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Conventional Type Welding Roller

Welding rotator role in windmill manufacturing

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Welding rotators play a crucial role in the manufacturing of windmills, particularly during the manufacturing and assembly processes. Windmills consist of large structures, including towers and blades, which require precise welding for their construction. Welding rotators are used to facilitate the welding of these components by providing controlled rotation and support.

Here’s how welding rotators contribute to windmill manufacturing:

Tower Fabrication: Windmill towers are typically made of steel sections that are welded together to form a tall cylindrical structure. Welding rotators are employed to rotate the tower sections, allowing welders to access all sides evenly. This ensures consistent and high-quality welds throughout the tower’s length.

Blade Manufacturing: Windmill blades are typically made of composite materials, such as fiberglass or carbon fiber reinforced polymers. However, the root sections of the blades, which attach to the rotor hub, often require steel reinforcements or additional structural elements. Welding rotators are used to rotate the blade root sections, enabling precise welding of these steel components onto the blade structure.

Component Assembly: In the assembly of windmills, various components need to be joined together. For example, the tower sections need to be connected to the nacelle, which houses the wind turbine generator and other electrical components. Welding rotators assist in positioning and rotating these components during the welding process, ensuring accurate alignment and secure welds.

Surface Treatment: Before welding, the steel components of windmills often undergo surface preparation, such as cleaning, grinding, or coating. Welding rotators can be used to rotate the components, allowing for efficient and thorough surface treatment across all areas.

Quality and Efficiency: Welding rotators improve the quality and efficiency of the welding process. By providing controlled rotation, they enable welders to achieve consistent weld penetration and prevent defects like uneven bead profiles or lack of fusion. Moreover, the use of welding rotators reduces the need for manual repositioning of large and heavy components, saving time and effort during welding operations.

The welding rotators used in windmill assembly are typically designed to handle the weight and dimensions of the components involved. They can be adjusted to accommodate different sizes and shapes of windmill parts, providing flexibility in the assembly process.

Overall, welding rotators play a vital role in windmill development by facilitating the welding process for various components, ensuring structural integrity, and contributing to the overall quality and efficiency of windmill manufacturing and assembly.

 

Welding Automation in Wind Tower Manufacturing

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Welding automation has become increasingly important in wind tower manufacturing as it can improve efficiency, productivity, and quality while reducing costs and minimizing the risks associated with manual welding.

Wind towers typically consist of large, tubular steel sections that need to be welded together to create the final structure. These welds must be precise and strong enough to withstand the extreme conditions that wind turbines are exposed to. Welding automation can help ensure the quality and consistency of these welds, while also speeding up the manufacturing process.

There are various types of welding automation technologies that can be used in wind tower manufacturing, such as robotic welding systems, automated welding machines, and welding manipulators. These systems can perform a variety of welding tasks, from welding seams on the outside of the tower to welding the internal connections between tower sections.

Welding role in wind tower building

Welding plays a crucial role in the construction of wind towers. Wind towers are typically made of steel, and welding is used extensively to join the different components of the tower together.

The tower sections are typically made from rolled steel plates, which are joined together using a variety of welding techniques, including arc welding and gas welding. In some cases, welding may also be used to attach brackets or other components to the tower.

Welding is important in wind tower construction because it helps ensure the structural integrity of the tower. The tower must be able to withstand high winds and other environmental stresses, so the welding must be of high quality and meet strict standards. Welding is also important for ensuring the tower’s longevity, as it helps prevent corrosion and other forms of damage.

Overall, welding is a critical component of wind tower construction and plays an important role in ensuring the safety, durability, and reliability of these important structure

Welding Rotators and welding Positioners for welding 

Welding rotators and welding Positioners are two types of equipment commonly used in welding to assist with the manipulation and positioning of large or heavy work pieces.

Welding rotators are used to rotate cylindrical work pieces, such as pipes or tanks, during welding. The rotators consist of two or more motorized rollers that are mounted on a frame and can be adjusted to fit the size of the work piece. The work piece is placed on the rollers, which rotate it slowly and steadily as it is welded, ensuring even and consistent welds.

Welding Positioners, on the other hand, are used to position work pieces in the optimal orientation for welding. They consist of a table or platform that can be tilted or rotated to allow the welder to access all sides of the work piece without having to move around it. This can be particularly useful for welding large or heavy work pieces, as it allows the welder to work more efficiently and safely.

Both welding rotators and welding Positioners can help improve the quality and efficiency of welding by providing better access to the work piece and allowing for more consistent and even welds. They are particularly useful for welding large or complex structures, such as pressure vessels or wind towers, and can help reduce the time and labor required for these types of projects.

Cubuilt Engineers Pvt Ltd

Welcome to Cubuilt Engineers Pvt Ltd

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Cubuilt Engineers Pvt Ltd is an ISO 9001:2015 Certified company, incorporated in the year 1995. We are well known for our trademark Custom Built.

Cubuilt Engineers Pvt Ltd is a pioneer in the field of Design, Manufacture, Supply, and Erection & Commissioning of the complete range of Welding Automation Systems. Under the visionary guidance of our respected Management Director Mr. P. S. Patil, we have attained a distinguished position in the market. His vast domain expertise, as well as business acumen, has supported us to enlarge our operations globally.

The first year proved to be a testing time with all our valuable customers and the year ended with a modest turnover of Rs. 12 Lakh. Thereafter there was no looking back. Quality products blended with perfect workmanship, unmatched after-sales service, and an urge for growth resulted in the company crossing the Rs. 50 Crore Annual Turnover. Over the years the domestic and overseas customers have been patronizing our products with repeat orders.

Our manufacturing unit & Corporate office is located in Bhosari, Pune. Which is approximately 155 kms from the Mumbai Metro City, the commercial capital of India.
We have an experienced R&D department and Modern manufacturing facilities to accomplish the exceeding needs of our customers with 280+ experienced employees and 5 full-fledged manufacturing facilities in India.

300 Ton Heavy Duty Welding Rotator with Trolley

300 Ton Heavy Duty Welding Rotator with Trolley

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300 Ton Heavy Duty Welding Rotator with Trolley has been specially designed to meet the modern requirements and incorporate features essential for efficient and economic welding. The basic function of this rotator is to turn the job continuously at a preset speed so that welding can be made on the circumference.

Variety for Welding Rotators

We are a leading Manufacturer of Conventional Type Welding Rotators, Self Centering Type Welding Rotators, Self Aligning Type Welding Rotators, Pipe Rotators, Stand Rotators, and Blasting And Painting Rotators from Pune, India.

Head and Tail stock Lifting arrangement

Head and Tail Stock Lifting Arrangement

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Head and Tail stock Lifting Arrangement

Head and Tail stock with lifting arrangement is mainly used for holding the Jobs from both ends and rotating it or Indexing it getting any position.

It can be used for Pipe to Flange welding, Pipe to Bush welding, and Pipe to Pipe welding applications as well.

It has been specially designed to meet modern welding requirements and incorporate features that are essential for efficient and economic welding production.

The job is rotated continuously at a preselected speed so that the quantity and quality of the weld can be made on the circumference.

Competitive Advantage: Lifting arrangement of Head & Tailstock

1 Offer lifting and electro-mechanical rotation
2 Capacities from 1,000 kg. to 100 tons
3 Slide positioning for varying fixture lengths
4 Low-maintenance brushless motor
5 Easily accessible hydraulics for inspection and maintenance

80 Ton Welding Positioner

80 Ton Welding Positioner

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80 Ton Welding Positioner

80 Ton Welding positioner automates the time and floor space, enabling more efficient production and cost reduction by reducing floor space and rising welding speed and quality.

Although welding positioners not only help the company financially, they also have a huge impact on the welder performance. Welding positioners permit welders to manufacture rotary welds of high quality.

Positioners improve the core strength of the welders as they are not required to perform out-of-position welding.

It speeds up the manufacturing process and gives the welder sufficient welding experience.

Repeatable welds optimize arc time and increase the rates of production while decreasing labor costs.

3 Axis Welding Manipulator

3 Axis Welding Manipulator

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3 Axis Welding Manipulator

Cubuilt is a 3 Axis Welding Manipulator manufacture and wholesaler of an assured quality range of Welding rotators, Welding Columns and Booms and Welding Positioners. These products are manufactured according to industry standards from high-quality input factors.

3 Axis Welding Manipulator Benefits

Once the job is loaded, all welding operations in the down position can be easily manipulated.  Welding positioners reduce the handling time and the frequent use of cranes.

The job can be tilted from 0° to 135° depending on the requirement of the specific location of welding.

Welding Positioners or welding manipulators can be conveniently used for complete circumferential welding, strip cladding, down hand position welding, to set the job conveniently for easy accessibility to intricate assemblies, etc.

Along with Column & Boom, a welding positioner can carry out any welding tasks which are impossible otherwise.

Welding Positioner / Manipulator Automation

Welding positioners automate the time and floor space, enabling more efficient production and cost reduction by reducing floor space and rising welding speed and quality.

Although welding positioners not only help the company financially, they also have a huge impact on the welder’s performance.
Welding positioners permit welders to manufacture rotary welds of high quality.

Positioners improve the core strength of the welders as they are not required to perform out-of-position welding.

Repeatable welds optimize arc time and increase the rates of production while decreasing labor costs.

Welding positions offer various advantages to all manufacturing plants, whether you aim to improve your profit and efficiency of production.

Hydraulic Fit up Rotators

Hydraulic Fit up Rotators

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Hydraulic Fit up Rotators

“Hydraulic Shell to Shell Fit-Up Rotators are specially designed to Align, Rotate and Support two sections of same diameter Shells for ‘Tack Welding’ or ‘Full Circumferential Seam Welding”.

Construction and Technical Details of Hydraulic Rotators

Fit-Up Rotators have Four Units, Two Units (1No. Drive Unit + 1No. Idler Unit) are with Trolley Wheels and the other Two are Hydraulic Fit Up Units Fixed Base Type.

The trolley of the Drive Unit has an inbuilt drive system, so that the shell section supported on them can be moved forward or backward, in order to butt the shell edge, against the edge of the other shell on the fixed units.

Hydraulic Fit up Rotators Features:

  1. Both sections have a free multi-dimensional adjustment capability.
  2. The adjustment work is more flexible and can better accommodate different types of welding seam status
  3. The hydraulic V-wheel facilitates the axial movement of the tower
  4. It could greatly improve the working efficiency for thin wall thickness and large pipe diameter production
  5. Hydraulic Fit up rotator consists of a 3D adjustable shift rotator, a hydraulic working station with effective control
  6. Rotator base is made of welded plate, with a higher strength to ensure no curvature occurs over a period of time
  7. Rotator base & boring is an embedded process to ensure precise rotation of the roller
Special Welding Turntable 30 Ton Capacity

Special Welding Turntable 30 Ton Capacity

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Special Welding Turntable 30 Ton Capacity has been specially designed to meet modern welding & Cutting requirements and incorporate features essential for efficient and economic welding production. The basic function is to bring the weldment to a convenient position or to turn the joint at a pre-selected speed so that quality weld can be made on the circumference.

Special Welding Turntable 30 Ton Capacity Features

The machine basically consists of a drive system for faceplate rotation. Here the Power is obtained through an A. C. Motor (Prime Mover). Further Speed reduction occurs at 3 stages i.e. Through Double reduction Worm Gear Box and by Spur Pinion & Spur Gear.

Special Features Provided

1. Acceleration and De-acceleration time set facility provided for smooth gradual speed pick-up.
2. Constant torque throughout the speed range.