EKONOR for orbital welding of pipe joints.
The focus is on orbital / pipe circumferential welding, but as a special machine builder, we have also implemented other applications according to customer requirements.
The heart of many systems is our internal clamping system, which enables simple alignment, clamping and purging of the components and in most cases does not require the time-consuming tacking process. This saves around 50% of the total production time, regardless of the welding process.
Can be combined with internal clamping device, cold wire, AVC and oscillation. The user-friendly EKOTRON control is used.
The internal clamping device (ISV) allows welding without an air gap and without tacking. The ISV is also used to purge the root of the weld, so there is no prepurging time.
This machine uses an internal clamping system, which is inserted into the pipe and fitting to align them and allows for zero-gap welding without the need to tack-weld. Depending on the WPS the bevel will either be a V groove or a J groove, with a 2 mm root face.
The pipe is moved onto the infeed supports using transfer arms mounted on the buffer table. These arms deposit the pipe on the supports, which then move it into the chuck. Once the pipe is clamped in the chuck, the mandrel carriage moves forward to insert the mandrel with the inner clamping device into the pipe.
When the mandrel is in position, the operator uses a foot switch to engage the first clamp. Then the fitting is moved into position, either by hand or, for heavier fittings, by crane. The operator then engages the second clamp, holding the fitting in place, and initiates the welding process.
The root run of the joint will be welded with TIG. Afterwards additional layers of TIG or MAG will be welded, according to the established WPS.
The pipe is transferred to the machine from the buffer table using movable transfer arms, which roll the pipe onto the machine’s pipe supports. These pipe supports then align the pipe with the flanges and move the pipe into position inside the first turn-table, while the second turn-table follows until both flanges and the pipe are properly aligned and positioned.
Then the second set of torches moves into position, and all four seams are welded simultaneously.
After welding the torches retract and the pipe is ejected onto a table or conveyor.
For sleeves the process is similar, however the machine only welds the outside seams, not the inside.
From Westfalen devolped clamping devices deliver a great benefit for pipe production. The numerous advantages simplify the pipe fitting in the workshop or on site and reduce the costs over 60 %.
This machine combines the advantages of our Quick-Change system with a secound turn-table with hollow shaft. This offers extrem flexibility for different pipe connections.
The torch position can be changed from 12 to 4 o’clock to adjust to different welding situations. High penetration and high quality for very sensitive materials.
Maintenance is better than repairing. That is why we offer our customers a wide range of maintenance options. From overhauling the systems in our factory to tailor-made maintenance contracts and on-site maintenance.
The maintenance contract can include both the mechanical and electrical testing of our systems. Make use of these possibilities, because the longevity is also a factor for the profitability of the system.
Despite high-quality system technology, repairs cannot always be avoided. In this case we offer quick and competent help. We ensure that your system is quickly ready for use again. Due to the modular structure, the system can still be partially operated in a restricted form. With a sensible storage of spare parts, many repairs can be done by yourself.
Renting a system is a good opportunity, especially for beginners, to experience the advantages of automated welding. The costs can be written directly to the project and extensive investment planning can be omitted. We offer a wide range of rental systems, whereby the rental costs can also be partially offset against a later purchase.