Tube Sheet Welder: The Core Equipment of High - efficiency Automated Welding Technology

 

As a core equipment in modern industrial manufacturing, the tube sheet welder is specifically designed for high - precision welding of pipes and tube sheets. It is widely used in the production and manufacturing of heat exchangers, boilers, nuclear power equipment, chemical containers, aerospace and other fields. Its core value lies in improving welding efficiency and quality through automation technology to meet the stringent process requirements under complex working conditions.

 

I. Core Features of Automated Welding Technology

1. Multi - dimensional Precise Control

The automated tube sheet welder adopts a stepping motor drive system, combined with a three - dimensional gantry and a five - dimensional fine - tuning device. It can achieve 180° rotation of the welding head on the horizontal plane and accurate spatial positioning. This design is particularly suitable for the welding of dense heat exchangers with small tube bridge spacing, effectively avoiding the misalignment problems that are prone to occur in traditional welding.

2. Diverse Welding Processes

It supports self - fusion welding, filler wire welding and multi - layer composite welding processes, and is suitable for the welding of various materials such as carbon steel, stainless steel and copper alloys. Some high - end equipment is compatible with both DC/pulse modes, and realizes stable arc control through inverter technology, ensuring uniform and beautiful weld formation and meeting the welding requirements of metals with high protection needs such as titanium alloys.

3. Intelligent Control System

It integrates a Siemens PLC controller and a seven - inch touch - screen operation interface, and supports the storage and dynamic adjustment of more than 99 welding parameters. During the welding process, the current intensity can be adjusted remotely, and it has the starting point memory function and weld overlap compensation technology, significantly improving the welding consistency and yield.

 

II. Industry Application Scenarios and Technological Advantages

1. Energy and Chemical Equipment Manufacturing

In the manufacturing of equipment such as boilers and heat exchangers, the tube sheet welder can complete the welding tasks of pipe diameters from 10mm to 80mm, meeting various joint types such as deep hole welding, fillet welding and butt welding. Its water - cooled positioning mandrel and circulating cooling system can ensure long - term continuous operation and adapt to high - intensity production requirements.

2. New Energy and High - end Equipment Fields

With the development of solar thermal systems, hydrogen storage tanks and aero - engine cooling components, welding equipment needs to have high - temperature resistance, corrosion resistance and ultra - high sealing performance. The new - generation tube sheet welder has achieved technical adaptation to these special working conditions by optimizing the shielding gas device and welding parameters.

3. Quality Control and Standardized Production

It meets the requirements of "GB/T 40424 - 2021 Welding Procedure Qualification Test for Tubes and Tube Sheets", and uses digital signal processing technology to monitor the weld penetration and width in real - time, ensuring that the welding quality meets international standards such as ASME and PED, and helping enterprises to pass industry certifications.

 

III. Industry Development Trends and Equipment Selection Suggestions

1. Energy - saving and Intelligent Upgrades

Current equipment generally adopts no - load energy - saving technology, with standby power consumption less than 10 watts. By integrating an AI parameter optimization system and fault self - diagnosis function, it can reduce the debugging time by more than 30%, which is suitable for flexible production lines with multiple varieties and small batches.

2. Modular and Highly Adaptable Design

For different pipe diameter requirements, the equipment provides two modes: elastic collet and mechanical positioning, and an optional trailing shield device to expand application scenarios. Users can choose from three - axis to six - axis models according to production scale to balance the degree of automation and investment cost.

3. Procurement and Technical Support Strategies

It is recommended to purchase equipment with CE certification through professional suppliers, and focus on the matching of welding power sources (such as PD200/PD400 programmable power sources) and the after - sales service system. Mainstream equipment supports cloud storage and remote upgrading of process programs, which can significantly reduce the difficulty of later operation and maintenance.