40 Tons Adjustable Welding Rotator

Description of Adjustable Welding Rotator
Parameter list of conventional HGK-40 welding rotator

Parameter list of conventional HGK series welding rotator

WUXI ABK 40-Ton Adjustable Height Positioner Product Introduction

Technical Specifications & Features

The WUXI ABK 40-Ton Adjustable Height Positioner is engineered for precision welding automation in heavy industrial applications, including pressure vessel fabrication, wind tower production, and shipbuilding. Its heavy-duty frame utilizes box-type steel construction for optimal load distribution, ensuring stability during high-capacity operations. The precision sliding track guarantees ±0.1mm positioning accuracy, while the quick-lock mechanism provides rigid fixation for consistent weld quality.

High-Performance Rollers

• ZG45 cast steel rollers (HRC 55-60 hardness) ensure superior wear resistance

• 30-ton dynamic load capacity per roller for handling large-diameter workpieces

• Optimized for structural steel welding and pipeline girth welding

Advanced Drive & Control System
The dual-motor drive system (2×7.5kW) with gear reducers delivers smooth rotation at 0.5-5 RPM (adjustable via frequency converter), maintaining ±2% torque synchronization. Key innovations include:
✓ Hydraulic elevation adjustment (±50mm range) for flexible workpiece alignment
✓ Automatic centerline alignment with <0.5mm creep prevention
✓ NOVO displacement sensors (German-made, 0.01mm resolution) for real-time measurement (±0.05% linearity)

Smart Industrial Automation
Equipped with Siemens/ABB PLC controls and IP65-rated protection, this welding positioner features:

• Axial movement monitoring for error detection

• Seamless integration with robotic welding systems

• CE & ISO certification for global compliance

Applications
✔ Offshore platform construction
✔ Boiler and heat exchanger manufacturing
✔ Heavy machinery component welding

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

WUXI ABK 40-Ton Adjustable Height Welding Positioner Maintenance & Service Guide

Pre-Operation Maintenance
Before operating the 40-ton adjustable height welding positioner, thoroughly clean all components to remove debris. The high-grade rubber rollers must be protected from oil exposure and temperatures exceeding 60°C to prevent premature aging. Assign certified personnel for operation and maintenance to ensure optimal performance of this industrial welding equipment.

Lubrication & Servicing

• Fill the precision gear reducer with 30# engine oil (ISO VG 150 equivalent) before initial startup

• In sub-zero conditions (<0°C), use low-temperature synthetic lubricant

• Replace oil after 30 days of operation, then every 500 operating hours (or 6 months)

• For heavy-duty positioners handling wind tower sections or pressure vessel components, conduct monthly grease replenishment

Critical Operational Protocols

1. Never use the rotator bed as a welding ground – employ separate grounding clamps to protect precision bearings

2. Monthly inspections of:

   • Hydraulic elevation system (40-ton capacity)

   • Anti-slip roller alignment

   • PLC control connections

Manufacturer Assurance
WUXI ABK brings 20+ years of welding positioner expertise, delivering:
✓ 5-400 ton capacity range for vessel fabrication and structural welding
✓ CE & ISO 9001 certified manufacturing processes
✓ 2-year warranty on gear reducers and free wearing parts replacement
✓ 24/7 technical support for offshore platform and wind turbine projects

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.