Flange Splice Welder
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Description
General Description
The flange clamp unit is composed of a rigid base assembly. The base includes leveling bolts and holes for concrete expansion anchors. The fixture is approximately 32 inches wide x 60 inches deep front to back. The flange welder is designed to single side splice weld flanges up to 16 inches wide and 1½ inches thick.
Two flange clamps are fabricated from a heavy bar. The clamps are moved by pneumatic force. Round rods hold the clamp bar in alignment during operation and transmit the clamping forces. The rods pass through line-bored structural steel tubes supporting precision, replaceable bushings.
Clamps
Pneumatic cylinders provide clamping force. Maximum clamping force is limited by air maximum PSI. With 125 PSI air, each clamp provides 2,450 pounds of clamp force.
Backer Bar
Flange ends are manually located over the copper backer bar. Pneumatic force raises and lowers the backer bar to contact the underside of the flanges being welded. The backer includes a groove machined in two sides. The groove holds flux and controls back bead shape. Each backer bar is composed of three short, replaceable segments.
The copper backer bars include flanges for positive attachment. The flanges maintain copper alignment, prevent the copper from sticking to the welded flanges when pulled away from the welded flanges and allow easy removal when needed. There is approximately 400 pounds of separation force between the backer bar and the welded flanges.
Backer Bar Cooling
A heat exchanger cools the backer bar. The coolant does not directly touch the copper. Coolant is contained within a sealed chamber to prevent leaks and make copper bar maintenance faster and easier.
Clamp Control
Each flange clamp and the copper backer bar are controlled by manual, detented air valves mounted at the operator station. The welder can control each clamp and the backer bar separately. A combination pneumatic filter/regulator/lubricator is included to extend cylinder and valve life.
Welding Equipment
A Lincoln DC 1000 power source, Lincoln NA-5 digital control with start and crater modules, a Lincoln NA-5 wire feeder and a Lincoln automatic flux dispensing hopper are included.
Weld Head Positioning
Weld head assembly power is provided by a gear-reduced, variable-speed drive system. Vertical weld head adjustment is included to allow for varying flange thickness.
Welding Shape Control
Disposable end dams are used to control weld bead shape at the ends of the weld. The end dams are easily positioned and removable after welding completion.
The flange clamp unit is composed of a rigid base assembly. The base includes leveling bolts and holes for concrete expansion anchors. The fixture is approximately 32 inches wide x 60 inches deep front to back. The flange welder is designed to single side splice weld flanges up to 16 inches wide and 1½ inches thick.
Two flange clamps are fabricated from a heavy bar. The clamps are moved by pneumatic force. Round rods hold the clamp bar in alignment during operation and transmit the clamping forces. The rods pass through line-bored structural steel tubes supporting precision, replaceable bushings.
Clamps
Pneumatic cylinders provide clamping force. Maximum clamping force is limited by air maximum PSI. With 125 PSI air, each clamp provides 2,450 pounds of clamp force.
Backer Bar
Flange ends are manually located over the copper backer bar. Pneumatic force raises and lowers the backer bar to contact the underside of the flanges being welded. The backer includes a groove machined in two sides. The groove holds flux and controls back bead shape. Each backer bar is composed of three short, replaceable segments.
The copper backer bars include flanges for positive attachment. The flanges maintain copper alignment, prevent the copper from sticking to the welded flanges when pulled away from the welded flanges and allow easy removal when needed. There is approximately 400 pounds of separation force between the backer bar and the welded flanges.
Backer Bar Cooling
A heat exchanger cools the backer bar. The coolant does not directly touch the copper. Coolant is contained within a sealed chamber to prevent leaks and make copper bar maintenance faster and easier.
Clamp Control
Each flange clamp and the copper backer bar are controlled by manual, detented air valves mounted at the operator station. The welder can control each clamp and the backer bar separately. A combination pneumatic filter/regulator/lubricator is included to extend cylinder and valve life.
Welding Equipment
A Lincoln DC 1000 power source, Lincoln NA-5 digital control with start and crater modules, a Lincoln NA-5 wire feeder and a Lincoln automatic flux dispensing hopper are included.
Weld Head Positioning
Weld head assembly power is provided by a gear-reduced, variable-speed drive system. Vertical weld head adjustment is included to allow for varying flange thickness.
Welding Shape Control
Disposable end dams are used to control weld bead shape at the ends of the weld. The end dams are easily positioned and removable after welding completion.
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Flange Splice Welder
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