Trackless Unguided All-position Crawling Welding Robot

Model: BOT-WTA17-421

Trackless Unguided All-position Crawling Welding Robot is an automatic welding system being used for all-position(1G-6G) welding on large-scale structural parts, pressure vessels and storage tanks in industries like: oil & gas, offshore, shipbuilding, construction, nuclear, and many more. The trackless design provides flexible movement, and laser vision tracking system ensures high seam tracking accuracy, ensuring high welding efficiency and excellent welding quality. In addition, automatic recognition system of welded seams provides effective robot guidance. All these features make it an excellent solution compare with semi-automatic welding and manual welding.

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Detailed Introduction



Crawler
Laser vision seam tracking system
Windproof shield
Multiple DOF welding swing system Load-bearing device
Permanent magnet adhesion walking mechanism



Technical advantages Reduce cost and improve efficiency

Welding amateurs could operate one or more robots after 3-day professional training which reduces the number of operators and level of skills.
No need for setting up guiding tracks or programming.
Stable and reliable Welding quality which significantly reduces rework
Low frequency pulse and program integrated double pulse welding procedures, high deposition rate, and greatly improved welding efficiency.
Welding procedures stored locally at your fingertips

Safe and easy to use

High load capacity, flexible movement, able to achieve multiple-degrees-of-freedom full position free crawling and spin turn on medium and large structural parts
Capability to cross obstacles
Remote control by control cabinet with molten pool observation camera installed on crawler; Rugged design, built to last
Equipped with four ultrasonic sensors with drop or falling prevention warning;








Application Scope
Welding bojects: storage tanks, spherical tanks, vessels, nuclear power infrastructure and other large-sized structural parts
Metal type: Carbon steel and alloy steel
Welding groove type: V,X,U,J
Welding positions:1G,2G,3G,4G, 5G,6G
Metal thickness: 6mm to 100mm


Transfer Trolley

All system components are mounted on the transfer trolley, including crawling welding robot, control cabinet, power source, wire feeder and water cooling unit, allowing for convenient operation and transportation.

Transfer trolley
Control cabinet
Trackless unguided crawling welding robot
Wire feeder Water cooling unit
Welding power source



Dimensions:1400(L)mmx800mm(W)xl500mm(H)
Drive type:Electric/manual






Control Cabinet

The control cabinet features modular design, metal housing and touch screen control panel. Its high-performance CPU adopts a multiprocessor system, enabling high-speed synchronous operation of the crawler and actuator. A servo controller is installed in the cabinet, and the drive and control of each axis are connected to the CPU through the physical interface. The control cabinet is designed with a variety of interfaces to connect with various types of industrial equipment.

Dimensions	580mm (L) x360mm (W) x630mm (H)
Interfaces	Analog interface: 4 I/ODigital interface: 32 I/O

Camera on Molten Pool

With a maximum observation distance of 100m, the camera on the molten pool is used for remotely monitoring open arc welding process. A 140 dB dynamic range is achieved because of the advanced sensing technology and precise electrical circuit design. Users can clearly observe the welding torch, welding wire and the whole welding process by means of the camera on the molten pool.

Image sensor	2/3" color HDR CMOS
Resolution	1280(H) X1024(V)
Pixel size	6.8μm X 6.8 μm (8.7mm X 7mm effective area）
Filter	blocks UV IR
Image sensor shutter	global or rolling
Dynamic range	140 dB
Pixel depth	8bit
Exposure time	100μs - 100ms
Image control	Shutter speed controls exposure time
Dimensions	85mm (L) X36.5mm(W) X38.5mm (H) (lens excluded)
Weight	200g (lens excluded)
Lens mount	C mount
Power consumption	6W at 12V

Welding Power Source

Welding power source can be configured according to customer's requirements. The standard version is digital series power source, which is integrated with more than 200 program memories. This makes welding material, wire diameter and gas work always at excellent performance level.

Welding current		BQT-I-400A	BQT-I-500A
Input voltage 50/60hz		400v( 20%/-20%)
Input current		25A	28.5A
Power factor at maximum current		0.96	0.93
Efficiency at maximum current		0.89	0.89
Duty cycle@40℃	100%	420A	500A
	60%	350A	450A
Duty cycle@25℃	100%	420A	500A
Current range (MIG/MAG)		15A-420A	15A-500A
Weight		34KG	40KG
Dimensions		738mm(L) *273mm(W) *521mm(H)

Wire Feeder

The wire feeder is designed with a metal housing, ensuring high durability. With storage of 99 welding programs, this wire feeding unit is applicable to various welding applications.

Model	DVU W500
Weight	16kg
Dimensions	603mm(L)x262mm(W)x446mm(H)
Number of wire feeding rolls	4
Wire diameter	0.6 mm-1.6 mm
Feeding speed	0-25 m/min
Wire reel diameter	300mm

Basic Specifications

Product weight	28.8kg	Max. obstacle crossing height	5mm
Max. load	60kg	Max. travel speed	5m/min
Min. diameter of curved surface	≥3.2m	Weld tracking accuracy	±0.5mm
Dimensions	621 mm (L) x394mm (W)x267mm (H)

Mechanical Specifications

Crawler	with caterpillar track	Torch motion types	linear, pendulum, oblique
Linear motion range of welding torch	±25mm	Stick-out range	±25mm
Torch travel angle (pendulum motion)	±30°	Torch oblique angle	±10°
Torch pitch angle	±30°	Rotation	spin around 360°

Other Specifications

Working temperature	-10℃~40℃	Relative humidity	below 90%
Control cable	10m standard length; extended length available upon request

An innovative alternative to manual welding and semi-automatic welding: Trackless Unguided Robotic Welding

Currently, welding of large-scale structural parts is performed mainly by manual or semi-automatic welding. A lot of hidden costs will be needed in the manual welding operation. A human welder needs to be trained for a long time to achieve sophisticated skills for quality welding operation. They may make mistakes during manual welding to affect production time, weld quality and costs. Manual welding may cause health and safety problems to the human welders due to the hazardous working environments full of flash, fumes, sparks, and heat. Semi-automatic welding in large structural components is affected by guiding tracks, which limits its degree of automation especially in the application scenarios with curved and irregular surface welds. Comparing with manual welding and semi-automatic welding, trackless unguided all-position robotic welding is an optimal alternative in the large-scale structural parts manufacturing industry, which can greatly improve welding quality and efficiency.

Disadvantages of Manual Welding

Unstable weld quality
Low efficiency
High labor costs
Pneumoconiosis
Employee risks
High management costs
Disadvantages of Semi-automatic Welding


Guiding track needed
Not applicable to the welding of irregular seam, especially curved surfaces
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