The tube-to-tube automatic welding machine is a specialized automated equipment used for the precise connection of metal tubes and their accessories. This equipment achieves full-position, high-precision welding of tube interfaces through an integrated welding power supply and motion control system. It is particularly suitable for processing thin-walled tubes, with typical application materials including stainless steel, carbon steel, titanium alloys, copper and its alloys, and can weld tubes with wall thicknesses generally not exceeding 3 mm.
The complete system mainly consists of a high-precision welding power supply, a dedicated welding torch and its motion mechanism, an intelligent control system, and a human-machine interface. The power module uses a self-developed digital control circuit, which can deeply cooperate with the welding process control system to ensure stable welding arc and consistent penetration depth, achieving high-quality, reproducible welding.
The core advantages and functions of the equipment are detailed below:
1. Intelligent Control System
The core controller is based on self-developed hardware circuits and embedded software, capable of long-term stable output of precise welding parameters. The system supports one-click rapid generation and recall of parameters, significantly shortening process debugging time and facilitating subsequent maintenance and upgrades.
2. User-Friendly Interface
Two high-precision industrial touch screen options are available (Kunlun Tongtai/Diwen), both using 10-inch color displays. The interface layout is intuitive, supporting graphical parameter settings and real-time status monitoring, significantly improving ease of operation and user experience.
3. Flexible Process Programming
It features both automatic and manual programming modes. In automatic mode, the system can generate welding parameters with one click based on a preset process library; in manual mode, engineers can finely adjust and store all parameters such as current, voltage, speed, and oscillation, adapting to all welding scenarios from standard to special.
4. Multifunctional Integration and Process Control
The system integrates both DC and pulse current output modes, and has linkage control functions for pre/post-gas time, gas flow rate, and water cooler start/stop. This integrated design ensures precise management of the welding process environment and heat input.
5. Complete Welding Data Traceability
Key parameters of each weld joint (such as current, voltage, welding speed, time, etc.) are automatically recorded by the system, and reports can be output through a built-in printer or data interface, providing reliable basis for quality traceability and process analysis.
6. Comprehensive Safety Protection Mechanism
Built-in multiple intelligent protection functions, including: real-time automatic fault diagnosis and Chinese information prompts, input overvoltage/undervoltage protection, output overcurrent/overload protection, system leakage monitoring, arc abnormal interruption protection, and tungsten electrode and workpiece short-circuit protection, maximizing the safety of the equipment and operators.
7. High-Performance Welding Torch Design
The welding torch body adopts a modular design, integrating independent argon gas internal protection channels and circulating water cooling channels. This dual design not only ensures the formation and protection effect of the weld seam on the back side, but also greatly improves the duty cycle of the welding torch, enabling it to handle long-term continuous welding tasks without overheating.
8. Adaptive Self-Centering Clamping System
Equipped with an elastic and flexible automatic self-centering fixture, it can adapt to slight ovality or size deviations of different pipe diameters within a certain range, reducing the requirements for machining accuracy of incoming pipe fittings and improving the efficiency of production preparation.
9. Convenient Operation and Pre-Inspection Simulation
The welding torch handle integrates multiple programmable function shortcut keys, making it easy for the operator to quickly adjust during the welding process. The system's unique "simulation run" function can completely simulate the welding torch's trajectory and the actions of each unit without actually striking an arc, allowing for early detection and elimination of potential mechanical or program problems, effectively reducing trial-and-error losses.