Product Details
The standard membrane panel welder is designed to a width of 1600mm operating with 4 welding torches utilising submerged arc welding (SAW) technology. This is the most commonly ordered specification for good reasons:
- High productivity/efficiency in fabrication
- Panel products within transportation limits
- Practical and stable application
- Lower cost of machine and meeting sufficiency
We may however custom built to the customer's requirement (owing to technical limitations). Our experiences span from panel welders with varying widths, number of welding heads , SAW or MIG/MAG or both utilizing your preferred power sources.
ZZ continues today to innovate and adopt newer technology in achieving user friendliness with the introduction of digital touch screen panels. The panel welder will greatly increase outputs and reduce overheads with just 1 operator.
Since 2008, we have actively exported our equipment to countries such as India, USA, Russia, Philippines, Malaysia , UAE and Indonesia. Not forgetting our customers (both foreign and local) numbering over 100 operating in China whom we have serviced since 1996.
Comparison Table between SAW and MIG/MAG we hope would help you better decide on your investment
|
2X SAW 4 torch membrane panel welding machine |
1X MIG/MAG 12 torch membrane panel welding machine |
Weld penetration |
Deep, 3 - 5mm |
Shallow, 1 - 1.5mm |
PPE |
No light pollution operator assumes basic PPE
|
Intense light pollution Welding mask Protective clothing
|
Weld quality |
Good weld presentation Minimal rework
|
Average weld presentation, often porosity, spatter, undercut Requires rework
|
Welding consumables |
Flux, can be recycled |
Inert gas, gas not recycled |
Left over |
Welding slag |
None, balance gas evaporates |
Process |
One side welded during a single pass |
Both top and bottom side welded during a single pass |
Productivity |
0.8 - 1.5m/min |
0.5 - 0.7m/min |
Manpower |
Easy to operate, one operator required for 4 torches |
Requires experienced welder |
Welding dies |
Minimal amount of welding dies, dies replaced when fin bar size or centering height changes |
High volume of welding dies. Different tube diameter or different fin bar size requires change of dies. Large effort in replacing dies.
|
Cost of welding dies |
Low cost, estimated at USD500.00 |
High cost, estimated at USD20,000.00 |
Acceptance |
Accepted by all |
Used only with allowed fabrication process, typically in small/low pressure applications within limited regions in the world |
Case study |
2 X 4 torch SAW panel welding machine Welding speed: 1.1m/min Production quantity: 8.8m/min
|
12 torch MIG/MAG panel welding machine Welding speed: 0.6m/min Productivity: 7.2m/min
|
Overview of Specification
Tube Diameter |
22-89mm |
Tube Wall Thickness |
3-10mm |
Width of Fin-bar |
8-120mm |
Thickness of Fin-bar |
3-12mm |
Welding Width |
1600mm |
Welding Speed. |
0.5-3m/min |
Welding Wire Diameter |
1.6-2.0mm |
Wire Feed Speed |
1-10m/min |
Wire Tray |
4 units (each with 150Kg capacity) |
Compressed Air Requirement |
6kg/cm2 |
Welding Head |
4 |
Installed Power. (with 4 welding heads) |
approx. 280KW |