5Tons Adjustable Welding Rotator

Description of Adjustable Welding Rotator
Parameter list of conventional HGK-5 welding rotator

Parameter list of conventional HGK series welding rotator

Heavy-Duty Construction & Precision Engineering
The WUXI ABK 5-ton welding rotator features a robust box-type steel frame construction that ensures optimal load distribution for industrial welding applications. Our precision sliding track system delivers ±0.1mm positioning accuracy, making it ideal for pressure vessel fabrication and structural steel welding. The quick-lock mechanism provides stable fixation during operation, while the heavy-duty design accommodates continuous use in demanding manufacturing environments.

High-Performance Roller System

• Constructed with premium ZG45 cast steel material (HRC 55-60 hardness)

• 30-ton dynamic load capacity for handling heavy workpieces

• Superior wear resistance for extended service life in pipeline welding applications

• Specially designed for wind tower manufacturing and shipbuilding components

Advanced Drive & Control Systems
The dual-motor drive system incorporates:
✓ 2×7.5kW motors with precision gear reducers
✓ Frequency converter speed control (0.5-5 RPM adjustable)
✓ ±2% torque synchronization accuracy
✓ Siemens/ABB PLC control components
✓ IP65 protection rating for harsh industrial environments

Precision Measurement & Anti-Creep Technology
Our welding positioner integrates German NOVO displacement sensors with:

• 0.01mm resolution for exact positioning

• ±0.05% linearity for consistent performance

• Hydraulic elevation adjustment (±50mm range)

• Automatic centerline alignment system

• <0.5mm creep prevention accuracy

Key Applications:
• Pressure vessel fabrication
• Pipeline girth welding
• Wind tower manufacturing
• Shipbuilding components
• Structural steel welding
• Heavy equipment fabrication

Technical Advantages:

• 40% higher positioning accuracy than standard models

• 35% longer component lifespan

• 50% faster setup and adjustment

• Full compliance with ASME and ISO standards

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

Product Overview
The WUXI ABK 5-ton welding rotator is a precision-engineered solution for cylindrical workpiece rotation in industrial welding applications. Designed for pipe welding, pressure vessel fabrication, and structural steel assembly, this adjustable rotator features a self-aligning roller system with ±0.5° accuracy. Its compact design accommodates diameters from 200mm to 2000mm, making it ideal for small to medium-sized fabrication projects.

Maintenance Guidelines

1. Pre-Use Preparation

   • Thoroughly clean the welding rotator, paying special attention to the rubber rollers which must be protected from oil contact and temperatures exceeding 60°C to prevent premature aging.

   • Assign trained personnel for operation and maintenance to ensure optimal performance.

2. Lubrication Requirements

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

   • In sub-zero conditions (<0°C), use winter-grade synthetic oil (e.g., Mobil SHC 634).

   • Replace oil after the first 30 days of operation, then every 500 operating hours or 6 months thereafter.

3. Critical Operational Rules

   • Never use the roller bed as a welding ground – always employ separate grounding clamps to protect the precision bearings.

   • Monthly inspections should verify roller alignment (±0.2mm tolerance) and bearing condition.

Why Choose WUXI ABK?
With 20+ years of expertise in welding positioner manufacturing, we deliver:

• 5-400 ton capacity range for diverse industrial needs

• CE & ISO 9001 certified quality assurance

• 1-year warranty with free wearing parts replacement

• Dedicated technical support for wind tower, pressure vessel, and pipeline projects

Technical Specifications

• Load Capacity: 5 tons

• Roller Adjustment Range: 200-2000mm diameter

• Speed: 0.5-3 RPM (stepless control)

• Power: 1.5kW AC motor

• Protection: IP54 rated

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.