or torch: The MIG/MAG welding torch is selected according to the process.

• Dual system coordinated control: Can be set to symmetrical synchronous welding (welding at both ends of the diameter simultaneously, perfectly balancing stress), or to perform step welding (e.g., one root pass followed by one cap pass).

 

3. Welding Power Supply System

It equipped with two high-performance digital welding power supplies, one for each of the two welding torches. The power supplies can coordinate parameter settings and synchronize arc initiation/out via network.

 

4. Automated Control System

• Core Control: Utilizes a PLC (Programmable Logic Controller)
• Human Machine Interface: Equipped with a touchscreen (HMI) for setting welding parameters (current, voltage, speed), welding program, number of passes, and real-time monitoring of welding status.
• Linkage Control: Precisely coordinates the rotation of the positioner with the movement of the welding torch, arc initiation, arc termination, wire feeding, and other actions.

 

 

This equipment can weld flanges and perform surfacing welding; taking flanges as an example:

 

• Flange Circumferential Butt Welding:

Workpiece Clamping: Clamp one end of the pipe (placed horizontally) on the headstock chuck, and secure the other end with a flange backing or a tailstock pin. The flange is usually pre-installed on the pipe or positioned by the tailstock side.

Welding Process: Two welding torches are symmetrically arranged on both sides of the weld seam. The workpiece rotates at a uniform speed, and both torches simultaneously initiate arc welding, completing the entire circumferential weld seam in one pass. This greatly reduces welding deformation and improves efficiency.

•  Surfacing Welding:

Workpiece Clamping: Clamp the workpiece to be welded horizontally.

Welding Process: Two welding torches are arranged radially along the workpiece. The rotation of the workpiece and the lateral movement of the welding torches are linked by PLC programming to achieve spiral trajectory surfacing welding, covering the entire annular surface to be welded. The number of layers and width are programmable.

 

 

 

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