100Tons Adjustable Welding Rotator

Description of Adjustable Welding Rotator
Parameter list of conventional HGK-100 welding rotator

Parameter list of conventional HGK series welding rotator

Heavy-Duty Construction & Precision Engineering
Our 100-ton welding rotator features a robust box-type steel frame construction specifically engineered for optimal load distribution in heavy industrial applications. The precision sliding track system delivers exceptional ±0.1mm positioning accuracy, making it ideal for pressure vessel fabrication and wind tower manufacturing. The quick-lock stabilization mechanism ensures rigid fixation during critical welding operations on large-diameter workpieces.

High-Performance Rotating System

• Premium Rollers: Manufactured from ZG45 high-grade cast steel (HRC 55-60 hardness) with 30-ton dynamic load capacity per roller

• Dual-Motor Drive: Twin 7.5kW motors with precision gear reducers provide reliable torque transmission

• Smart Speed Control: Frequency converter enables stepless 0.5-5 RPM adjustment with ±2% torque synchronization

Advanced Positioning Technology
The welding positioner incorporates multiple precision systems:

1. Anti-Creep Mechanism: Hydraulic elevation adjustment (±50mm range) with automatic centerline alignment maintains <0.5mm positional accuracy

2. Measurement System: German NOVO displacement sensors provide 0.01mm resolution with ±0.05% linearity

3. Control System: Siemens/ABB PLC components with IP65 protection and real-time axial movement monitoring

Technical Advantages for Industrial Applications
This heavy-duty welding rotator delivers unmatched performance in:

• Pressure vessel rolling and positioning

• Wind tower flange welding

• Shipbuilding component fabrication

• Large-diameter pipe girth welding

Key Features:
✓ 100-ton load capacity for heavy fabrication
✓ Military-grade precision measurement
✓ Industrial-grade IP65 protection
✓ Smart torque synchronization
✓ Low-maintenance cast steel rollers

Maintenance of Welding Rotator

1. This welding rotator needs cleaning before putting into use. And to avoid aging, the rubber rollers should stay away from oils and high temperature. If possible, there should be a specific person to operate and maintain this device.
2. Before starting, the speed reducer should be full of 30# engine oil, which is also necessary when the environment temperature is below 0ºC.
3. The oil inside the speed reducer should be completely replaced after the use of first month, and later, the engine oil can be changed every six months.
4. The roller bed can not be used as the welding ground so that bearings can be prevented from damaging.

Features of Welding Rotator

1. 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.

Product details

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

Pre-Operation Maintenance
Prior to operating our heavy-duty welding rotator, conduct a thorough cleaning to remove debris and contaminants. The high-strength rubber rollers must be protected from oil exposure and temperatures exceeding 60°C to prevent premature aging. We strongly recommend assigning certified personnel for all industrial rotator operations and maintenance procedures to ensure optimal performance.

Lubrication Protocol
For the 100-ton capacity welding positioner‘s speed reducer:

• Initial fill with 30# engine oil (ISO VG 150 equivalent)

• Below 0°C, use winter-grade synthetic lubricant

• First oil change after 30 days of operation

• Subsequent changes every 500 operating hours or 6 months

Critical Operational Guidelines

1. Never utilize the rotator bed as a welding ground – employ separate grounding clamps

2. Monthly inspection of roller alignment (±0.2mm tolerance)

3. Quarterly bearing condition checks (replace if radial play >0.3mm)

Why Choose WUXI ABK?
With 20+ years specializing in self-aligning welding rotators, we deliver:

• 5-400 ton capacity range for pressure vessel fabrication and wind tower production

• CE & ISO 9001 certified manufacturing processes

• 2-year warranty with complimentary wear components

• 24/7 technical support for large-scale welding projects

Performance Advantages
Our adjustable welding rotators provide:
✓ ±0.1° rotation accuracy for precision welding
✓ Dual-motor drive system stability
✓ Custom configurations for specialized applications

Keywords:
heavy-duty welding rotator, 100-ton positioner, industrial welding equipment, pressure vessel rotator, wind tower fabrication, self-aligning rotator, CE-certified positioner, welding ground safety, roller alignment, bearing protection, speed reducer maintenance, ABK welding machinery, large-capacity rotator, precision welding technology, offshore welding equipment, pipe welding rotator, structural steel fabrication, industrial maintenance protocol, wear-resistant rollers, technical support services

This maintenance program ensures your 100-ton adjustable welding rotator achieves:

• 30% extended service life versus standard maintenance

• 95% operational availability

• Full compliance with international welding standards

For emergency support, contact our welding automation specialists with your machine serial number.

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.