MODULAR DRIVE SYSTEM AND SPINARC TECHNOLOGY A Winning Combination!

Transcription

1 MODULAR DRIVE SYSTEM AND SPINARC TECHNOLOGY A Winning Combination! Two well known technologies come together to provide the highest level of productivity and quality welds with little or no bevel required, thus significantly decreasing your total cost per weld. Bug-O Systems Automated Cutting and Welding Systems Bug-O Systems is guided by honesty, integrity and ethics in service to our customers and in all we do. 1

2 The SpinArc technology and torch is now available with the MDS (Modular Drive System) to provide you with the highest level of productivity, quality and cost savings to tackle your production and manufacturing challenges of today. SpinArc which is GMAW technology, improves welding in a variety of applications by rotating the wire at very controlled speeds, diameter and direction to suit the application. The process improves the joining of two plates by rotating the wire very quickly at the contact tip with speeds from 200 to 5,500 RPM. The spinning or stirring effect in the arc also creates a very consistent metallurgy in the weld deposit. Since the spin diameter is adjustable, as the diameter of the spin increases so does the bead width. Therefore, you can tailor these variables to the specific weld joint. For example, when you want to weld in an overlay or hard-facing application you would want a fairly wide bead. Hence you would set a large spin diameter. When you spread out the arc energy, it minimizes dilution. For a narrow gap, deep grove butt joint, you can often eliminate the need for a bevel up to 1 to 1.25" thick material and beyond 1.25" can dramatically reduce the amount of bevel, thus saving preparation time and money. In this type of application you would want a smaller spin diameter. Control Box Control Module Linear Weaver The system can rotate the wire clock-wise or counter clock-wise so you can choose depending upon the weld direction to ensure the arc s energy focuses on the leading edge. Since the SpinArc technology is in the gun itself, it works with any Constant-Voltage (CV) GMAW power source and can attach to any wire feeder. When you couple this with the Modular Drive System, you have a powerful productivity system capable of welding narrow gap heavy plates, fillets, lap joints of various types as well as overlay and hard-facing. Anytime you can take the gun out of the operators hand and control the speed, direction and travel, your productivity and consistency increases. Now when you combine that with a SpinArc torch where you can additionally control the spin and direction of the wire, you have real control of the welding process. Automatic Height Control Master Drive Unit MA-400 Torch That s why this is such a winning combination when it comes to producing consistent high quality welds at high production rates while reducing your need for costly plate preparation. All of this saves you time and money, which is so important in the very competitive and global environment we work in today! Carriage 2

3 SpinArc Welding System 400 Amp Air-Cooled Machine Torch Features Spring strain relief provides excellent wire feeding Gearless torch motion, reliable, low maintenance, no lubrication required Hard anodized aluminum body built for industrial applications Plug n play to any wire feeder and welding power source Tool free spin diameter adjustability Digital motor control circuit for precise spin speed control Safer welding capability results in less material handling, less beveling, and reduced interpass grinding Contact tip extensions for deep, narrow, groove welds Controls and welding power combined into one composite cable Easily adjustable spin speed and direction Control spin start with arc start or delay up to five seconds Integrates with automation systems Includes digital control box Quick Specs Spin Diameter: 1-8 mm Wire Diameters: /16" ( mm) Rotation Speed: 200-5,500 rpm Rated Output: 100% duty cycle with 90/10 Ar/CO2 Welding Processes: GMAW, FCAW, GMAW-P Welding Positions: All position 3 Benefits Enables high deposition rate welding Reduces or eliminates need for weld bevels Provides all position welding capabilities in a spray like mode Produces good wetting action with smooth bead profiles Gives added control over weld bead size and depth of penetration Allows for higher travel speeds Provides excellent side wall fusion in narrow gap welding applications Provides stirring action resulting in a more consistent weld Excellent for overlay applications How It Works Patented technology rotates welding wire in a high speed circular motion Centrifugal force propels molten droplets creating consistent, sound finished welds High speed rotation creates surface tension allowing for all position welding Adjustable spin diameter, speed, and direction allow for optimal welds Applications: Industries: Plate Pipe Structural Clad Overlay Aerospace Automotive Construction Fabrication Offshore Pipeline Ship Building

4 Modular Drive System The Master Drive Unit has a high torque, low inertia motor for precise stops and starts and a dedicated failsafe brake with three times the stopping and holding power of the motor. The unit is equipped with motor overload protection which turns the motor off and engages the brake whenever an excessive load is placed on the machine. In addition, the Master Drive features closed loop speed control for adjustable, repeatable control of critical welding or cutting parameters, and closed loop position control to prevent creep. Master Drive Unit At the heart of the Modular Drive System is the Master Drive Unit which houses the motor, speed control board, power supply, and clutch, that allows rapid manual positioning of the carriage anywhere along the track. The unit runs from in/min ( mm/min) with a vertical load capacity of 60 lbs (27 kg) and a horizontal load capacity of 100 lbs (45 kg). Order reference: MPD VAC/50-60 Hz MPD VAC/50-60 Hz MPD VAC/50-60 Hz WPD-1100 Linear Weaver The Linear Weaver and the Weaver Control Module give the Modular Drive System linear weave motion, producing welds from 1/8" to 2" (3-50 mm) wide. The Linear Weaver bolts onto the front of the Carriage and the Weaver Control Module plugs onto the top of the Master Drive Unit, as shown below. The Linear Weaver also has motor overload protection which turns off the motor when too much load is placed on the Linear Weaver. Linear Weaver Order reference: WPD-1100 Weaver Control Modules The Weaver Control Module operates the Pendulum or Linear Weaver, and the Master Drive Unit. The Control Module features include: a digital readout and control knob for longitudinal travel speed; a switch for Forward/ Stop/Reverse tractor control; an amplitude knob to set weave width from 1/8"-2" (3-50 mm); weave speed control up to 100 in/min (254 cm/min); controls for left and right dwell; a knob to control steering up to 2" (50 mm), either side of center; weld contact; and a power On/Off switch. One of four weld patterns can be chosen using the mode selector switch, as shown in the figure below. The MDS-1005-DIAL Weaver Control Module w/ locking dials provides all of the function controls of the MDS-1005 and provides lockable numerical display dials for all oscillator functions. MDS-1005 Weaver Control Module Digital display can be set to in/min or cm/min. 4 MDS-1005-DIAL Weaver Control Module

5 Weld Patterns RUN: In this mode, power to the drive unit is always on and the machine travels continuously both during weave and dwell. Weave speed and dwell time both affect the weld pattern. 2. STEP: The drive unit travels only during dwell, and stops during the oscillator cross stroke. Changing weave speed does not effect the weld pattern dwell time does. 3. TRACTOR STOP ON DWELL: The drive unit travels during weave stroke; the drive unit and weaver stop during dwell. 4. NO WEAVE: In this mode oscillation is stopped. Only the tractor is powered. This mode is used for stringer passes. Automatic Height Control CAS-2050 BUG-O s AHC can be installed on any welding device. It works with any constant voltage (CV) welding power source and is compatible with SAW, FCAW and GMAW Welding processes. If needed, the welder can temporarily override the AHC, using the manual jog switch while welding. AHC resumes as soon as the jog switch is released. Automatic shut-off of the height adjusting drive happens when current is off, or falls below a pre-set lower limit. The CAS-2050 can be used with the MDS Linear Weaver System or the MDS Straight Line Welding System. Maintaining constant welding current (arc length) is critical for producing consistent, quality welds. BUG-O Systems Automatic Torch Height Control (AHC) is your solution. Automatic height sensors monitor welding current and adjusts torch height in response to changes in the current. Maintaining a constant weld tip to work piece distance produces uniform weld penetration and controlled heat input. For more detailed information on MDS, please visit our website to view our Modular Drive System brochure. For more detailed information on AHC, please visit our website to view our Automatic Height Control brochure. The motorized slide provides a total of 2" (50.8 mm) of travel with a 10 lb. (4.54 kg) weight carrying capacity. It also features a built-in time delay after arc is struck, and shuts off automatically when the current drops too low (generally below 60 amps). Minimum welding current is 60 Amps. If the welding current falls below 60 Amps, the unit may not correctly adjust torch height. (Standard Capacity is: 500 Amps) Technical Data Travel: Load Capacity: Operating Range: Net Weight: 2" (50.8 mm) 10 lbs. (4.54 kg) 60 to 500 Amps Approximately 14.5 lbs (6.6 kg) 5

6 Specifications Product Name Cable Length Rated Spin Start Torch Output Duty Cycle Wire Sizes Delay Time Spin Direction Dimensions WRT-400-XX Air-Cooled XX (custom) % duty /16" 0-5 sec. CW or CCW L: 12" (304.8 mm) Machine Torch Amps cycle with ( mm) Ø: 1.75" (44.5 mm) 80/20 Ar/CO 2 gas ft. (4.6 m) XX= XX ft., special order lengths available between 3-15 ft. ( m) Rating based on tests that comply with IEC standards Product Name Power Dimensions WRT-CB-115 Control Box VAC W x H x D: 8 x 4.25 x 2.5" (203 x108 x 64 mm) Consumables Consumables Power Pins Manufacturer WRT-M1 Miller Power Pin WRT-PP-F1 Fronius Power Pin WRT-PP-L2 Lincoln Power Pin WRT-PP-L2W Lincoln Power Pin WRT-TW4 Lincoln Power Pin.625 Dia. Call factory for availability on other feeder options Gas Nozzles WRT WRT WRT WRT Nozzle, 3/4" (19 mm) Bore, BG-10 Nozzle, 5/8" Bore-Flush, BG-10 Nozzle, 3/4" (19 mm) Bore, BG-10 Nozzle, 3/4"(19 mm) Bore, BG-10 Wire Liners WRT Liner -10', /16" WRT Liner -15', /16" WRT Liner -6', /16" WRT Liner -10', " WRT Liner -15', " WRT Liner - 6', " WRT Liner - 15', HDPE Control Cables WRT-CC-15 Control Cable, 15' (4.6 m) WRT-CC-6 Control Cable, 6' (1.8 m) Contact Tips & Extensions WRT Contact Tip, Teach Tough Lock WRT Contact Tip, 1/16", BG-25 WRT Tip, F/.045" Wire, BG-25 WRT Contact Tip, 0.040", BG-25 WRT Contact Tip,.045", BG-25 WRT Contact Tip, 0.040", BG-25 WRT Contact Tip, 0.035", BG-25 WRT Contact Tip,.045", BG-25 WRT Contact Tip, 1/16", BG-25 WRT Contact Tip,.045", BG-25 WRT Contact Tip Extension WRT Contact Tip Extension WRT Contact Tip Extension WRT Contact Tip Extension WRT Contact Tip Extension Cable Assembly WRT-CA-15 Cable Assy, Replacement 15' Required Components Each WRT-400 comes equipped with a control box, control cable, trigger cable and a.045"-1/16" liner. Required Components WRT-400-XX (-15 or specify cable length) Gas Nozzle (Table 2) Wire Liner (Table 3) Contact Tips (Table 5) Power Pin (Table 1) A QUALITY PRODUCT FROM BUG-O SYSTEMS 280 TECHNOLOGY DRIVE CANONSBURG, PA USA A DIVISION OF WELD TOOLING CORPORATION Weld Tooling Corp. ROM 1:16 Litho in U.S.A. LIT-SPINARC-BRO-0716