Innovic Technology

Karamsad, Anand, Gujarat

Welding Positioners: Boosting Efficiency in Steel Fabrication

Welding positioners are essential equipment for steel fabrication shops, enabling faster and more efficient handling of bulky fabrications. Designed to minimize the need for cranes and additional manpower, welding positioners allow fabrications to be easily placed in the optimal 'downhand' position. The positioner’s table rotates at precise, variable speeds and tilts through 135°, accommodating high center-of-gravity loads and enabling accurate welding of angular jobs. These welding positioners can also interface with Column and Boom Manipulators for seamless operation.

Key Features of INNOVIC Welding Positioners:

• Durable Construction: Built with robust, all-steel fabrication for long-lasting performance.
• 360° Table Rotation: Variable or single-speed rotation options for complete control.
• Customizable Table Design: Available with square or round tables, featuring T-slots and concentric rings for fast, precise alignment and clamping.
• Tilt Functionality: Power-operated tilting mechanism through 135°, with limit switches to prevent overrun.
• High-Quality Bearings: Center spindle supported by sealed, pre-loaded bearings or large-diameter cross-roll bearings, depending on load capacity.
• Precision Gearing: Machine-cut steel gears for smooth, accurate operation.
• Efficient Earthing: Built-in earthing system for enhanced safety during operation.
• Enclosed Electrical System: Fully enclosed motors with electromagnetic brakes for added safety and reliability.
• Remote Control: Pendant remote push-button controls for all movements, including speed adjustment via a potentiometer.

By investing in INNOVIC welding positioners, fabrication shops can significantly improve productivity, reduce labor costs, and ensure precise, consistent welds for a wide range of applications.

Head Stock and Tail Stock Welding Positioners: Ideal for Long Workpieces

Headstock and Tailstock positioners are essential for rotating long workpieces around a horizontal centerline, providing efficient handling and positioning. Typically, the headstock is powered while the tailstock remains free-wheeling, with no additional support required beneath the workpiece. These positioners are especially beneficial for turning large, complex structures, allowing welders to perform tasks more easily. In some cases, only a headstock unit is needed, as demonstrated in pipe spool fabrication.

Head Stock and Tail Stock Welding Positioners

INNOVIC’s headstock and tailstock welding positioners are versatile and well-suited for handling long objects. Typically used for rectangular shapes requiring support from both ends, these positioners provide ergonomic and efficient solutions for welding complex structures. Options include both fixed-height rotation centerlines and power-elevating models, offering flexibility for different job sizes and configurations.

Key Features of INNOVIC Head Stock and Tail Stock Positioners:

• Capacity up to 100 Tons: Designed to handle heavy loads and large jobs with ease.
• Fixed and Variable Height Models: Choose from fixed-height or power-elevating models for ergonomic positioning.
• Customizable Center Height Adjustment: Center height adjustment available for larger job swings and improved flexibility in handling.
• Wide Rotation Speed Range: Supports all major welding processes, including MIG, TIG, and SAW welding.
• Advanced Control Options: Includes models with additional control capabilities for enhanced precision.

In addition to the standard models, INNOVIC offers advanced versions with elevating headstock and tailstock configurations to cater to more complex welding requirements.

Column and Boom Manipulators: Precision and Stability for Welding Operations

INNOVIC's Column and Boom Manipulators are engineered for precision, durability, and enhanced performance during welding operations. Designed to handle various welding processes, they provide stable and controlled movement of the welding head and boom, ensuring smooth operation even at extended heights and lengths. The manipulators are supported by precision cross-roll bearings, which eliminate free play, a crucial factor when the boom is fully raised and extended.

Key Features of INNOVIC Column and Boom Manipulators:

• Precision Cross-Roll Bearings: These bearings ensure smooth and accurate rotation of the column, eliminating any free play that can lead to instability during operation. Larger machines come equipped with pre-loaded cross-roll bearings for added precision.
• Manual or Motorized Column Rotation: Column rotation can be motorized or manually locked in any of the 360° positions, allowing for flexibility in welding applications.
• Boom Elevation with Rack and Pinion Drive: Boom elevation is powered by a high-torque AC geared motor with an electromagnetic brake, providing smooth and reliable movement. Unlike chain or lead-screw mechanisms used by some competitors, INNOVIC uses a rack and pinion system to eliminate bounce and ensure consistent boom movement.
• Counterbalanced Design: The boom, welding head, and accessories are counterbalanced by a weight inside the column, reducing strain on the elevation gearing. This system enhances the stability of the machine, particularly when operating at full extension.
• Advanced Boom Traverse Drive: The boom traverse is driven by an AC frequency variable drive system, featuring a rack and pinion setup for smooth and controlled movement. A two-speed gearbox allows for slow retraction during cladding operations, accommodating processes such as spiral cladding using strip or wire electrode methods.
• High Load Capacity with Minimal Deflection: INNOVIC’s manipulators are designed to minimize deflection, even when carrying loads of up to 300 kg at the end of the boom. The combination of a precision cross-roll bearing and wide rollers ensures better stability and accuracy during operations.
• Customizable Configurations: INNOVIC Column and Boom Manipulators are available in five different designs, each tailored to meet the specific needs of various applications, such as cylindrical vessel manufacturing or high-precision welding tasks.

Base and Travelling Carriage Options:

• Free-Standing Base or Travelling Carriage: The manipulators are designed with a robust base that provides maximum rigidity. The base can either be stationary or supported on wheels to form a travelling carriage, depending on the requirements. Travelling versions include either constant-speed or variable-speed drives for accurate tracking and movement.
• AC Motorized Column Rotation: Larger machines are equipped with motorized column rotation through an AC motor and heavy-duty reduction gearboxes, providing smooth start-stop movement and reducing strain on the system.

Speeds and Performance:

• The manipulators offer precise control over speeds, ranging from as slow as 5 mm per minute to 1000 mm per minute, ensuring flexibility for various welding and cladding operations.
• These machines are ideal for applications requiring high stability and minimal deflection, such as spiral cladding or when handling heavy loads at extended boom lengths.