The XVC-1000e Xiris Weld Camera System is LJ’s camera & monitor package of choice for viewing open arc welding processes including MIG (GMAW), TIG (GTAW), Plasma (PAW) and Stick (SMAW).  The monitor can be set up as far as 100 meters away from the welding location, providing live video of the weld joint, torch, filler metal, arc, puddle and base material, or other areas of interest.  Two cameras can be mounted for simultaneous viewing of different areas, and videos can be recorded for troubleshooting, quality control, or welding process optimization.  

The LJ SubArc Camera System is available for integration on any C&B manipulator that utilizes LJ’s PLC/HMI controls package.  It provides a real-time view of the weld joint, torch, flux and base material when welding with submerged arc (SAW).  It is particularly useful when placed on large column and boom welding manipulators, as it allows the operator to observe the weld area and accurately position the submerged arc torch from ground level. 

What Is Tactile Seam Tracking?

As the name suggests, tactile sensors physically follow the weld joint using a contact probe. It works much the same way a needle traces a record's groove.

How Does Tactile Seam Tracking Work?

The probe and welding torch are aligned and set to an optimal position for the joint type.  During welding, as the probe position changes relative to the workpiece, it deflects and the controller makes adjustments to return the probe to its original position, which in turn keeps the torch in the desired location. 

Benefits of Tactile Seam Tracking

Tactile seam tracking systems are best suited for weld seams with large, distinct geometry. If the weld seam is too small, the probe can lose contact with the seam and run the welding torch off track.

Tactile Seam Tracking Is Best Suited for the following:

• Welds that are the same basic shape and similar seam configuration with variations in size, length and width.
• Pressure vessels, cylinders, tanks and other circumferential welding projects.
• Beam welding fabrication where operators would otherwise have to manually reposition the torch for the full length.
• Single or multi-pass lap joints, fillet weld or v-groove seam configurations.
• Cylinder sag on large thin wall tanks.

What Is Laser Vision Seam Tracking?

Watch this CaB welding manipulator use laser seam tracking on aluminum and steel below:

Powered Cross Slides & Joystick Controller

Powered Cross Slides allow precision movement of the welding torch.  They are typically specified on a system-specific basis, as they can be used as stand-alone devices with their own controller, or integrated into larger systems.  They can be used alone or in pairs depending on the level of precision control required.  Different lengths and load capacities are available depending on the chosen accessories, welding process and equipment configuration.  

Weld Weaver Oscillator System

What Is A Flux Delivery (Feed) System?

Flux delivery, or feed systems, provide a means of moving flux from the column and boom manipulator platform to the weld head. A small pressure vessel is used to maintain positive pressure on the flux and aerate the flux so that it flows easily upwards to the welding torch.

How Does A Flux Delivery (Feed) System Work?

Typically, flux is delivered to a flux hopper located at the weld head; however for systems where space is limited, flux can be delivered directly to the welding torch, eliminating the need for a flux hopper at the weld head.

What Flux Delivery Capacities Are Available?

Pressure feed flux delivery systems are typically sized between 100 - 300 lbs, but can be provided at up to 2,000 lbs to reduce system downtime. They can be equipped with heating, which is useful in humid environments and/or for critical applications.  

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What Is A Flux Recovery System?

Flux recovery systems are used to capture unused flux so that it can be reused. Typically, 2 lbs of flux are required for every 1 lb of deposited weld; however, recovering flux can reduce this ratio to 1.25 lbs of flux per 1 lb of weld metal. Electric and pneumatic versions are available.

How Does A Flux Recovery System Work?

Electric flux recovery systems use an electric motor to create a vacuum strong enough to suck flux back into the flux hopper. Pneumatic recovery systems require shop air pressure and using a venturi-like device, compressed air is used to create a vacuum strong enough to suck flux back into the flux hopper. Heated flux hoppers are also available.

LJ offers an integrated powered boom carriage for customers with limited shop floor space and demanding production schedules.

The key advantage to the boom mounted weld head carriage is that it allows the weld head to move laterally along the boom, rather than manipulating the boom with a weld head at the end.  In other words, the boom remains stationary and the weld head moves along the boom, which allows for the manipulator to be placed up against walls or in tight spaces where a retracting boom doesn’t fit.

The integrated powered cart option is most commonly used with LJ's MNP-600 portable column and boom welding manipulator.

What Are HMI Touch Screen Controls?

HMI (Human machine interface) is the computer interface that communicates and commands all major functions of your welding manipulator or beam welding gantry system.

What Can the HMI Touch Screen Control?

• Rotation speed of tank turning rollers and weld positoners.
• Weld speed.
• Height adjustment (positioners if powered height adjust.)
• Welding controls.
• Camera.
• Seam tracking.
• Data Collection

How Do I know If I Should Choose HMI Controls For My Welding Application?

It will depend on the complexity of your welding application, scope and budget. If your application has many moving parts, such as seam tracking, welding turning rolls, a column and boom manipulator and camera, an HMI would streamline all variable factors into a simplified screen.

If you aren't integrating your CaB manipulator with any other material handling equipment, standard equipment controls are sufficient.

HMI Controls Further Reading

The HMI control is a PC based computer that is easy to set or change, store useful data for quality assurance purposes, and can fully integrate with all LJ Welding products. The HMI touchscreen panel controls all complex welding automation functions from one single location.

Boom mounted controls ensure the weld operator has direct sight of the weld in order to make the correct adjustments during welding if needed.

The welding boom mount controls allow the operator to:

• Controls flux delivery/recovery when integrated.
• Preprogram multiple weld settings (for repetitive welds).
• Control material handling systems if integrated with other LJ equipment.
• Manage seam tracking settings for laser or tactile.
• Control wire feed from boom.
• Control cross slides / weld head from boom.

For Productivity

For Productivity

LJ's wireless hand pendant gives the operator more mobility that the conventional cable wire version, reduced the likelihood of the operator getting tangled up in wired systems.

For Safety

and has a "deadman switch" or "e-stop" to respond quickly in an emergency situation. Additionally, the pendant with communicate to the system it's connected to switch off if it loses communication with the transmitter.

For Compatibility

The wireless hand pendant uses a 19pin connector found on nearly all of LJ's equipment.

LJ's standard hand pendant comes with standard weld start, weld stop and wire feed, along with rotation for integrated material handling set-ups.

Column and Boom (C&B) welding manipulators most commonly use Submerged Arc Welding (“SubArc” or SAW) equipment because SAW is widely known to be the most economical and highest quality welding process for many applications.  It is known for high deposition rates, high travel speeds, no spatter, low fume, no exposed arc, and consistent weld quality through a wide range of weld parameters.

Conventional SAW is generally done using DC current and electrode positive polarity.  DC SAW power sources are available in a range of outputs.  LJ recommends the following power source and controller configurations, with other configurations available upon request: Miller SubArc DC Digital 650, 800, 1000 or 1250 with SubArc Motor Control Digital and PLC control from the HMI using ModBus; Lincoln FlexTec® 650X with MAXsa 10 Controller.  Other available DC SAW power sources are the Lincoln Idealarc® 1000 and 1500, which are paired with the NA-5 Controller.              

The following square wave SAW power sources are all capable of DC welding, as well as variable-balance AC.  The main benefits of square wave AC SAW over DC SAW are shallower and broadened penetration profile (lower burnthrough risk and larger process window, especially on thinner materials), increased deposition rate for a given heat input (which can allow increased welding travel speeds and/or reduced arc time), lowered base material dilution, and reduced tendency for arc blow/wander.  The use of square wave SAW power sources also allows the potential for tandem and triple arc configurations for dramatic productivity enhancement.  LJ recommends the following power source and controller configurations, with other configurations available upon request: Lincoln Power Wave® AC/DC 1000® SD with Lincoln MAXsa® 19 Controller with LJ PLC control of parameters, Lincoln Power Wave® AC/DC 1000® SD with Lincoln MAXsa® 10 Controller; Miller SubArc AC/DC Digital 1000 or 1250 with Miller SubArc Motor Control Digital with LJ PLC control of parameters, Miller SubArc AC/DC Digital 1000 or 1250 with Miller SubArc Motor Control Digital and Miller SubArc Remote Pendant Digital.      

MIG is another popular process to mount to a manipulator, especially when using high capacity power sources with large diameter wires at elevated duty cycles.  Although the arc is bright and fume generation is significantly higher than SAW, MIG power sources are generally lower cost, and shielding gas delivery is more straightforward and lightweight than SAW flux delivery and recovery.  For high duty cycle applications, water-coolers and torches can be integrated to ensure long contact tip life.      

LJ recommends the following advanced-process power source and controller configurations, with other configurations available upon request: Lincoln Power Wave S350, S500 or S700 with Lincoln Power Feed 84 User Interface; Lincoln Power Wave R450 or i400 with LJ PLC control of parameters; Miller Continuum™ 350 or 500 with Miller Single or Dual Remote Operator Interface; Miller Auto-Continuum™ with LJ PLC control of parameters; Fronius TPS 320i, 400i, 500i or 600i with robot interface and LJ PLC control of parameters.  Note, other power sources and configurations can also be integrated on a case-by-case basis. 

For some materials and applications TIG is most suitable.  Equipping a C&B manipulator with TIG can provide significantly higher productivity than manual TIG for suitable applications.  Most often when integrated on a manipulator a cold or hot wire feeder is used, with reciprocating (forward-reverse) wire feed options providing significant productivity and quality benefits for some applications and materials.  Additionally, there is a range of keyhole TIG equipment can be selected from for high penetration applications.  Given the application-specific nature of TIG welding, power sources and options/accessories are recommended on a case-by-case basis.         

All LJ C&B manipulators come standard with a 350° rotating swivel base and a swivel lock and can be either free standing or integrated with a rail car system. This allows for more agile job set-ups than a fixed base column and boom.

The powered rail travel car is an ideal option for shops that require 3-axis motion on their manipulator (up/down vertically, in/out horizontally, and along rail parallel to workpiece).

The powered travel car option is included on most LJ C&B manipulators as a safe and efficient method for indexing the weld head to the location it is needed, and in some special cases, for long seam welding.  Free-standing (stationary) welding manipulators are more common with rentals or shorter-term projects where setting up a rail system is either not practical or economical.

Rail installation and cable management can be quoted on request.

The wall mounted option is best suited when floor space is unavailable and the manipulator does not require a full 360º range of movement. The Boom Mounted Carriage option compliments the wall mounted base set-up because movement of the weld head can still be achieved on 2 axis.