DH-FW45 Rebar Friction Welding Machine
- Description
- Friction welding is a "solid" welding method. By mechanical friction and axial pressure, the surface heat is generated so that the material is in a semi-melted state, and then the workpiece is subjected to pressure to firmly weld the same or different metals into one body.
- In order to build a low-carbon society, it is necessary to save energy as much as possible during the welding process. By reducing the heat input, the material at the joint does not generate splashes or smoke, and no additional materials or fillers are needed, bringing new possibilities to your manufacturing field. revolution.
- The “Friction Welding” method has been a staple of construction in Taiwan for many years. The steps of Friction welding are as followed: Warmup, normal pressure then forging pressure. The traditional method of using 2 hydraulic cylinders as the pushing driver would cause inconsistent oil temperature, which in turn causes the success rate to drop drastically.
- Our patented “Friction Welding Machine with Servo Mechanism” uses a servo motor to drive a screw and turns traditional hydraulic pressure values into digital data. Making it possible to produce well coupled Rebar with consistent quality and therefore greatly reinforcing the structural integrity of any building while exceeding government safety regulations. Also, our technology also eliminates any human errors that may be caused by inexperienced workers. And once the verified data have been entered, our machine will handle the rest of the process.
- Using the latest servo drive, the welding efficiency of our rebar friction welding machine can be faster and more accurate.
Our full touch panel can be much more flexible, changeable and high degree of freedom which is able to equipped with cutting device and driving pushing structure by automatic cutting waste servo motor. The use of friction welding in production process ensures such benefits as high process efficiency, high productivity, very good properties of joints and safe working conditions. - The coupler cost of using friction welding is lower than that offorging, and it can be formed quickly.Its strength
is no less than that of forged products, and the surface is cleaner.
- SpecificationAutomatic Friction Welding Machine
ITEMMODEL
DH-FW-45
Spindle Speed (RPM)
1800 RPM Max. Material size on spindle side (mm.)
Ø40*200L Main Spindle Motor
40HP Servo motor-Max. Thrust (TON)
23TON Welding capacity diameter range
Ø16- Ø40 Cooling model
Oil cooling Clutch
Wet multiple magnetic clutch Brake device
Wet multiple magnetic brake Braking time 0.2sec Control system Touch panel Welding material
Aluminum,Iron,Steel,Copper,Stainless steel,Steel bar - Video
- Principle
- Unique welding function
The welding surface is welded to the two end faces of the metal, and the joint has strong toughness.
Its tensile and torsional strength far exceeds the strength of arc welding and argon welding. - Adding dissimilar materials can reduce material costs
Metal combinations that are not compatible with conventional welding can be joined by friction welding.
It can save a lot of cost and is an application method of lightweight components. - Improve welding accuracy
After welding, the materials at both ends are not easily deformed, and the center eccentricity is within 0.5m/m.
Ensuring the quality of the workpiece reduces machining allowances and reduces material and processing costs. - Eco-friendly and energy efficient
Do not use materials or fillers such as metal, flux, gas, etc.
Uniform heat, no arc or toxic, can effectively improve the working environment. - Faster and more accurate welding efficiency
The production cost of using friction welding is lower than that of forging, and it can be formed quickly.
Its strength is no less than that of forged products, and the surface is cleaner. - Can eliminate manual welding errors
The machine-controlled friction welding process is consistent and repeatable, eliminating human error.
At the same time, it produces independent and higher than the operator's technical level of welding quality.
- Unique welding function
- Features
The welding surface is melted together at both ends of the metal, and the connecting point is strong and tough, and the strength of tensile and torsional resistance far exceeds the strength of arc welding and argon welding.
- Dissimilar materials can be welded together, For example, the stainless steel material can be welded with ordinary iron materials with various medium and high carbon steel materials, However,Require annealing after completed welding high carbon steel.
- After welding, the materials at both ends are not easily deformed, Center eccentricity difference within 0.5m/m,To ensure the quality of the work piece can reduce the processing reservation,Can reduce materials and processing costs
- The cost of production using friction welding is lower than that of forging, also It can be formed quickly. However, the strength is not less than of forged products, and the surface is cleaner.
- It does not require the use of expendable materials such as fuels or metal-filled solvents, gases, etc., and generates uniform heat with friction between the contact surfaces, so there is no arc or toxic material to improve the working environment.
- Optional1.Optical scale positioning module
-Easy and fast operation, precise length adjustment
-Detectable work piece lengthOptical scale positioning module2.Rotary angle positioning
-both ends of the work piece after welding can be stopped at certain angles3. Inverter
-Adjustable spindle speed
-Save spindle start energy consumption
-Extended service lifeInverter4.Chip system
-Increased chip system
-Servo Motor Chips (Simple PLC Control or CNC Program Control)
Chip system5.Electric control box cooling system
- Standard original fan
- Upgradeable the heat exchanger or air conditioner.
Electric control box cooling system6.Safety Light buzzer
- Protecting the operators safety.7.Mechanical full cover safety guard8.Bar Conveyor9. Coulpers clamping robot - Advantages of servo control
Stable operation without being subjected to oil temperature. High-precision weld is possible. Angle control expands the range of the application of friction welding such as to phase adjusting workpiece. Servo control reduces more carbon dioxide emissions than hydraulic control dose. Better energy-saver. No oil leakage >>> Improved working environment. No waste oil >>> Environment-friendly. Feedback control of forge force enables smooth drive at low speed range. Uniform output under any conditions (temperature, humidity and so on) Downsized hydraulic unit >>> Space-saving and low noise.
Advantages of this friction welding machine
- Using the latest servo drive, the shift is more accurate
- Free and fast moving shift speed
- Does not affect the oil temperature
- Full touch panel can be flexible and flexible, with high degree of freedom
- Can be attached with cutting device, automatic cutting waste
- Using well-known brand parts from all countries, accurate accuracy
- 5 times faster than traditional car shaping
- Fully automated production, increased production and reduced manpower
- DH-FW Specification form
Machine specifications
DH-FW30
DH-FW45
DH-FW60
welding ability
Round rod diameter
Ø9 ~ Ø25 Ø15 ~ Ø36 Ø20 ~ Ø60 Pipe Fittings
Ø16 Ø48.3 Ø88.9 The Max. length of the rotating side
300 mm 300 mm 300 mm The length of the fixed side
9m 9m 9m Maximum thrust
Frictional heating time
8,000 Kg 10,000 Kg 12,000 Kg Forging pressurization
16,000 Kg 20,000 Kg 26,000 Kg Spindle
Number of spindle rotation (50Hz)
3000 rpm 2250 rpm 1780 rpm Number of spindle rotation (60Hz)
2500 rpm 1780 rpm 1570 rpm Clutch Direction
Oil Actuated Multi-Disc Clutch and Brake Clutch Torque
800 (N.m) 800 (N.m) 1600 (N.m) brakes System Direction
Oil Actuated Multi-Disc Clutch and Brake brakes System Dynamic Torque
800 (N.m) 800 (N.m) 1600 (N.m) Brakinf Time
0.3 sec 0.3 sec 0.3 sec Spindle Fixture
Three-jaw 6”/(Hydraulic Pressure) Three-jaw 8”/(Hydraulic Pressure) Three-jaw 10”/(Hydraulic Pressure) Slide Speed
Rapid Traverse rate
20 m/min 20 m/min 20 m/min Machine Processing speed
1~1000 mm/min 1~1000 mm/min 1~1000 mm/min The Max. moving
150 mm 200 mm 250 mm work piece clamping manner
Vise splint method
Horizontal double-open synchronous fixture Clamping force
8,600 Kg 17,000 Kg 25,000 Kg Processing Methods
Size adjustment
0 ~ 100 mm 0 ~ 100 mm 0 ~ 100 mm Time adjustment
0 ~ 999 秒 0 ~ 999 秒 0 ~ 999 秒 Motor Power
Spindle
22 kw 30 kw 37 kw Hydraulic Pressure
5 kw 9 kw 9 kw Servo motors
7 kw 9 kw 11 kw Hydraulic Oil Temperature cooling system
1.5T / 1.1 Kw 2T / 2 Kw 2T / 2 Kw Dimension
Machine Dimensions
2750 x 2800 x 2000 2750 x 3100 x 2000 2750 x 3400 x 2000 Machine Weight
6,000 Kg 6,800 Kg 7,300 Kg