Our manipulators play a significant role in the automated welding processes of large vessels and other workpieces. Automatic welding heads (typically submerged arc) are designed to be mounted on a stiff and nearly vibrationless boom and moved to the desired height with powered columns.
LJ’s portable welding manipulator MNC4-100 allows maximum flexibility to welding head manipulation which results in a higher quality of welds. Another benefit is the low skill cap for operators due to automated processes. Generally, our welding manipulators are indispensable for applications that involve pipes and vessels. They are ideal for hard automation welding solutions and they offer modular construction that ensures 360-degrees radial accessibility to welding heads, covering vast areas in the shop.
MNC4-100 easily integrates with PEMA roller beds and positioners. Operators also use them for welding of longitudinal and circumferential seams. Our MNC4-100 has a loading capacity of 500 lbs and boom/column stroke of 72". We also offer a wide selection of accessories and options available depending on the customer's request and need. As far as the welding source options are concerned, we offer submerged arc (SAW), MIG, or a solution to customer’s specification. We also offer control upgrades including full integration to LJ welding positioners or turning rolls through HMI touchscreens and master PLC.
Looking for a welding positioner with different technical parameters? Make sure to check out our MNP-600, MN6-100, MN9-300, MN12-200, or MN16-100.
|Load Capacity (at boom end)||500 lbs|
|Boom Traverse Speed Range||5–120 in/min|
|Mast Traverse Speed Range||5–120 in/min|
|Travel Car Speed||5–120 in/min|
|Power Requirements||480 V, 3-ph|
Welding Power Source Options: Submerged Arc (SAW), MIG, or to customer specification
Customizable with full integration capabilities for most existing mainstream welding equipment
The Xiris XVC-O Weld Camera monitors and is capable of recording all open arc, welding processes including MIG, MAG, TIG, Plasma, Laser and Stick welding. Processes can be viewed remotely (40 m / 130 ft. away), providing live images of the torch, weld area and material during standard and high-power welding conditions.
The XVC-S Weld Camera provides a real-time view of the torch when welding with submerged arc (SAW). It is particularly useful when placed on column and boom welding manipulators as it allows the operator to observe the weld area from ground level.
Housed in a rugged enclosure, the XVC-S features single or dual crosshairs and can act as a set-up tool to position the submerged arc torch. The visual feedback it provides to the operator can also be used as a means to adjust the position of the boom and column welding manipulator or parameters during the welding operations.
As the name suggests, tactile sensors physically contact the weld seam using a contact probe.
As the torch position changes relative to the workpiece, the probe deflects in the opposite direction and the controller makes adjustments to return the torch to its original position.
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:
Watch a column and boom manipulator use laser seam tracking on aluminum and steel below:
Powered Cross Slides & Joystick Controller Powered cross-slides have a nominal travel of 6" x 6" and can be used as stand-alone devices with their own controller, or they can be integrated directly into larger systems. A 2-Axis adjustable mount can be used to set and maintain position of welding torch for both submerged arc and MIG torches.
Powered cross-slides can support up to 200lbs at a distance of 6" from the mounting face, or 150lbs at a distance of 12" from the mounting face - sufficient for most submerged arc welding heads.
Click the dropdown to learn about LJ's flux delivery, recovery and storage systems:
Flux delivery 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.
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.
Flux delivery systems come in 100lb and 300lb capacities. Heated delivery systems are available as well. Larger capacities help to reduce non-essential, non-arc time activity.
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.
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 welding booms are built using large sections so that they are stiff to allow for precision and delivering consistent high quality welds, any day of the week. Welding booms can range from 4 feet to 16 feet and are customizable to your specifications. Variable speed boom (in/out) is a standard offering.
LJ offers an integrated powered cart option for customers' with limited shop floor space and demanding production schedules.
The key advantage to the integrated powered cart 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.
The integrated powered cart option is most commonly used with LJ's MNP-600 portable column and boom welding manipulator.
LJ’s manipulator columns are equipped with variable speed function (up/down) to adjust the height of the weld head with the flick of a joystick to suit your desired workpiece height requirements. Columns range from 5 feet to 16 feet in height clearance and are customizable upon request.
The control platform comes with a joystick or fully integrated touchscreen option. The optional user-friendly HMI touch screens are available to control all your welding manipulator functions. Wireless hand pendants are available so your operator can weld from wherever it’s most convenient.
Boom mounted controls are also available for clients who wish to operate the manipulator at the weld head. If more advanced controls are desired, contact LJ Welding for further assistance with your application.
HMI (Human machine interface) is the computer interface that communicates and commands all major functions of your welding manipulator or beam welding gantry system.
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:
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.
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.
The wireless hand pendant uses a 19pin connector found on nearly all of LJ's equipment.
Every single robot, welding manipulator and gantry LJ produces is a combination of the right power source coupled with the right automation process (seam tracking, camera, oscillator, process control, etc.).
Some power sources are known for their high deposition rates, others with a reputation for low splatter and welding disimilar metals seamlessly. We'll help you to squeeze the most productivity out of your system.
Based on your project application, LJ's sales and engineering team will recommend a power source that fits your goals. Click the drop down below to learn more about Open Arc and Submerged Arc power sources we use for our column and boom welding manipulators.
Column and Boom (CaB) welding manipulators are most commonly used for Submerged Arc Welding (subarc or SAW) applications; however, they can be used for GMAW or other open-arc applications as well. LJ can also integrate virtually any open or subarc system to column and boom manipulators.
Subarc welding’s most significant advantage is maximizing welding deposition rates, to rates that are 3-5x higher than other comparable processes. Deposition rates of 20-30lbs/hour (or more) can be achieved depending on the weld joint, consumables, and procedure. DC SAW power sources are only capable of supplying direct current to the electrode. Lincoln Electric's Idealarc DC-1000 and DC-1500 and Miller's Subarc 650, 800, 1000, and 1250 are all DC power sources that can all be readily integrated with LJ's welding manipulators.
AC/DC SAW power sources can weld at higher efficiencies, with lower power consumption, and can supply an alternating or square wave current to the electrode. Lincoln's Powerwave AC/DC 1000 and Miller's Subarc AC/DC Digital and AC/DC 1250 Digital are AC/DC power sources that can be readily integrated with LJ's column and boom welding manipulators. AC/DC power sources offer the benefits of variable wave form and the best characteristics of DC+ and DC- polarity.
Power sources for open arc applications must be both powerful and welder-friendly. Miller’s XMT® 350 CC/CV, Dinse and XMT® 450 CC/CV 230/460 V start arcs and stick electrodes without contaminations and inclusions. The Dimension™ 650 is especially versatile, with a gouging mode that provides up to 800 amps of full power. Three wire modes make it ideal for GMAW, FCAW, or SAW applications.
User-friendly controls with common welding terminologies help mitigate errors. Miller’s Pipeworx 400 Welding System 230/460 V even allows welders to change between welding processes at the touch of a button. Wind technology provides cooling and protects components from dust and contaminants for maximum reliability. The fans run only on demand to save energy. All power sources can be used with spool guns and feeders, and are easy to integrate into LJ’s column and boom manipulators.
Click the dropdowns to learn more about each base option.
All LJ column and boom welding 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 rail track manipulator option is ideal for shops that require their manipulator weld head's movements on three axis (up & down, forward & reverse and along the workpiece).
The rail track option fully integrates with other track mounted equipment including tank turning rolls, pipe alignment rolls, vessel rotators and pipe rolls.
Rail installation and cable management can be quoted on request.