Orbital Welding

Model 81
Permalink Gallery

Model 81

Model 81

,

The Model 81 is a full function orbital pipe weld head featuring programmable AVC (Arc Voltage Control), Torch Oscillation (weaving), onboard Wire Feeder and Travel in a very compact package.The Model 81 has found widespread use in a variety of applications that require high quality welding results in applications with limited axial and radial clearances. Common uses for the Model 81 include shipbuilding and high-pressure steam piping in fossil fuel power plants and many other applications. The Model 81 can be equipped with a wide variety of options to allow its use in specialized applications that include remote arc viewing vision systems and fillet welding options.The Arc Machines’ Model 81 is a field-proven weld head which represents the culmination of over 35 years experience in the successful design and development of precision low-profile orbital welding heads. The Model 81 in its standard configuration will weld pipe from 1.9″ OD to 5.563″ OD with as little as 1.750″ radial clearance and 6.325″ axial clearance. Our unique clamping assembly increases production rates by minimizing the mounting and dismounting times of the weld head to as little as 30 seconds each.
Features:

Extremely compact, rugged weld head with 200 A water-cooled torch and body
Mount/dismount in as little as 30 seconds
Range from 1/2” to 5” schedule pipe
Rotation speeds from 0.1 to 10 IPM (2,5 mm – 250 mm/min.)
On-board wire feed mechanics, synchronized pulsed wire feed
Servo-controlled rotation
Servo-controlled AVC
Servo-controlled synchronized wire feed
Servo-controlled torch oscillation and dwell
Electronically controlled torch steering

Configuration Options:

200 A Torch with Video Camera for welding in hazardous environments
AVC Tilt: Allows the AVC motion of the torch to work in the same plane as the torch tilt, to weld flanges, sockets and similar joints
Adapter Kits for 1/2″ pipe through 1.90″ OD
Spool […]

95 W45o-1
Permalink Gallery

Model 95 Series

Model 95 Series

,

The Model 95 series of weld heads is a low-cost, easy set-up, rapid mount and dismount type of weld head that features precise but rugged mechanics. It is mainly intended for small diameter pipe and fitting welds that have limited axial and/or radial clearance or require a high productivity (quick set-up) type of welding head.

The arc length and torch cross-seam positions are manually controlled. The Model 95 weld heads use an off-board wire feeder and the same adjustable mounting system as the Model 79 weld heads. They can be used as fusion weld heads or with the wire feeder. Several torch options are available for a variety of welding applications. The Model 95 series weld heads are versatile and compatible with a variety of joint designs, such as “J” prep, socket and square butt. They will weld materials ranging from stainless steels or carbon steels to exotic alloys like Hastelloy™, Inconel™ and Monel™ as well as all other TIG weldable materials. Root passes may be done fusion-only, with filler wire, or with the use of insert rings. Autogenous welds (without filler metal) with 100% penetration may be done on wall thicknesses up to 0.154” (3,9 mm) depending on the alloy.
Features:

Series of orbital, GTAW (TIG) wire feed pipe weld heads for field or fab shop
Accommodates tube, pipe, flanges, sockets or fittings from 0.625” to 6.625” OD with wall thicknesses up to 0.44”
Welds standard weld preps, square butt preps and socket welds
Rapid mount and dismount capability
Centers the weld head to the pipe automatically
Low radial / axial clearance provides high visibility torch with easy access to wire manipulator controls

Compatible with the AMI Model 227, Model 307 and Model 415 Power Supplies or the AMI Model 207 Power […]

207 fixed pic for front
Permalink Gallery

Model 227

Model 227

,

The Model 227 is a 100/225 A pre-programmed / programmable, inverter-type, GTAW welding power supply and controller designed for (but not limited to) automatic orbital welding applications that require the addition of filler material.
Welds produced by this machine, together with Arc Machines’ weld heads, meet or exceed the specifications required by industries as diverse as: food, dairy, brewery, pharmaceutical, power generation, petrochemical, chemical, pulp and paper, nuclear, shipbuilding, etc. Its small size and rugged casing makes it useful in field applications where portability is required. High-integrity, code-quality welds are easily reproduced at the touch of a button.
Features:

Internal memory for up to 100 multi-level, multi-function weld schedules
8 multi-level functions for total process control
Programmable, continuous or pulsed current, rotation, wire feed, oscillation and AVC, 100 levels per pass
Dust/moisture-proof stoft-touch membrane switches
Standard software prompts in multiple languages
Built-in, high speed printer
Off-line programming option available (PC Compatible)
Key-switch to limit operator access
Standard remote operator’s pendant
Optional water cooling unit
Optional external memory module

Compatible AMI weld heads: Fusion weld heads without filler wire – Model 96, Model 6, Model 8 series, Model 9 series Pipe weld heads with filler wire – Model 81, and Model 15 Open-frame weld heads with or without filler wire – Model 79 series, and Model 95 series
Quick Specs:

Overrides
Programmable from 0% to 100%

Weld Current
3 to 100 A DC @ 100 / 120 VAC input, 100% Duty Cycle
3 to 225 A DC @ 200 / 240 VAC input, 100% Duty Cycle

Current Accuracy
± 1%

Travel/Rotation Speed
Range depends on weld head type, typically 0.5 to 10 RPM or 0.1 to 20 IPM

Cooling System
Water cooling unit available

Wire Feed Speed
Range depends on weld head size, typically 0 to 200 IPM

Input Power
100 to 240 VAC, ± 10%, Single phase 50/60 Hz.

Dimensions
Height: 15″ (381 mm)
Width: 23″ (584 […]

model-4-500508046db3b720.png
Permalink Gallery

Model 4-500

Model 4-500

,

The Model 4-500 is a fully integrated orbital tube weld head with an available component support and position tooling plate.

The Model 4-500 is designed for high-production bench welding of tubing, fittings, valves and other small component assemblies. It is ideally suited for sub-assembly of components for semiconductor, aerospace, biopharmaceutical and other industries requiring high-integrity, high-purity welded assemblies.
Features:

All stainless steel, ball-bearing gear-drive
Ceramic heat shields protect housing from heat and allow high duty cycle operation
Water-cooled base unit, tooling and rotor facilitates high duty-cycles and increases weld head longevity
A torque-limited clutch protects the drive-train from damage

Compatible with all Model 9-500/9-500C tooling, and all AMI Power Supplies.

Quick Specs:          

Weld Current
75 A max.

Rotation Speed
1.00 – 20.00 RPM

Electrode Size
0.040″ (1 mm)

Cable Length
20 ft. (6,1 m)

Tooling Plate
12″ x 12″ (305 mm x 305 mm)

model-79
Permalink Gallery

Model 79 Series

Model 79 Series

,

The Arc Machines’ Model 79 series weld heads are economical, easy-to-use, sturdy weld heads designed for precision orbital welding – with or without filler wire – of tube, pipe, and fittings.Each Model 79 weld head features Arc Voltage Control (AVC) for precise arc gap control, programmable oscillation (weaving) and a precision wire feeder and wire entry mechanics. All Model 79 weld heads operate using the GTAW (TIG) process and will accommodate a range of pipe sizes from 0.75″ OD to 6.625″ OD (19 mm to 170 mm) and wall thicknesses up to 0.75″ (19 mm).
Features:

Precision orbital welding heads – with or without filler wire – of tube, pipe, and fittings.
Versatile and compatible with a variety of joint designs, such as “V” prep, “J” prep, socket and square butt
Accommodates tube, pipe and fittings from 0.75” OD to 6.625” OD (19 mm – 170 mm) with wall thicknesses up to 0.750”. (19 mm)
Will weld materials ranging from carbon or stainless steels to exotic alloys including Hastelloy®, Inconel®, and Monel® as well as all other TIG weldable materials.

Compatible with the AMI Model 227 and Model 415 Power Supplies.

model-52
Permalink Gallery

Model 52

Model 52

,

The Model 52 is intended for all-position, automated welding of pipe, plate or fittings using the Cold or Hot Wire Feed GTAW (TIG) process. It is a rugged, precision tool with minimal radial clearance for welding of all pipe sizes from 8″ pipe up to an unlimited size, including flat plate.
The Model 52 is intended for field or heavy duty shop use in the nuclear, shipbuilding, chemical, petrochemical and construction industries where weld quality requirements are stringent and the use of the GTAW process is beneficial. The Model 52 is a “full function” welding head, meaning that it provides all functions necessary for true automated welding including Arc Rotation, Arc Voltage Control (AVC) for arc gap control, Wire Feed (weld filler) and Torch Oscillation (weave). The Model 52 also features range expandability of most of these functions as well as providing other standard features that are options on most other weld heads. The Model 52 weld head provides a durable, extremely versatile, heavy-duty platform for using a variety of torch options. These torch options range from a “standard” head using a single-entry torch and a single wire feeder to more complex torches for Narrow Groove Welding, Remote Welding with Vision and Hot Wire Welding. It can be ordered or retrofitted with numerous application-specific accessories customizing the head for a user’s needs.
Features:

On-board wire feed mechanics, single or dual wire feed system, up to 30 lbs. spools
Digital encoder feedback on all functions
Water-cooled main housing
Zero-backlash dual-motor gear drive for consistent travel speeds in all positions
Extremely quick mount/dismount
Cross-seam steering
Synchronized torch oscillation, AVC, rotation and wire feed (AVC/OSC 4″ standard)

Compatible with the AMI Model 415 Power Supply. Compatible with many AMI torch assemblies, including video-equipped torches.
Model 52 “P” Torch
The […]

model-15
Permalink Gallery

Model 15

Model 15

,

The Model 15 is a rugged, precision weld head with low radial clearance for GTAW welding of all pipe sizes from 3″ (76 mm) pipe up to an unlimited size, including flat plate.It is primarily designed for field use in the nuclear, shipbuilding, petrochemical, and construction industries where exceptional weld quality is strictly required. The Model 15 features rotation, wire feed, automatic voltage control, cross-seam steering and torch oscillation. It is available in many standard configurations, and can be retro-fitted or customized with numerous application-specific accessories to accommodate every need. The Model 15 is just one element of an automated pipe welding system. A torch assembly, precision guide rings, AMI Power Supply, and other options comprise a complete system suitable for high-quality orbital pipe welding.
Features:

Rugged, compact weld head with water-cooled torches
Zero-backlash dual-motor gear drive for consistent travel speeds in all positions
Range from 3″ pipe (76 mm) through all standard pipe sizes, such as 6″, 8″, 10″, 12″ up to any diameter. Flat track for flat plate welds and large-radius curved track are available
Extremely quick mount/dismount
A spring-loaded break-away mount that prevents accidental breakage of torch parts
Cross-seam steering
Synchronized torch oscillation, AVC, rotation and wire feed
On-board wire feed mechanics, single or dual wire feed system
Most torches accommodate a wide variety of gas cups and gas lenses
Several different “standard” torch types are available with different dimensions, functions and features, such as: – Electrode-to-wire-nozzle height adjustment – Lead/lag adjustment – Cross-seam torch tilt (in/out)

Compatible with the AMI Model 227 and Model 415 Power Supplies.

Quick Specs:

AVC Stroke
1.75″ (44 mm)

Torch Oscillation Stroke
1″ (25,4 mm) max.

Wire Feed Speed
5 – 200 IPM

Travel Speeds
0.1 – 20 RPM

Tungsten Size
3/32″, 1/8″ or 5/32″ (2,3 mm, 3,3 mm, or 4 mm Ø)

Filler Wire
0.020″ – 0.045″ (0,5 mm […]

model-501-0
Permalink Gallery

Model 501

Model 501

,

The Model 501 Hot Wire Power Supply is designed to increase the deposition rate of the filler wire in the weld joint by resistively preheating it.
HIGH DEPOSITION RATE=HIGH PRODUCTIVITY
The Model 501 is suitable for welding high-quality stainless steel tanks and vessels that are rotated during welding. The addition of hot wire can optimize the corrosion resistance and/or mechanical properties of the weldment and have a beneficial effect on the material performance in service. The hot wire GTAW process produces a very clean weld with a very low incidence of porosity and increases filler deposition rates similar to GMAW.
Features:

Constant Voltage (CV) True RMS mode-of-operation
Calibrated, Precision, Closed Loop Servo Output Control
Voltage Feedback Sensing at the wire feed tip or internal to the Power Supply
True RMS instrumentation Outputs (Amps and Volts)
Optional Manual Remote Programming Pendant
Control input for connection to an external controller

The Model 501 implements advanced technology with significant competitive advantages. To minimize magnetic interference , the unit uses AC current to preheat the wire. This current is far more precise than competitive machines, being very close to a true sine wave.
The Model 501 Hot-Wire Power Supply can be used:

as a stand-alone unit with its own Operator Pendant
with the AMI Model 415 Power Supply/Controller
or by and external weld process controller programmer

Quick Specs:

Input Power:
200 – 240 VAC, 25 A, 1Ø

Output Power:
CV Mode 0-10 V True RMS AC, +/- 3% max.

Open Circuit Voltage:
16 VAC

Loop Response:
1.2 sec

Dimensions:
Heigth: 23″ (585 mm) Width: 19″ (485 mm) Length: 9.5″ (240 mm)

Weight:
135 lbs. (61,5 kg)

model-415
Permalink Gallery

Model 415

Model 415

,

The Model 415 is an all-in-one computer controlled GTAW Power Supply. It is primarily designed to work with AMI’s orbital and fixed automation weld heads.

The Model 415 Power Supply can control third party positioners and welding manipulators. The Model 415 incorporates a powerful automation controller designed to meet the challenges of the most demanding welding applications. At the heart of the power supply is an industrial computer programmed via a large 12” touch screen or keyboard. The intuitive graphical user interface (GUI) makes programming easy using standard welding industry terminology and clearly organized input fields.
Features:

Computer-controlled, Windows™ operating system
4 standard and 4 optional closed-loop motor servos
8 motor controls for positioning (jog)
High-precision gas and water flow sensor
Built-in water cooling and system diagnostics
Weld project data recording
High-capacity memory for program storage
Operator’s pendant with heads-up display
Automatic configuration for AMI held heads
2 USB ports
Remote control PC interface via Ethernet LAN

Optional Features:

Remote welding video systems
Up to 8 open-loop motor servos
Measurement outputs
Offline programming

Compatible with most AMI pipe weld heads.

Quick Specs:

Input Power
200 – 575 VAC service, 3-phase 50/60 Hz

Weld Current
5-400 A, 100% Duty Cycle

I/O Devices
2 USB ports. RS232 serial interface, Data Acquisition Output, Ethernet over fiber optic

Memory Capacity
Over 1000 weld programs

Water Cooling
Included

Dimensions
Height: 39″ (990 mm) Width: 26″ (660 mm) Length: 36″ (915 mm)

Weight
710 lbs. (325 kg)