Orbital welding machines are now considered as the primary tools preferred for all types of applications concerning welded manufacturers from the industries such as aerospace, automobile and many others. These machines are a top priority in the production process since the weld quality and the precision arrive impeccable. However , like any other equipment, Orbital welding machines require periodical maintenance and handling of faults in order to Long lasting, High performing and very reliable faculties. Here within the context of this Blog, what shall be our focus is the Best Practices in Welding System Maintenance as well as Some of the Usual Suspects of Welding System Troubleshooting.
Tips That Will Help One to Maintain Welding Systems
1. You should perform a regular inspection and cleaning of your kitchen equipment to enhance cleanliness in the facility.
It is essential to perform initial examination of your orbital welding machine and check for any parts that have been worn out. Look out for areas where things might have come loose, cables that may have frayed or other parts of the circuit that could impact on its function. Remember the machine should also be cleaned from time to time to get rid of dust, dirt or grease that may settle on the machine.
2. Oil Frequently or Lubricate Mechanical Pieces
Lastly, ensure that all the moving parts of the orbital welding machine are greased so that every spinning part will spin smoothly. There are lubricants that are recommend by the manufacturer and for how often they should be applied check the manufacturer’s manual.
3. The Wire Feed rate and Pressure Settings should be adjusted in order to achieve the best results.
Proper wire feed and pressure settings are important to get appropriate beaded and quality welds. There will always be changes in the appropriate settings to be set depending on the type of material to be cut or the application of the specific project.
4. Replace Consumables as Needed
Consumable accessories of orbital welding machines include the contact tips, nozzles and shielding gas filters . Check on their condition and replace them when they are spoilt or worn out to avoid polluting the welding process results into substandard welds.
5. Monitor Electrode Wear
The wear rate of electrode is one of the critical parameters which determine the status of the welding machine. Measured the wear rate and consequently electrode feed rate so as to ensure that the electrode is in proper contact with the workpiece all the time.
How to Resolve Orbital Welding Machine Issues
1. Poor Weld Quality
The first thing to do if your weld quality is a cause for concern is to review welding settings that include; wire feed rate, voltage and current. These factors must be changed according to the material and application to make the weld of the desired quality. Examine the welding torch and the consumables and check whether it has the optimum condition to be used or not and if not then replace it.
2. Inconsistent Weld Penetration
Inconsistency in the weld penetration may be attributed to the use of incorrect electrode angles; the fluctuations or difficulties in feeding the wire; or differences in the flow of shielding gas. To overcome this problem, the electrode angle should be changed and wire feed rate should be kept uniform. Verify that both the shielding gas flow rate, and the regulator are free of damage such as leaks or visible obstruction.
3. Excessive Spatter
The wrong positions of the wire feed speed, voltage or current can lead to an over-emitting of the weld. Modify these settings and be certain that the welding machine is well-earthed. Moreover, check whether there is some deposits on the contact tip and nozzle of the heater block.
4. Machine Shutdowns
In case your orbital welding machine is switching off, then it is high time you assessed the functionality of the power supply. Also, make sure that the machine is getting the proper airflow that it needs for cooling purposes. If that doesn’t solve the problem, seek help from the technical support personnel from the manufacturing company or an expert technician.
5. Wire Feed Problems
A non-fiber type or low worm wire feed can by caused by several reasons such as a dirty or damaged wire feeder, faulty electrical connections, or a worn out drive roller. Check the condensation of the wire feeder and interchange the faulty parts of the wire feeder. Looking at the electrical connections, most of the time they will be loose or corroded.
6. Excessive Noise
Any kind of strange sound coming from the orbital welding machine can be an alert to the conditions of the motor, the drive or the bearings. These parts should be checked frequently and replaced to minimize noises Auto Mechanic Parts and Tools.
Conclusion
These orbital welding machines are widely used in automated welding industries. Proper maintenance and timely problem-solving are crucial to ensuring optimal performance, longevity, and uninterrupted operation. To get the best out of these machines, it’s essential to follow recommended maintenance procedures and apply general troubleshooting techniques. This not only enhances the efficiency of the equipment but also ensures consistent quality in production welds. For more advanced orbital welding solutions and maintenance insights, explore UPM Technology to keep your systems running at peak performance.