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Thursday, 26 February 2015
There is not a moment of the day when massive metal fabrication projects are not underway somewhere in the world.The modern,technological society of today requires a steady stream of manufactured metal objects,whether as parts for other objects or as finished goods like cars, trucks,railway cars,aircraft,ships,fuel tanks,medical machinery, refrigerators, stoves,tools,furnaces,and countless other items and appliances.
Nearly all of these devices include at least some welding, and the colossal numbers and high-precision assembly needed for all of them drives another need a requirement for industrial welding machines.
Industrial welding machines are welders manufactured to be able to handle large volumes of welding in a short time and,frequently,to provide very large,strong welds as well.A small, slow welding machine will not be sufficient on an assembly line that rolls out a thousand new cars a week.In these cases,the welding machine must be not only quick and durable, but powerful as well.
Industrial welding machines are not a single,overall type that is good for all heavy duty work and does not vary between factories. Instead, they are probably even more diverse than the smaller-scale, portable or workshop based welding machines, as the tasks they face are not only more challenging but more various as well.
A few of the more common types include:
Seam welding machines – seam welding machines operate on the electrical resistance welding principle.These machines roll the edges of the two pieces of metal sheeting to be joined between two copper wheels, which are actually electrodes linked by a high-ampere electric current.The metal resists the electricity, which converts the energy to heat, and as the metal becomes molten, the two pieces are squeezed together and combined at the weld. The electrodes roll the sheets steadily forward, quickly creating a strong, continuous welded seam.
Spot welding machines – these large-scale relatives of the portable tong spot welders that were pioneered in Wisconsin by Niels Miller also operate on the electrical resistance principle, though the electrodes do not move the workpiece.The spot welder makes a weld at a single spot, tacking the pieces of metal together.This method is often used in automobile manufacture.
Wire mesh welding machines – ranging from fairly simple roller-and-die machines that create a square or rectangular wire grid for fencing,to sophisticated computer-guided machines that feature multiple welding heads and are shuttled back and forth on servos to weld complex patterns of wires or rods to create everything from shopping cart sides to concrete reinforcement,wire mesh welding machines are purely industrial devices thanks to their large size,cost,and complicated maintenance and operation.
Plasma arc welding – plasma arc welding,or PAW,is another application of electric arc welding which places the electrode inside the welding torch.This creates a plasma arc that is squirted out through an extremely fine nozzle made of copper,meaning that the plasma is accelerated to close to the speed of sound and can reach temperatures of around 36,000 degrees Fahrenheit,or about four times the temperature of Sol’s surface.This welding method is an advance on MIG welding and is often used in industrial applications.
Submerged arc welding machines – another type of industrial welding machine is the submerged arc welding machine.This is a flat-bed welder which is used only on horizontal welding because of the nature of the process.The machine is almost always runautomatically,on a preprogrammed basis, thanks to the special constraints of the method.The entire welding area is covered in a slurry of flux, which conducts the electric arc from the welding electrode to the workpiece.
The weld is constantly submerged under this pool of flux, preventing spattering and oxidation without the need for shielding gas.The welding must be carried out in the horizontal position so that the flux does not simply run off.However,the method allows welding at speeds ten times faster standard gas-shielded welding, while maintaining a very high quality of weld.
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