IS SEAM TRACKING RIGHT FOR YOU?
Take this short quiz to determine if seam tracking is right for your application.
1) Are your parts the same basic shape with similar seam configuration, varying only in size—diameter and/or length?
2) Is your welding application repetitive in nature—many of the same parts are welded before the welding station is retooled for another part type?
3) For circumferential welding projects, like tanks, cylinders and/or pressure vessels:
• Are operators required to manually weld the end-caps or manually position a torch while welding?
• Would you like to weld both end-caps at the same time?
4) For beam fabrication:
• Are operators required to manually weld the beam or manually position a torch throughout the full length?
• Would you like to weld both sides of the beam at the same time?
5) Is your seam configuration a lap joint, v-groove or fillet weld, either single or multi-pass?
6) Is your fit-up good, but some variation exists that prevent the joint from being welded reliably by hand? For example, on large tanks the shell / cylinder sag under the weight or walks on the turning rolls.
If you’ve answered YES to any of the questions above, adding a seam tracking system to your application could offer significant benefits over your current welding process.
Tactile systems track the seam using a sensor with a tip that rides the seam, much like a needle follows the groove of a phonograph.
CHOOSING THE RIGHT SYSTEM
With advances in welding power sources and arc technology, weld travel speed is increasing beyond the operator’s ability to manually position the torch accurately over the seam, making a seam tracking system a worthwhile investment. They offer a good balance between cost and flexibility, and are available in two models: standard and advanced. To determine which seam tracking system is right for your application, follow this simple, four-step process:
Step 1 – Payload Requirement:
Determine the weight the system will carry and select the appropriate cross slide. Cross slides are offered in weight capacities of 40 (18), 250 (113) and 450 (204) pound (kg) models. Be sure to select a model with a rating higher than your requirement. Pricing differences between models is usually not significant, so if your requirements are near the rating of one of the cross slides, upgrade to the next model to provide much longer service life and less maintenance.
Step 2 – Stroke Length Requirement:
Determine the stroke length of the cross slide you will need. The 40-pound (18 kg) model is typically offered in 3” x 3” (8 cm x 8 cm) and 6” x 6” (15 cm x 15 cm) stroke lengths, whereas the larger models are offered in standard 5” x 5” (13 cm x 13 cm) or 10” x 10” (25 cm x 25 cm) stroke lengths. The first number represents the horizontal stroke length and the second is the vertical stroke length (use “H” before “V”, just as in the alphabet, to be sure your order is built correctly).
Custom stroke lengths are available in 5” (13 cm) increments up to 60” (152 cm) for the 250 (113) and 450 (204) models. The cross slides can be configured with each axis having a different stroke length to accommodate specific applications, where, most commonly, more horizontal stroke length is needed—a 20” x 10” (51 cm x 25 cm) or 30” x 5” (76 cm x 13 cm), for example.
Step 3 – Level of Automation:
Select the level of automation—fully automatic or semi-automatic. Selecting fully automatic will require use of an advanced model, which can take full advantage of the remote inputs and outputs. The standard model would fit the semi-automatic selection, providing basic seam tracking but requiring the operator to manually start and stop the welding process.
Step 4 – Sensor Tip Selection: Selecting the appropriate tip is simple and primarily involves matching a tip size to the seam type and the material thickness.