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FW1000 FWM1000 100tons Friction Welding Machine
  • FW1000 FWM1000 100tons Friction Welding Machine
  • FW1000 FWM1000 100tons Friction Welding Machine
  • FW1000 FWM1000 100tons Friction Welding Machine

FW1000 FWM1000 100tons Friction Welding Machine

FW1000 FWM1000 100tons Friction Welding Machine can realize automatic welding. It can realize outer flash removal in continuous and accurate operation (external flash removal mode is turning);
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Technical parameters of FW1000 FWM1000 100tons Friction Welding Machine
Model FW1000 FWM1000
External flashes CNC turn removal device Without With External flashes CNC turn removal device (with GSK system)
Product processing range
 
   
Pipe outer diameter Φ50mm -Φ102mm Φ50mm -Φ102mm
Joint length 150mm-350mm 150mm-350mm
Finished product length 2-12m 2-12m
Maximum welding area ≤ 5000mm2 ≤ 5000mm2
Welding workpiece material low and medium carbon steel low and medium carbon steel
Equipment power voltage    
Spindle motor 380V, 50Hz, 110kW, one set 380V, 50Hz, 110kW, one set
Driver ParKer 590C series DC driver ParKer 590C series DC driver
Oil pump motor 380V, 50Hz, 37kW and 22kW one set each 380V, 50Hz, 37kW and 22kW one set each
Lubrication Motor 380V, 50Hz, 550W, two sets 380V, 50Hz, 550W, two sets
Main technical requirements    
Weld eccentricity ≤ 0.6mm (sample rod) ≤ 0.6mm (sample rod)
Rotating fixture self-centering collets self-centering collets
Fixing fixtures a set of horizontal split-type self-centering V-shape jaw,  3 sets of horizontal split-type C-shape jaw,
two sets of anti-runout center rest
a set of horizontal split-type self-centering V-shape jaw,  3 sets of horizontal split-type C-shape jaw,
two sets of anti-runout center rest
Spindle speed 0-890 r/min when in friction welding 0-890 r/min when in friction welding
 0-375r/min in turning external flashes
 
Headstock stroke 400 mm (Idle stroke speed 80mm/s) 400 mm (Idle stroke speed 80mm/s)
Maximum upset force ≥ 1000 kN ≥ 1000 kN
System pressure 17 MPa for working condition 17 MPa for working condition
Ambient temperature 0℃-45℃ 0℃-45℃
Humidity ≤90% ≤90%
Brake Electric Brake Electric Brake
 
Equipment for FW1000 100tons Friction Welding Machine
1. Oil cooler system;
 
Equipment for FWM1000 100tons Friction Welding Machine
1. External flashes CNC turn removal device;       
2. Oil cooler system;

Optional of FW1000 FWM1000 100tons Friction Welding Machine
1. Hydraulic proportional control system;    2. Auto bar feeder;
3. Quality monitoring system;              4. Hydraulic runout prevention center rest;
5. Impact chipping internal flash device;     6. Welding parameters records;
 
Main part of FW1000 FWM1000 100tons Friction Welding Machine
1. One set of moveable headstock, including DC main motor, Parker driver made in Britain, spindle, synchronous belt transmission, bearings, symmetrical pulling double hydraulic cylinders, one set of rotary fixture, with hydraulic collets chuck, one set of fixed split jaw.
One set of two-axis CNC turning external flash removal system (just for FWM1000);
2. One set of fixed jaw for bed: a set of self-centering V-shape jaw can accommodate all rod diameters; one set of fixture includes three groups of horizontal split C-shape ragged jaw.
One group of self-centering external flash removal center rest (just for FWM1000);
3. The whole bed body is heat-treated;
4. Monitoring system (optional);    
5. Electric control system;

6. Hydraulic system, one set of oil-cooler;   
7. Lubrication system;

 
Key performances of FW1000 FWM1000 100tons Friction Welding Machine
1. FW1000 FWM1000 100tons Friction Welding Machine can realize automatic welding. It can realize outer flash removal in continuous and accurate operation (external flash removal mode is turning);
2. Self-centering chucks and clamps can ensure full welding of contact surface for weld, and accurate axial and radial positioning;
3. Control system: The control system shall adopt Delta company's products. Dual control using the time and variable can ensure the stability of welding quality and specification. Welding parameter can be set or changed via the touch screen to satisfy the requirements of drill pipe of different specifications;
4. Welding parameters records: record and store the welding parameters in welding process, such as speed, pressure, displacement and time. If the test data is out of settings range, alarm will automatically send. Test results, when necessary, can be printed by a printer, providing the evidence for welding quality, and the basic for weld quality and stable and normal operation of the equipment; (optional items)
5. If you choose to use proportional control system for hydraulic control system, its performance is stable and reliable and the pressure of different systems can be continuously adjustable within specified range, so as to ensure different specifications according to different products. (Optional items);
 
Mechanical part of FW1000 FWM1000 100tons Friction Welding Machine
1. The main machine shall consist of a movable headstock, double upset hydraulic cylinder (bed body not subject to stress), tailstock, bed body, internal and external flashes removal device and other components. The headstock shall use a welded structure, the bed body and tailstock shall use a structure welded by high strength steel plate, which have to undergo the overall heat treatment to eliminate stress and to prevent deformation during use.
2. Headstock system: at upper part of headstock, main motor drives the spindle rotating at rear end of headstock through synchronous belt pulley, the transmission part shall be provided with a protective cover. Headstock shall adopt the overall forging structure to facilitate the belt replacement or clutch brake system maintenance, the spindle should be provided with rotating fixture at its front part. The main motor is a DC driving variable speed motor to meet the requirements of welding of different specifications and welding flash removal.
2.1 FAG bearing shall be adopted for spindle bearing using forced oil lubricating method, and the spindle motor shall adopt a famous brand in China, SIMO motor.
2.2 Headstock shall slide on a linear guide to effectively reduce the sliding resistance, with oil nozzle on each slide block. The guide shall use grease lubrication, which should be added every three months to ensure the moving accuracy and welding accuracy of the headstock.
3. Rotating/fixing fixture shall be controlled by separate oil circuit and electricity circuit to achieve different clamping forces and action requirements. We can offer 3 fixtures according to the drawing provided by the Buyer; other fixtures shall be manufactured by user.
3.1 Rotating fixture shall adopt self-centering collets structure, using axis motion of connecting rod of hydraulic oil cylinder in the spindle to control its clamping and releasing, FW1000 FWM1000 100tons Friction Welding Machine is only required to replace the transition pad on collet chuck for workpeice of different specifications
3.2 The fixing fixture shall use a self-centering horizontal split structure, consisting of one set of V-shape jaw and three sets of C-shape jaw. A set of V-shaped jaw shall be set at front, with high precision synchronous clamping and releasing, with advantages of precision self-centering, V-shape jaw can be used for workpieces of all specifications. 3 sets of C-shape jaw shall be set at middle place, clamping and releasing synchronously, with advantages of holding workpiece with the greatest area and ragged anti-slip contact surface with workpiece, which maximize the upset and locking function, and it is only required to replace C-shape clamping block accordingly when replacing workpeices of different specifications.
4. The equipment shall apply force by double cylinders in working process, two master pulling cylinders axis are in symmetrical placed on both sides of the headstock. That using reverse pulling headstock for movement (main motor shall be set on this top) and tailstock jaw fixing on the bed body with high strength to increase rigidity can effectively reduce the impact damage to guide track in upsetting process, and bed body is only subject to gravity but not to bending force caused by welding upset, and this structure is compact and artistic.
5. For model FWM1000, the equipment should be provided with external flash removal devices.
5.1 The external flash removal device shall consist of cutting system and four sets of anti-run out center rest. The external flash removal device shall realize longitudinal (axial) and radial movement under control of independent NC system to remove the external flashes through turning. One set of runout center rest shall be installed at tail part of tailstock, and the other three groups shall be on the charge rack of rod body.

Hydraulic system of FW1000 FWM1000 100tons Friction Welding Machine
1. FW1000 FWM1000 100tons Friction Welding Machine hydraulic devices, which shall adopts Yuken products, include motor, oil pump, hydraulic cylinder, hydraulic valve, (proportional flow valves, proportional overflow valve, optional proportional hydraulic station components), relief valve, change valve, check-valve, plunger and double vane pump, fuel tank, pressure sensors and other components
2. Hydraulic system is mainly to control the clamping and release as well as main pressurizing of rotating workpiece. It shall adopt a fully enclosed hydraulic system including three-stage pressurizing, i.e. primary friction pressure, secondary friction pressure and upset pressure; FW1000 FWM1000 100tons Friction Welding Machine hydraulic system is a fully enclosed system, main oil and clamping circuit are separate and supply oil separately, realizing stable, reliable, non-interfering operation of the system.
3. The hydraulic system shall be provided with 200P oil cooler for cooling or heating hydraulic oil.
 
Lubrication system of FW1000 FWM1000 100tons Friction Welding Machine
1. The system shall consist of filter, oil pump, overflow valve, pressure gauge and fuel tank.
2. The lubrication system is to mainly provide lubrication for moving parts and bearings, thus reducing mechanical resistance and extending the equipment life.
3. FW1000 FWM1000 100tons Friction Welding Machine lubrication system shall use two lubrication motors, one using for spindle lubrication and the other is for clamp and auxiliary equipment lubrication.

Electric control part of FW1000 FWM1000 100tons Friction Welding Machine
The electronic control part shall mainly consist of two parts, electrical cabinet and control cabinet (Grantech IPC monitoring control unit).
1. Monitoring system and control system shall be integrated into a control cabinet, 17-inch LCD display shall be set on top of the control cabinet, middle operating panel shall be provided with a 10.4-inch touch-screen control panel, and double-color fault warning indicator and emergency shutdown switch, etc
1.1 After welding procedure for a workpiece of a specification has been input for first time, if it logs on again, it is simply required to enter the number previously saved welding procedure to call up desired welding procedure for the workpiece, without needing to input welding procedure parameter repeatedly (proportional control hydraulic station function).
Welding process:
A. Charge process: first raise the rod head on rod head material rack to the axis line position through driving by hydraulic cylinder, and pull the rod body including rod head into the rotating fixture through axial movement of rod body driving by motor driven friction pulley on charge and discharge rack on rod body; (made by users themselves)
B. Workpiece clamping adjustment: rotate the fixture for slight clamping and fix it for tighten clamping, After pre-upset, rotate the fixture for tighten clamping and withdraw headstock, and then enter primary friction stage.
C. Primary friction: when the headstock stops withdrawing, the motor and the spindle clutch engage, and the main motor and lubricating motor start at same time, after a delay, headstock advances without load until to its place and then enter into primary friction. To reduce the impact force when contacting the workpiece, the primary friction shall be contact in low pressure advancing.
D. Secondary friction: once primary friction is complete, it will automatically enter secondary friction, the friction time, friction displacement, pressure, current, torque, and other information will be displayed on the display. The secondary friction can be completed by time and displacement control or finished by manual intervention.
E. Upset: After secondary friction is complete, FW1000 FWM1000 100tons Friction Welding Machine enters into the upset stage, the upset time, upset displacement, pressure, current, torque, and other information will be displayed on the display. Upset can be completed by time and displacement control or finished by manual intervention.
F. After upset is complete, main motor and lubricating motor stall, delay, fixed jaw release and headstock automatically withdraw to original point.
G. Flash removal (Just for model FWM1000): External flash removal starting signal shall be controlled with time, and the spindle starts low speed rotating and start to remove external flash of corresponding specification in turning type with presetting program.
H. Blanking: after flash removal is complete, rotating fixture releases and the charge and discharge rack on rod body will automatically transfer the finished welding product to the material discharge point and automatic welding process completes now. (Buyers shall make it by themselves).
1.2 Monitoring system interface structure: monitoring system shall adopt configuration software development design to enhance the practicality and versatility, which can be changed at any time according to the special requirements, FW1000 FWM1000 100tons Friction Welding Machine is running in Windows environment, including main interface (display welding setting parameters, welding state parameters), set interface, abnormal history query interface, weld data records query interface, the sensor position display interface, etc. As a system independent from main machine, the hardware shall use Advantech IPC box made in Taiwan to monitor and display welding parameters for friction welding machine, and send an alarm in case it exceeds a preset value.
1.3 Starting from primary friction, FW1000 FWM1000 100tons Friction Welding Machine shall perform monitoring on spindle speed, torque, pressure, displacement in welding process, and make friction welding machine work in the best condition, and thus ensuring the welding quality.
1.4 The parameter signals in welding process shall be displayed visually on the screen display in curves and values Alph after collection, conversion, calculation processing of welding process parameter signals by corresponding pressure, displacement, electric current and rotation measuring sensors.
1.5 FW1000 FWM1000 100tons Friction Welding Machine monitoring parameters for different links can be pre-set with allowable upper and lower error range, in the event the allowable error is exceeded, sound and light alarm shall be sent first and then manual intervention can choose whether to terminate the weld.
1.6 The recording device can record spindle speed, current, pressure, displacement for welded workpiece to test and distinct the quality of workpiece. All monitoring data can be exported from the USB interface for storage and can be printed if connecting with a printer.
2. Ammeter, voltmeter, three-phase voltage converter and indicators shall be installed on upper part of electrical cabinet to observe whether the three-phase power supply is normal, the lower part shall be installed with side-by-side cabinet door with a safety lock. Electrical cabinet shall be installed with inverter, switching power supplies, circuit breakers, AC contactors, current transformers, over current protection devices or motor phase open protector, PLC programmable controller and electrical control components.

Manufacturing standards of FW1000 FWM1000 100tons Friction Welding Machine
API Spec5DP-2009 / JB/T8086-1999  Friction welding

Working environment of FW1000 FWM1000 100tons Friction Welding Machine
1. Ambient temperature: 0 ℃ -50 ℃
2. Ambient humidity: ≤ 50% when 40 ℃ 
                                  ≤90% when 20 ℃
3. Power supply: three-phase 380V ± 10%, 50Hz 

Main configuration list of the equipment of FW1000 FWM1000 100tons Friction Welding Machine
1 Main configuration list of mechanical part of FW1000 FWM1000 100tons Friction Welding Machine
No Items Model Manufacturer
1 Headstock guide RGW65-HC HIWIN or similar Brand, Taiwan
2 Main motor 132kW; 380V/50Hz SIMO, China
3 Thrust bearing   FAG, Germany
4 Collet chuck   China
5 V-shape jaw   China
6 C-shape jaw   China
7 Main pushing oil cylinder    China
 
2. Main configuration list for hydraulic parts of FW1000 FWM1000 100tons Friction Welding Machine
No Items Model Manufacturer
1 Oil tank (with cleaning port) Closed type, circular part China
2 Hydraulic station motor 37kW; 380V/50Hz /3P SIMO, China
3 Hydraulic station motor 22kW; 380V/50Hz /3P SIMO
4 Double vane pump PV2R24A series YUKEN
5 Pressure gauge YUKEN YUKEN
6 Electromagnetic overflow valve S-BSG series YUKEN
7 Insert type check valve LD-32 series YUKEN
8 Overlapped relief valve MRP series YUKEN
9 Plunger pump A10-FR01 series YUKEN
10 Vane pump PV2R series YUKEN
11 Plunger pump A2F125R2P1 series YUKEN
12 Other valves Different types of auxiliary valve YUKEN
 
3. Main configuration list for electrical parts of FW1000 FWM1000 100tons Friction Welding Machine
No. Items Model Manufacturer
1 Industrial control computer 8248V Grantech
2 PLC and extended module FX2N series Delta
3 Touch screen GT1575-STBD  10.4inches Delta
4 Rotary encoder E6B2-CWZ6C OMRON, Japan
5 Pressure sensors   IFM, Germany
For detailed electrical configuration list, please refer to the attachment table
Note: The component models and parameters in this table are for reference only.
 
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FORTUNE PACIFIC LIMITED
+86-538-6918256
Sijiazhuang, Zhoudian, Taian City
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