Stand for automatic welding of a center sill with I-beam

Stand for automatic welding of a center sill with I-beam

The stand is designed for the assembly of a gondola car center sill with I-beam and I-beam welding to the center sill in automatic mode with making of two seams simultaneously.

Structure 
The stand comprises: 
- welding plant 
- supporting blocks 
- deflection device 
- screw clamp 
- electrical equipment 

The welding plant provides a set of technological operations connected with the automatic welding of a center sill with I-beam and consists of a bogie, a bogie guide, columns, two semiautomatic welding machines and two contour followers.

Supporting blocks provide location of a center sill in longitudinal, transverse and vertical directions. Supporting blocks are equipped with a pneumatic rammer for the center sill fixation in longitudinal direction. The center sill fixation in vertical direction is provided by swivel screw clamps.

The deflection device provides reverse deflection of the center sill which compensates welding deformations caused by extensive seams welding. The device represents welded metalwork equipped with a lever mechanism of deflection set in motion by two brake pneumatic cylinders. A screw clamp is used for pressing of I-beam to a center sill in the process of tacking. Mounting of the I-beam on the center sill in transverse direction is carried out using the gage (the gage is not included in the scope of delivery). 

Specifications

1.

Overall dimensions of the items to be assembled, mm

12960х610х500

Weight, kg

2700

2.

Welding plant

Welding plant bogie type

bicycle-type

Bogie traverse drive

electromechanical

Number of drives, pieces

1

Drive type

gear-motor PC090-NMRV 105

Drive capacity, kw

1,1

Torque on the wheel shaft, N х m

599

Drive gear ratio

121

Driven wheel revolutions number, rpm

11,6

Cruising speed, m/hour

450

Welding speed, m/hour

40 … 120

Welding speed control principle

frequency

Seam type

lap

Number of simultaneously welded seams, pieces

2

Seam tracking system

mechanical

Number of semiautomatic welding machines, pieces

2

Welding method

gas-shielded

Power source type

Fronius VS5000-2

Power sources number, pieces

2

3.

Welding stand

Center sill longitudinal alignment mechanism

pneumatic

Center sill transverse alignment mechanism

catching mechanisms

Center sill deflection mechanism

pneumatic

Deflection force, kg-force

32000

Deflection extent, mm

135

Center sill vertical pressing mechanism

screw

4.

Air operating pressure, MPa

5 … 6

5.

Air consumption, m³/hour

6

6.

Overall dimensions, mm

16440х1860х2230

7.

Weight, kg

6010