ROTOWELD 3.0 AUTOMATED PIPE WELDING WORKSTATION

• 4D Synergy Welding™ is a unique patented technology of proprietary algorithms that link together the four key welding parameters so that any joystick command maintains ideal welding conditions.
• The 4 key welding parameters
  • Travel speed
  • Wire feed rat
  • Arc voltage
  • Weaving width
• The computer’s fast reaction time means the machine can work at high deposition rates and travel speeds at which weld pool conditions are too critical to be sustained by hand.
• Addition information on 4D Synergy Welding™ at link below:

https://rotoweld.com/innovations/4d-synergy-welding/ 

• The Rotoweld system is designed to maximize efficiency and uptime. Using only two positioners we can achieve up to 90% arc-on time.
• By adding additional positioners, you will take up more real estate, require more operators and gain no additional arc-on time.

• Rotoweld offers the smallest square foot requirements of any pipe welding robot.
• The latest Twin Face to Face setup only require 48’ between twin faceplates.
• Check out the various Rotoweld configurations at the link below:

https://rotoweld.com/rotowelds-configuration/ 

• Traditional welding positioners are typically manufactured using spur gears. While these are great for manual welding, they tend to add backlash into the system over time. You can add a servo motor to these positioners, but they will develop backlash within the gearing, cause the welding parameters to deteriorate.
• The Rotoweld system utilizes servo motors and zero-backlash planetary reducers. This is the same type of moto/reducer setup that is used on 6-axis industrial robots.
• The Rotoweld positioners offer 50,000 in-lbs. of rotating torque. A standard 3,000 lb. welding positioner only provides 18,000 in-lbs. of rotating torque. The Rotoweld positioner is over 2.5 times stronger than a typical welding positioner.
• The positioners on the Rotoweld system have a 65” centerline of rotation. This allows for rotating of elbows without hitting the floor. Traditional welding positioners typically have only a 36” centerline of rotation.
• Rotoweld gives you single point of contact for the entire system. In the unlikely event you develop a problem, you make one phone call. There is no finger pointing.

• Rotoweld system is quoted fully integrated:
  • Includes positioners.
  • Includes track system to assure level along entire length of pipe to be welded
  • Robotic manipulator
  • Idler support rolls
  • Software included
  • Lincoln Powerwave 500 with STT and pulse capabilities
• We believe only a fully integrated work cell can deliver the most high-quality, reproducible, productive and consistent welds.
• Additional information at link below:

https://rotoweld.com/innovations/fully-integrated-design/ 

• There is no additional cost for software updates.
• The Rotoweld software is proprietary software and the heart of the welding system. The customer is entitled to all software upgrades for as long as they own the system.

• Available as an option, Rotoweld is compatible with MSUITE, STRATUS and others, making it a versatile tool for manufacturers who want to streamline their operations and work more efficiently. 
  • Easily identifies and pushes the weld ID and information to the Rotoweld software.
  • Automatically loads the right welding program, if specified
  • Links the Prodatalog weld information to the shop’s valid weld ID.
  • Notifies the plant tracking software when the weld is complete.
  • Sends critical weld information to the weld ID, such as heat input and arc-on-time.

• There are no fees associated with our Prodatalog™ 
• Prodatalog™ brings industry 4.0 to your welding fabrication process.
• Prodatalog™ has two main goals:
  • Productivity Tracking 
  • Quality Control. 
• Additional information:

https://rotoweld.com/innovations/prodatalog/ 

• The rail-based system is the backbone of automated welding.
• The rail-based design is key to automation since it is the link between the welding robot, the positioners, and the support rollers. That’s why it’s essential to ensure reproducible positioning of the welding torch (stick-out) and the same welding position every time, regardless of the diameter of the pipe or length of the spool assembly. 
• The welding robot is seamlessly carried to a second welding station along the rails, so the Twin Bay model eliminates set- up time and increases productivity.
• Upon loading the proper welding program, the Rotoweld’s welding arm, driven by zero-backlash harmonic drives, will position itself automatically, respecting the pipe diameter and indicated stick-out. The welding head is always perpendicular to the pipe axis without the operator re-adjusting for every weld.
• All the welding cables are embedded in the rail design for safer and simpler shop operations.

• Rootomatic™ is the ultimate solution for automating root pass welding on pipe.
• Rootomatic works in tandem with the 4D Synergy Welding™ technology, providing real-time image processing of the weld puddle and welding arc.
• Rootomatic™ fully automates root pass penetration and prevents missed fusion due to improper arc positioning. It tracks the position of the puddle and the arc to ensure complete fusion of inside edges. It also adapts to the presence of tacks while welding to produce a smooth weld bead ready for the first fill pass.
• Minimal pipe welding experience required. The Rootomatic performs a 100% automatic open-bevel root pass at travel speeds between 8 and 10 in./min. (200 and 250 mm /min.) with normal fit-up imperfections (gap variations and high-low) after just 2 to 3 days of training.
• Truly adaptive to changing conditions experienced by pipe fabricators. Based on Rotowelds recommended pipe preparation, the Rootomatic adapts the welding process to varying conditions, such as changes in gap, alignment, and root face by adding real-time puddle and arc image analysis to the 4D Synergy Welding algorithm, resulting in the most adaptive automated root pass welding ever engineered.
• Additional information at link below:

https://rotoweld.com/innovations/rootomatic/ 

• Ongoing support and warranty.
• Rotoweld takes pride in offering the best manufacturing/engineering warranty and support in the business so you can rely on Rotoweld 3.0 technology for years to come.

• Due to Rotoweld’s unique ability to handle out of round pipe, Rotoweld can weld pipe 40’ away from the positioner.

• Rotoweld is designed to handle down to 3” diameter pipe.

• Yes, the Rotoweld system has been successfully welding stainless steel for years.
•  Watch the video of pipe to elbow welding:

https://www.youtube.com/watch?v=_l3obUmKpz0&t=18s 

• On-site Technician for commissioning - included.
• On site Training, immediately following commissioning – included.
• Travel expenses and accommodations – included.

• Yes, integrated fume extraction is a standard option for Rotoweld.
• Additional information at link below:

https://rotoweld.com/models/products-options/ 

• Yes, welding of slip-on flanges is a standard option for Rotoweld.
• Additional information at link below:

https://rotoweld.com/models/products-options/

• This is one question we cannot answer