100 Tons Standard Welding Rotator
WUXI ABK 100-Ton Welding Rotator delivers precision rotation for heavy fabrication. Featuring dual 7.5kW motors (0.5-5 RPM), ZG45 alloy rollers (HRC 55-60), and ±0.1mm accuracy, it handles pressure vessels, wind towers, and ship components. The smart anti-creep system (<0.5mm deviation) and Siemens PLC controls ensure reliable performance. CE/ISO certified with 18-month warranty.
Description of Standard Welding Rotator:
Parameter list of conventional HGZ-100 welding rotator
| Model | HGZ-100 | |
| Load capacity(Ton) | 100 | |
| Suitable diameter(mm) | 1000-5000 | |
| Wheel Size(mm) | PU | Φ500*120 |
| Steel | Φ490*80 | |
| Rotation Speed(mm/min) | 100-1000 | |
| Speed Control | Electric magnetism of frequency conversion setting | |
| Motor Power(kw) | 5.5 | |
| Control Voltage | 24VAC | |
| Pendant Cable | 10m/Wireless | |
| Incoming Power | 380V/400V/415V/440V/460V-3P-50Hz/60Hz | |
| Color | RAL 3003 Red 9005 Black (Optional) | |
Application
lAutomated welding of circular metal containers
lIndustries: Oil & gas | Pressure vessels | Wind towers | Pipe manufacturing
Key Advantages
✓ Wide Compatibility: Handles various diameters (customizable)
✓ Precision Control: Frequency conversion + stepless speed regulation (0.5-15 RPM)
✓ Certified Quality: CE compliant | ISO 9001 certified
✓ Global Reliability: Exported to 20+ countries (UK, EU, Middle East, etc.)
Performance Features
• Ultra-stable rotation (<0.1mm runout)
• Low-noise operation (<65dB)
• User-friendly interface
Parameter list of conventional HGZ series welding rotator
The WUXI ABK 100 Tons Standard Welding Rotator represents the pinnacle of heavy-duty welding positioner technology, designed for precision rotation of large cylindrical components in industrial fabrication. Our advanced roller frame system features a robust box-type steel construction that ensures optimal load distribution across all working conditions. The precision linear guide movement system maintains ±0.1mm positioning accuracy, while the quick-lock mechanism provides rigid fixation for stable welding operations.
Core Components
At the heart of the system are premium ZG45 high-strength cast steel rollers with HRC 55-60 hardness, each capable of handling 30 tons dynamic load. The dual-motor drive system combines two 7.5kW AC motors with reducers, offering precise speed control from 0.5 to 5 RPM through frequency converter regulation, with torque synchronization maintained within ±2% accuracy.
Advanced Control Systems
The rotator incorporates multiple precision technologies:
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Hydraulic elevation adjustment (±50mm range) with automatic centerline alignment
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German-made NOVO displacement sensors providing 0.01mm resolution
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Siemens/ABB PLC-based intelligent control system with IP65 protection
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Real-time axial movement monitoring interface
Performance Advantages
Compared to conventional welding rotators, the WUXI ABK system delivers:
✓ 40% higher positioning accuracy
✓ 35% longer component service life
✓ 50% faster adjustment operations
✓ <0.5mm creep prevention accuracy
✓ ±0.05% linearity measurement precision
Technical Specifications
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Maximum Load Capacity: 100 tons
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Roller Material: ZG45 cast steel (HRC 55-60)
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Drive System: 2×7.5kW AC motors with reducers
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Speed Range: 0.5-5 RPM (stepless adjustment)
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Positioning Accuracy: ±0.1mm
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Control System: Siemens/ABB PLC with IP65 rating
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Sensor Resolution: 0.01mm
Applications
Ideal for heavy fabrication projects including:
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Pressure vessel manufacturing
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Wind tower production
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Shipbuilding components
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Large-diameter pipeline welding
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Energy equipment fabrication
Quality Assurance
Every 100 Tons Standard Welding Rotator undergoes rigorous testing and includes:
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CE and ISO certification
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18-month warranty on critical components
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On-site technical support
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Custom configuration options
Features of Welding Rotator
- The rollers’ distance automatically adjusts to accommodate different barrel diameters.
Speed is adjustable via a frequency control system, enhancing operational reliability.
3.Easy operation is ensured with a manual control box.
4.Available in multiple configurations, including movable and lifting types.
5.A specially designed roller bed offers enhanced convenience during welding.
6.Rollers can be crafted from a variety of materials, such as black rubber, polyurethane, and steel. 
Pre-Operation Preparation
Before initial use, thoroughly clean the welding rotator to remove any protective coatings or debris. Pay special attention to the rubber rollers, which must be kept free from oil contamination and high-temperature exposure (above 60°C) to prevent premature aging. We recommend assigning qualified personnel for all operation and maintenance procedures to ensure optimal performance.
Lubrication Requirements
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Fill the speed reducer with 30# engine oil (ISO VG 150 equivalent) prior to initial startup
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In low-temperature environments (<0°C), use synthetic winter-grade oil (e.g., Mobil SHC 634)
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Conduct the first oil change after 30 days of operation
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Subsequent oil changes should be performed every 500 operating hours or 6 months (whichever comes first)
Critical Operational Guidelines
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Never use the roller bed as a welding ground connection – always employ separate grounding clamps
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Regularly inspect bearing temperatures (should not exceed 70°C during continuous operation)
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Check roller alignment monthly using our patented laser alignment tool (optional accessory)
Maintenance Schedule
| Interval | Task | Standard |
|---|---|---|
| Daily | Visual inspection of rollers and drive components | No visible damage or deformation |
| Weekly | Lubrication of guide rails and moving parts | Use Mobilux EP 2 grease |
| Monthly | Torque check on all fasteners | 85-95 Nm for M20 bolts |
| Quarterly | Bearing condition inspection | Replace if radial play exceeds 0.3mm |
Troubleshooting Tips
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Uneven rotation: Verify roller parallelism (tolerance: ±0.2mm/m)
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Abnormal noise: Check gear reducer oil level and quality
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Power fluctuations: Inspect motor brushes (replace if <5mm remaining)
Safety Precautions
✓ Always disconnect power before maintenance
✓ Use only ABK-approved replacement parts
✓ Record all maintenance activities in the provided logbook
For technical support, contact WUXI ABK’s 24/7 service hotline with your machine serial number ready. Our field engineers can provide remote diagnostics or on-site assistance within 72 hours for critical issues.
Product details
| · Trusted design | · Reliable Quality |
| · Renowned parts | · Inverter control |
| · Direct drive system | · Motorised travel option |
| · Build to order custom design | · OEM |
Wheel introduction
Polyurethane wheels offer exceptional abrasion resistance, versatile processing, wide applicability, and superior resistance to oil, ozone, aging, radiation, and low temperatures. They also provide strong adhesion, excellent sound transmission, biocompatibility, and blood compatibility.
Motor introduction
Top quality rotator manufacturer
1.With over 20 years of specialized experience in manufacturing self-aligning rotators.
2.Our products feature a bearing capacity that ranges from 5 tons to 400 tons.
3.We provide CE and ISO certifications, ensuring compliance with stringent sub-regulations. Additionally.
4.We offer a one-year warranty and free wearing parts.
5.Our highly skilled technical team is dedicated to supporting you and your large-scale projects, such as wind turbine welding.
Product certification
Step into the future of welding technology with our cutting-edge solutions.
From automated processes to intuitive controls, our products are at the forefront of innovation, providing you with the tools you need to stay ahead in today’s competitive market!
Wuxi ABK Machinery Co.Ltd is a professional manufacturer of welding rotator in China. And our welding rotator mainly includes standard welding rotator, adjustable welding rotator, and special welding rotator. We can also provide our clients around the world with many other products including welding turntable, pile welding machine, wind tower production line, H beam welding line, pipe welding equipment, CNC cutting machine, grinding machine, roll forming machine, plate bending machine, etc. We have obtained ISO and CE certification, and we also offer OEM service.
