Standard Features on Column and Boom Manipulator Systems
The manipulators feature thick-wall steel construction that is thermally stress relieved prior to machining, which extends the life and increases the rigidity.
The boom is driven by a variable speed AC motor with a rack and pinion gear drive for smooth in/out motion. Boom speed is 300 – 3000 mm/min (12 – 118 in/min) and is upgradable to a servo motor drive for programmable motion control.
Vertical boom motion is delivered by a fixed speed AC motor and ACME screw drive with dual ACME nuts. One nut is used to drive and support the load of the boom. The second nut is included as a backup and works in conjunction with electrical sensors to lock the boom in place in the unlikely event that the first nut fails. The ACME screw and dual nuts ensure smooth up/down motion while also providing a very high level of safety. This drive is upgradable to variable speed or precision motion with a servo motor for programmable control.
Cable carriers are included on both axes to extend the life of the cables and hoses. The carriers also keep the cables organized and prevent entanglement during operation.
Precision hardened linear rails are included for the entire length of the column and boom motions. The rails coupled with recirculating ball bearing blocks ensure smooth operation throughout the life of the manipulator.
The column features a kingpin for 360 degrees of manual rotation with manual brakes to lock the column into position. A handle is included on larger manipulators to aid in rotation.
A sturdy freestanding base supports the manipulator fixture. Each leg of the base includes a hole that can be used for anchoring the manipulator to the factory floor for additional stability.
Optional Features on Column and Boom Manipulator Systems
Offline Programming Software
Weld programs can be created, modified, or stored on a PC. These programs can be moved back and forth between the controller and the PC using a USB storage device or through an Ethernet connection. This software can increase productivity by allowing programs to be created/edited while the weld controller is executing another weld program.
AMET® offers a full line of turning rolls for part rotation with weight capacities from 2.5 to 150 ton. The turning rolls can either be operated independently for positioning purposes or integrated into the welding system through the XM® or XPro Controller for controlled and programmable part rotation.
Arc Viewing Camera
Arc Viewing Cameras can be added to a GTAW/PAW system giving the operator a view of the weld arc from a remote location. This keeps the operator in a safe location and reduces operator stress and fatigue. Additionally, the image that is shown on the monitor is magnified and shows greater detail than what could be observed without the camera. Multiple cameras may be integrated for projects where a view of the lead and trail side of the weld zone is required. Please see the Arc Viewing Camera page for additional information.
Data Acquisition and Tolerance Checking Software
Data is collected and analyzed in real-time to ensure all modules are within the set tolerances. The data points can be displayed graphically on the display and can also be exported as a .csv file and viewed on a program such as Microsoft Excel. These files can be exported through one of the USB or Ethernet ports on the XM® or XPro Controller.
Laser Seam Tracking
The XM® or XPro integrate with a laser sensor to scan and track the weld joint during welding. The laser continuously scans the joint profile and makes the necessary adjustments to ensure the torch maintains the programmed location. The scanned profile is also displayed in real-time on the operator console monitor. Seam tracking can be configured for single or multi-pass welds.
AVC for GTAW/PAW System
An AVC (Arc Voltage Control) Module is added to provide the weld head with automatic arc standoff. The module provides automatic height adjustments to maintain a consistent arc voltage throughout the entire weld, including automatic adjustments on multi-pass welds.
Camera System (SAW)
A video camera and cross-hair laser generator are mounted to the weld head to aid in monitoring during welding operations. The video feed is displayed in real-time on the operator console monitor. The camera is also used to aid in positioning the torch(es) during setup.
Multiple Process Weld Head
Our advanced controls allow us to integrate multiple weld processes into one weld head. Each process can be operated independently or simultaneously. For example, a TIG & Plasma weld head would feature two AVC axes (one for each torch) and either torch could operate or they can both operate simultaneously for Keyhole Plasma with a TIG trail. We offer TIG & Plasma, TIG & MIG, TIG MIG & Plasma, and SAW & MIG. Any of these combinations are available and would be completely programmable from ONE central controller. Other combinations are also available. Please contact us with any requests.
Single Point Power Distribution
AMET® provides fuse-protected power to all system components from a single primary power circuit (provided by customer).
Virtual Alignment (Teaching Mode)
The operator can “teach” a weld path by manually moving the weld torch along the seam and selecting points. Up to 20 points can be selected to create a circumferential, longitudinal, or combination weld path. After all of the desired points are selected, the system will retrace each one to create a custom weld path. This can be helpful if parts or materials vary or have unique joint configurations. The path can be repeated for multiple pass welds, or offsets can be applied to repeat the motions of the original path in a new location.
Travel Cart with Rails
Manipulators can be mounted to a travel cart for increased capacity. The travel carts are typically motorized, but are available as non-motorized units for our two smallest classes of manipulators. The motorized travel cart can be operated independently for positioning purposes or upgraded and used as a welding axis for longitudinal welds.
The travel cart can be extended for mounting the weld equipment next to the manipulator to keep everything centrally located. This helps eliminate excess cabling and reduces trip hazards.
Flux Delivery and Recovery System
The entire system is air-pressurized and heated to provide continuous flux delivery and recovers unused flux to help reduce costs. The system consists of a feed tank, delivery and recovery unit with 5 HP vacuum, and hopper for delivery at the weld head. The hopper is equipped with a valve to allow the operator to control the ratio of new and recovered flux delivered at the weld head.
AMET® manufactures a full line of high precision turn tables with weight capacities from 550 to 22,100 lb (250 to 10000 kg). We also offer standard version turn tables with weight capacities from 2,200 to 132,200 lb (1000 to 60,000 kg). Each turn table faceplate includes a thru-hole for a gas purge device.
AMET® manufactures a wide range of positioners with weight capacities from 550 to 22,000 lb (250 to 10000 kg). They feature 135 degrees of motorized tilting and continuous motorized rotation. The rotation axis can be integrated with the XM® or XPro to provide programmable control for welding operations. High-precision models are also available with harmonic drive rotation for the most stringent needs. The standard configurations include a fixed base, but an elevating base is also available. Each positioner includes a thru-hole for a gas purge device.
Programmable Gas Control
Adds programmable gas flow control for GTAW and PAW applications.
Both the horizontal and vertical boom motion can be upgraded with a servo motor and encoder for precise programmable control of the boom. The upgraded motion axis can then be used as an additional welding axis.
Arc initiated by touching the torch tip to the part for GTAW and PAW applications. This capability requires an AVC module.
A precision servo motor driven ball screw slide with encoder feedback provides mechanical oscillation. The oscillation motion is completely programmable including dwell time, oscillation frequency and width, and travel speed.
Magnetic probe is used to deflect the arc back and forth in a stirring motion for excellent sidewall tie in. The arc can also be deflected and maintained in a set position. This can be beneficial for fillet or otherwise hard-to-reach joints. Dwell time, oscillation frequency, and width are all programmable from AMET® controls. Compatible with both magnetic and non-magnetic materials.
End Uses For Column and Boom Manipulator Systems
Precision engine components for the aerospace industry have tight tolerances and strict quality control. Precision motion and repeatability are essential when manufacturing these components. AMET's servo controlled axes of motion are well-suited to meet such stringent requirements.
Blowout preventers require corrosion-resistant overlays of the bores and components to ensure they can withstand harsh oil and gas environments. Our systems and controls provide an excellent solution for BOPs whether your company is the primary manufacturer or performs repairs.
ID and OD pipe cladding are available on our systems. We offer spiral and step-index cladding to fulfill the needs of most applications.