Flash Butt Welder

The flash butt welder is a specialized machine for welding wheel rims. Its welding parameters are set via a touch screen, offering high automation, reliable operation, and convenient adjustment. It effectively ensures strong welds and superior joint strength, even when working with high-strength steel plates. Intelligent features include servo‑valve‑controlled flash‑heating, which stabilizes the welding process and delivers rapid response. For rims of varying thicknesses, users can select the appropriate welding setting. Future development aims to achieve unmanned production, incorporating automated loading and unloading systems to enable seamless integration with supporting equipment.

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Product Information

Overview

This flash butt welder is a specialized machine for welding wheel rims. Both workpiece clamping and welding are hydraulically driven, and welding parameters can be set via a touch screen. It features a high degree of automation, reliable operation, and convenient adjustment. The equipment consists of three main components: the main unit, the electrical system, and the hydraulic system.

Technical Features

The flash butt welder is a specialized machine for welding wheel rims. Welding parameters are set via a touch screen, and it features a high degree of automation, reliable operation, and convenient adjustment. It effectively ensures strong welds on high-strength steel plates and excellent weld‑joint strength.

Intelligent Control: The flashing and melting process is regulated by a servo valve, ensuring stable welding with rapid response. For rims of varying thicknesses, the appropriate welding setting can be selected.

Development direction: Achieve unmanned production, implement automated component loading and unloading systems, and establish corresponding supporting infrastructure.

Electrical system

The electrical system comprises the main welding circuit and the control circuit.

(1) The main welding circuit consists of the main switch QS, the thyristor switch KP, and the transformer TC3, among other components. The main switch QS is used to connect or disconnect the power supply to the welding circuit; it should be opened when adjusting the transformer’s tap settings or when the welder is not in use for an extended period. During operation, the thyristor switch serves to turn the welding power supply on or off. Transformer TC3 provides welding voltages at eight distinct levels.

(2) The control circuit comprises the PLC’s input/output circuits, operator interface components, and a touch screen. The PLC serves as the core of the control system; the welding machine operates according to the PLC program. A rotary encoder, connected to the moving plate via a gear–rack mechanism, measures the displacement of the moving plate with an accuracy of 35 pulses per millimeter. Based on these pulse signals, the PLC controls the speed changes and direction reversals of the moving plate, while the touch screen enables monitoring of the welding machine’s operation and allows parameter adjustments as required.

Hydraulic system

The hydraulic system consists of a hydraulic power unit, piping, and cylinders and valves mounted on the main machine. The hydraulic power unit supplies system pressure. The valve manifold on the main machine controls the operation of each cylinder; the upsetting pressure, clamping pressure, and preheating pressure can all be adjusted independently, with pressure gauges indicating the set values. A lever‑type regulating valve is installed on the upsetting cylinder to control the forward speed of the moving platen.

Technical Data

Device model	UNB3-600-A
Rated input voltage of the main circuit: single-phase	AC 400~430V, 50Hz, single phase
Control circuit rated input voltage: three-phase	AC 380V, 50Hz, 3-phase
Main circuit output voltage	8.8V～14.6V
Solenoid valve voltage (DC)	DC 24V
Total Input Power (kVA)	630KVA
Maximum upset forging force	200KN
Maximum clamping force	550KN
Maximum weld cross-sectional area	2800mm2
Maximum board width	320mm
Maximum plate thickness	4.5mm (up to 5.0mm)
Minimum welded steel ring diameter	250mm
Chiller water fill volume	1300L
Cooling water temperature	≤ 25℃