Axle Flange Automatic Muti-torches Seam Welding Machine

1.Mechanical Body and Positioning System:

• Headstock and Tailstock Positioner: The headstock (active end) drives the workpiece rotation, while the tailstock (driven end) provides support and clamps it in place. It uses an AC servo motor drive, enabling precise speed control and stepless speed regulation.
• Bed or Gantry: The rigid foundation supporting the entire machine.

2.Four-Torch Welding System (Core) :

• Four independent welding torches and their sliding mechanism: Four welding torches (usually MIG/MAG gas shielded welding torches) are evenly distributed at 90 degrees around the workpiece circumference, arranged symmetrically. Each torch is mounted on a linear guide rail, allowing for fine adjustment in the radial (X), axial (Y), and height (Z) directions to accommodate different workpiece sizes and weld requirements.
• Welding Power Supply and Wire Feeding System: Typically equipped with four high-performance digital welding power supplies (such as Panasonic, Phonix, Lincoln, etc.), four wire feeders, and wire spools. The wire feeding system requires stability and anti-clogging properties.

3.Automatic Control System:

• Core Controller: Typically uses a PLC (Programmable Logic Controller) as the main control unit to coordinate the overall machine operation.
• Human Machine Interface (HMI): A color touchscreen for parameter setting (such as welding speed, oscillation parameters, segmented current and voltage), program calling, and equipment status monitoring.
• Welding Process Control: Integrates a welding expert database, enabling segmented programming (such as different parameters for the arc initiation, welding, and arc termination stages) to ensure consistent welding quality.

 1.Loading: The operator or robot hoists the assembled bridge housing and flange workpiece between the head and tailstocks, and the tailstock advances and tightens.

 2.Positioning and Clamping: The workpiece is securely clamped, ensuring the flange end face is aligned with the welding torch position.

 3.Starting Welding: The operator selects the corresponding program on the touchscreen and presses the start button.

 4.Synchronous Welding: The headstock rotates the workpiece at a uniform speed, and all four welding torches simultaneously ignite the arc, welding according to preset welding parameters (current, voltage, speed, oscillation mode).

5.Segmented Control: The controller automatically controls the welding process, typically attenuating parameters in the overlapping areas at the beginning and end of the weld to prevent arc initiation and termination defects.

• High Efficiency: Simultaneous four-gun welding reduces welding time by over 60% compared to single-gun or dual-gun equipment, resulting in extremely high production efficiency, making it particularly suitable for mass production.
• High Quality: Symmetrical four-gun welding ensures uniform heat distribution, significantly reducing welding deformation and stress concentration.
• Parameterized and automated welding process eliminates human error, resulting in aesthetically pleasing and consistent weld formations. Typically, it produces deep welds with high strength, meeting the high standards required for vehicle axles.
• High Automation and Intelligence: Equipped with automatic welding, torch cleaning, and alarm functions, it is easy to operate and has low dependence on welder skills. Integrated weld tracking technology enhances adaptability.
• High Stability: Specialized design for fixed products ensures high mechanical structural rigidity, stable and reliable operation, and a low failure rate.

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