200Tons Adjustable Welding Rotator

Description of Adjustable Welding Rotator
Parameter list of conventional HGK-200 welding rotator

Parameter list of conventional HGK series welding rotator

Heavy-Duty Construction for Industrial Applications
The WUXI ABK 200-ton adjustable welding rotator features a robust box-type steel frame construction specifically engineered for heavy industrial applications in pressure vessel fabrication, wind tower production, and shipbuilding components manufacturing. Our precision-engineered sliding track system maintains ±0.1mm positioning accuracy even under full 200-ton load capacity, ensuring consistent weld quality for large-diameter cylindrical workpieces.

High-Performance Rotating System
At the core of this industrial welding positioner are premium ZG45 cast steel rollers with HRC 55-60 hardness rating, delivering:

• 30-ton dynamic load capacity per roller

• Superior wear resistance for extended service life

• Optimized surface treatment for friction reduction
  The dual-motor drive system incorporates two 7.5kW AC motors with precision gear reducers, offering stepless speed control from 0.5 to 5 RPM through advanced frequency converter technology, with torque synchronization maintained within ±2% accuracy.

Advanced Control and Measurement Systems
The welding rotator integrates multiple precision technologies:

• Hydraulic elevation adjustment (±50mm range) with automatic centerline alignment

• German-engineered NOVO displacement sensors providing 0.01mm resolution

• Siemens/ABB PLC-based intelligent control system with IP65 protection

• Real-time axial movement monitoring interface

• <0.5mm creep prevention accuracy for critical welding applications

Technical Specifications

• Maximum Load Capacity: 200 tons

• Roller Material: ZG45 cast steel (HRC 55-60)

• Drive System: 2×7.5kW AC motors with reducers

• Speed Range: 0.5-5 RPM (stepless adjustment)

• Positioning Accuracy: ±0.1mm

• Control System: Siemens/ABB PLC with IP65 rating

• Sensor Resolution: 0.01mm

• Linear Accuracy: ±0.05% F.S.

Industrial Applications
This heavy-duty welding rotator is ideal for:

• Pressure vessel manufacturing

• Wind tower fabrication

• Shipbuilding and offshore structures

• Large-diameter pipeline welding

• Energy equipment production

• Chemical plant components

Quality Assurance
Every 200-ton adjustable welding rotator includes:

• CE and ISO certification

• 24-month warranty on critical components

• On-site technical support

• Custom configuration options

• Preventive maintenance program

WUXI ABK 200-Ton Adjustable Welding Rotator Maintenance Guide

Pre-Operation Preparation
Prior to initial operation, the 200-ton heavy-duty welding rotator must undergo thorough cleaning to remove any protective coatings or debris. Special attention should be paid to the high-strength rubber rollers, which must be protected from oil contamination and temperatures exceeding 60°C to prevent premature aging. We strongly recommend assigning certified personnel for all welding positioner operations and maintenance procedures to ensure optimal performance of this industrial rotator equipment.

Lubrication System Maintenance
The speed reducer of this large-capacity welding rotator requires proper lubrication:

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

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

• First oil change after 30 days of operation

• Subsequent changes every 500 operating hours or 6 months (whichever comes first)

Critical Operational Guidelines

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

2. Monitor bearing temperatures during operation (maximum 70°C continuous)

3. Monthly laser alignment checks of rollers (tolerance ±0.2mm)

Maintenance Schedule

Safety & Support
✓ Always disconnect power before servicing this heavy fabrication equipment
✓ Use only ABK-certified replacement parts
✓ 24/7 technical support available for this 200-ton positioner

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 200-Ton Adjustable Welding Rotator – Maintenance & Specifications

Maintenance Guidelines
Prior to operation, thoroughly clean the heavy-duty welding rotator to remove contaminants. Protect the high-strength rubber rollers from oil exposure and temperatures exceeding 60°C to prevent premature degradation. We recommend assigning certified personnel for all maintenance tasks to ensure optimal performance of this industrial positioner.

For lubrication:

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

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

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

Critical Operational Notes

• Never utilize the rotator bed as a welding ground – employ separate grounding clamps to protect the heavy-load bearings

• Monthly inspections should verify roller alignment (±0.2mm tolerance) and bearing temperatures (<70°C)

Manufacturer Advantages
WUXI ABK brings 20+ years of expertise in large-diameter welding equipment manufacturing. Our adjustable welding rotators feature:

• 200-ton load capacity (range: 5-400 tons)

• Self-aligning roller system for pressure vessel fabrication

• CE & ISO 3834 certified components

• 24-month warranty on core drive systems

• Complimentary replacement of wear parts (rollers, seals)

Technical Support
Our engineering team provides:
✓ On-site wind tower welding assistance
✓ Pipeline girth welding process optimization
✓ 24/7 remote diagnostics for rotary positioners

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.