Automatic Transformer Oil Tank Robot Welding Workstation (Robotic Arc Welding Machine)
● 9-Axis Synchronization：6-axis robot + gantry + positioner coordinated motion for complex tank geometry.
● Laser Seam Tracking (40μm)：Full-V sensor compensates fit-up deviation, no manual touch-up.
● Low-Spatter Process：Fanuc STT/Pulse mode, 80%Ar+20%CO₂, suitable for thin corrugated sheet and galvanized steel.
● Quick Changeover：Servo-centered tank-edge fixture remembers any size, recipe-based calling,10min changeover.
● 24h×3-shift Capable：Theoretical 1.2h/pc (J100) to 2.3h/pc (S1600), designed for continuous running.
● Turnkey Commissioning：Trihope provides installation, programming, operator training.
Process Introduction
1.1 Workpiece Dimensions:
● Min. Size: 850mm (L) × 510mm (W) × 885mm (D); Flipping Diameter: 1500mm; Weight: 200kg.
● Max. Size: 1150mm (L) × 650mm (W) × 1420mm (D); Flipping Diameter: 2400mm; Weight: 900kg.
● Fixture Range: Min. internal size 640×340mm; Max. 1400×650mm; Max. depth 1250mm; Max. load 600kg (using standard positioner). Larger units require the Heavy-Duty Positioner.
1.2 Process Brief
● Fit-up: Manual pairing.
● Loading/Unloading: Manual clamping.
● Displacement: Automated workpiece positioning via servo-driven positioners.
● Welding: Executed by a 6-axis robotic arm controlling the welding torch.
● Programming: On-site demonstration and digital programming.
● Seam Types: Fillet weld and flat weld.
● Process: Single wire Gas Metal Arc Welding (GMAW).
● Shielding Gas: 80% Argon + 20% CO2.
1.3 Workflow
The process consists of two stages: Laser Seam Tracking (Location) followed by automated Welding.
Equipment Configuration
The workstation integrates a gantry system, robotic welding, and dual-positioners to allow continuous 24/7 operation.
2.1 Layout & Fixtures
● Footprint: Approx. 14,000mm × 7,000mm.
● Tank Edge Fixture: Features servo-centering technology. The system memorizes positions for any tank size, allowing instant recall via program. Optional automatic feeding robots can be added for full automation.
● Positioners: Equipped with a Large Tilt Positioner (up to 2000kg) and a Medium Tilt Positioner (up to 600kg).
2.2 Pitch Time Calculation (Reference)
Based on typical production cycles:
● J100-7 Product: Scanning & Auxiliary Welding: 11 Minutes
● S400-4 Product: Scanning & Auxiliary Welding: 46 Minutes
● S1600-4 Product: Scanning & Auxiliary Welding: 68 Minutes
Detailed Cycle Analysis (S1600-4 Example):
● Total Seam Length: 33,963 mm
● Number of Seams: 74 pcs
● Scan Time (25mm/s): 1,359 s
● Welding Time (6mm/s): 5,661 s
● Auxiliary Time: 40 s
● Arc Start/Stop Time (2s/pc): 148 s
● Total Theoretical Time: ~122 min (2.0 hrs)
● Total Actual Time (90% Efficiency Factor): ~133.5 min (2.3 hrs)
Control System Architecture
The system employs a robust three-layer network structure:
1.Upper Computer (HMI): Handles model input, data logging, quality tracking, and real-time monitoring.
2.Main Control System (PLC): Monitors station status, graphical interface display, and comprehensive self-diagnosis.
● Fault Management: Classifies faults (Shutdown vs. Non-Shutdown), visual/audible alarms (Red/Yellow indicators), and guided troubleshooting.
3.Execution System: Comprises sensors, welders, and robotic drives.
Technical Parameter
|
Item |
Parameters |
|
Welding Process |
Gas Metal Arc Welding (GMAW) with single wire |
|
Shielding Gas |
80% Argon + 20% CO2 |
|
Weld Types |
Fillet weld, Flat weld |
|
Robotic System |
9-axis synchronized motion (6-axis robot + 2-axis gantry + 1-axis positioner) |
|
Teaching Method |
On-site teaching & Laser Seam Tracking (Full-V series, resolution: 40 μm) |
|
Welding Speed |
6 mm/s (Theoretical) |
|
Tracking Speed |
25 mm/s |
|
Power Supply |
3-Phase, 5-wire, 400V / 60Hz ±1Hz |
|
Operating Environment |
Temperature: 0~45ºC, Relative Humidity: ≤90% (Non-condensing) |
About Trihope
We are a 5A Class turnkey solution provider for Transformer Industry.
The First A: we are a real manufacturer with complete in-house facilities
The Third A, We have Top Performance Certificated with International Standards likes ISO, CE, SGS, BV
The Forth A, We are better cost-efficient supplier equipped with international brand components like Siemens Schneider, etc. And we provide 24 hours 24-hour after-sales service, providing services in Chinese, English, and Spanish
The Fifth A, We are a reliable business partner, served for ABB, TBEA, ALFANAR, PEL, IUSA etc in the last decades, And our customer are more than 50 countries all over the world.
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