Welding Rotators Custom Built Welding Machines, Welding Rotators, Welding Column and Booms, Welding Positioners, Saw Pipes Welding Systems, Saw Pipe Handling Systems, Electroslag Welding Machine, Fixed and Portable Electroslag Welding Machine

Welding Rotators are very essential equipments for heavy and light fabrication shop. They are mainly used to rotate or position the cylindrical jobs for circumferential welding (TIG / MIG / Sub Arc) or for intricate assemblies. The machine consists of INo Drive unit and INo Idler unit and Control panel with pendant. For step less speed variation, AC frequency variable drive is used. The rollers are either made of Steel or moulded with polyurethane as per customers requirement.

Application : Welding of Pipes, API pipes, Boilers, Heat exchangers, Pressure Vessels, Mounted vessels, LPG Bullets, Barrels, Tanks etc

Advantages :

• An indispensable tool for shell fabrication shops.

• Attains exceptional quality circumferential joints on shells.

• Increased production with reduced labour.

• Leads to minimum handling for the Shell / Job .

• Lesser usage of crane thereby reduces idle time.

• Useful for internal assembly of intricate designs of circular jobs.

• Adaptable for automatic or manual welding.

There are three Design Variants in Modern Rotators:

1. The Conventional Type: Model 'CUCR' - Types.

Main base frames are fabricated and stress relieved before machining. There are basically two units, the Drive and Idler - one unit each. The precisely machined (on boring machine) Roller Brackets are bolted on the roller beds. Both the Roller Brackets have to be manually moved as per the job diameter keeping the job center fixed. This model has double ended drive to avoid use of intermediate drive shaft. The fixing holes for the brackets on the bed are precisely factory set.

Salient Features :

• Low investment cost.

• Ideal version to start with new fabrication line.

• Most suitable for small and heavy febrication shops.

• Simple & Sturdy design.

• Proven reliability.

• Accepts wide range of Job diameters.

Standard capacity ranges:

Load carrying capacity - 2 Tonnes to 1200 Tonnes

Job diameter Ranges - 350mm to 8000mm (Higher diameters on request)

Standard Drive Options:

A.C. Variable Speed OR A.C. fixed speed

Types of Roller Options :

Polyurethane / Steel.

2. The Self Centering types : - Model 'CUSR' - types.

The construction of this type is similar to Conventional Type except that this model has a provision to slide the Roller Brackets over the Base Frame equally in both directions through a lead screw having LH & RH threads.
Unlike in Conventional Type the Roller Brackets in Self Centering Type is not bolted on the base frame. The rotation of lead screw can either be Manual or Motorised (Optional). The Technical Specifications are same as Conventional Type.

SPECIFICATION FOR CONVENTIONAL TYPE WELDING ROTATORS

MODEL	TOTAL LOAD CAPACITY FOR DRIVE+IDLER (TONNES)	ROTATING CAPACITY OF DRIVE UNIT. (TONNES)	JOBDIA RANGE; MIN to MAX (mm)	SPEED RANGE- SURFACE SPEED OF ROLLER. (mm/min)	TYPE OF VARIABLE SPEED DRIVE.	ROLLER SIZE. DlA. X WIDTH (mm)	ROLLER MATL.	OVER ALL DIMENSIONS
								DRIVE UNIT			IDLER UNIT
								'L' mm	W' mm	'H' mm	'L' mm	W mm	'H' mm
CUCR-2	2	2	300 To 3000	100 To 1500	A.C.-VFD	0300 x 90	PU.	2100	500	507	1900	400	507
CUCR-5	5	5	350 To 3500	100 To 1500	A.C.-VFD	0400 x 120	PU.	2350	580	577	2150	450	577
CUCR-10	10	10	350 To 3500	100 To 1500	A.C.-VFD	0400 x 120	PU.	2900	650	604	2650	525	604
CUCR-15	15	15	400 To 4500	100 To 1500	A.C.-VFD	0400 x 145	PU.	3000	650	604	2800	525	604
CUCR-20	20	20	400 To 4500	100 To 1500	A.C.-VFD	0400 x 145	PU.	3000	700	654	2850	575	654
CUCR-30	30	30	450 To 5000	100 To 1500	A.C.-VFD	0500 x 145	PU.	3500	700	760	3300	600	760
CUCR-40	40	40	450 To 5000	100 To 1500	A.C.-VFD	0500 x 175	PU.	3500	750	770	3300	650	770
CUCR-50	50	50	450 To 5000	100 To 1500	A.C.-VFD	0500 x 250	PU.	3500	800	910	3300	650	910
CUCR-60	60	60	450 To 5000	100 To 1500	A.C.-VFD	0500 x 250	PU.	3500	900	916	3300	700	916
CUCR-70	70	70	450 To 5000	100 To 1500	A.C.-VFD	0550 x 200	PU.	3550	900	924	3300	700	924
CUCR-80	80	80	450 To 5000	100 To 1500	A.C.-VFD	0550 x 250	PU.	4200	1100	960	3750	900	960
CUCR-90	90	90	450 To 5000	100 To 1500	A.C.-VFD	0550 x 300	PU.	4200	1200	960	3750	900	960
CUCR-100	100	100	500 To 6000	100 To 1500	A.C.-VFD	0550 x 350	PU.	4600	1250	960	4200	950	960
CUCR-120	120	120	450 To 6000	100 To 1500	A.C.-VFD	0550 x 400	PU.	4600	1250	960	4200	950	960
CUCR-150	150	150	500 To 6000	100 To 1500	A.C.-VFD	0550 x 435	PU.	4700	1280	960	4340	975	960
CUCR-200	200	200	800 To 8000	100 To 1500	A.C.-VFD	0650 x 250	STEEL	5900	1650	1420	5700	1400	1420
CUCR-250	250	250	800 To 8000	100 To 1500	A.C.-VFD	0800 x 300	STEEL	5900	1700	1420	5700	1450	1420
CUCR-300	300	300	800 To 8000	100 To 1500	A.C.-VFD	0800 x 300	STEEL	6250	1700	1445	5960	1450	1445
CUCR-400	400	400	800 To 8000	100 To 1500	A.C.-VFD	0800 x 300	STEEL	6350	1750	1450	5960	1500	1450
CUCR-5OO	500	500	1000 To 8000	100 To 1500	A.C.-VFD	0800 x 300	STEEL	6400	1950	1540	6100	1500	1540
CUCR-800	800	800	1000 To 10000	100 To 1500	A.C.-VFD	0950 x 350	STEEL	8500	1500	1980	7250	1500	1980
CUCR-1200	1200	1200	1000 To 10000	100 To 1500	A.C.-VFD	01000 x 400	STEEL	8500	1600	2100	7300	1600	2100

The Self Centering types : - Model 'CUSR' - types.

3. The Self Aligning Types :- Model 'CSAR' -Type

Self Aligning Rotators automatically adjust the Roller Housings to accept any job diameters with in the specified diameter range. These type of machines are generally used to cope with the increased production demands. The roller housings of this type of machine are hinged to the beds and open up automatically when a larger diameter job is introduced. In this type of rotators, each hinged Roller Bracket Assembly has two sets of Roller Assemblies resulting in doubling the supporting points to the shell. Thus this type of Rotators is ideal for jobs with more imbalanced loads and also for protecting thin walled shells.

Salient Features :

• Both the rollers automatically get adjusted for all job diameters.

• Accepts complete range of job diameters in one setting.

• Centre axis of job remain stable for all job diameters.

• Wide range of Job diameters and Load capacities.

• Most suitable for 'thin walled' shells of large diameters.

• 'Four roller' contacts gives superior 'slip free' traction for thin walled vessels

• Better acceptability to ovality of vessels compared to other models.

• Proven reliability and higher productivity.

• Most accepted design for very busy fabrication shops.

• Ideal design for using in conjunction with Column & Boom.

Standard capacity ranges :

Load carrying capacity - 2 Tonnes to 800 Tonnes

Job diameter Ranges - 350mm to 10000 mm (Higher diameters on request)

Standard Drive Options :

A.C. Variable Speed OR A.C. fixed speed

Types of Roller Options :

Polyurethane / Steel

Special Note (Optional) :

All types of Rotators can be Designed/Supplied with either manual or motorized bogie.