Mag Tool Inc. - Mini-Brazer MB-6

MIG-MAG Orbital welding

WHY DON'T YOU TRY ORBITAL MIG-MAG WELDING?

Orbital MIG-MAG welding is competitive today.

Defect free MIG-MAG becomes a reality with Orbital technology! Difficulties renowned in manual MIG-MAG welding disappear with a repetitive mechanised process. Nowadays increasing demands for robotic positional welding has pushed wire manufacturer to develop a wide range of innershield and outer-shield wires adapted to industrial application. At the same time, new MIG-MAG welding power sources with improved features appear on the market. Orbital welding profits directly from these new developments.

Compared to manual stick welding, productivity can be greatly increased by a factor of two to three, depending on quality requirements. Industrial applications have demonstrated that deposit rates can be realised in excess of 3 kg/hour. With an automatic process, all parameters can be adjusted and maintained at their optimum over the entire welding cycle in order to achieve extremely high productivity levels. Only mechanized welding systems can maintain this level of deposition. The process no longer requires highly skilled welders; even "root passes" are easily achievable with x-ray quality results.

The payback period depends on many factors, however in general terms 1 to 2 years may be considered achievable. The three main factors that contribute directly to this high value are: the process that procures a high deposit level, the machine efficiency in automatic welding against manual methods and finally the non-conformity level which is lower than that in manual welding methods. POLYSOUDE's solution POLYSOUDE's task is to propose mechanised systems for industrial welding applications. For more than 30 years POLYSOUDE has designed, manufactured and installed modular solutions on a global scale, and has customised these special systems to customer needs.

POLYSOUDE is able to propose a vast array of mechanised solutions using a wide range of orbital or linear welding processes: cold or hot wire GTAW (TIG), narrow gap GTAW, plasma, GMAW, FCAW.

Our philosophy is to develop standard equipment modules that can be combined together in order to meet the requirements of the client.

Our control systems and programming software are designed in such away to minimize any software/hardware modifications that may be required to interface our equipment modules. The modular design enables us to directly interface to various peripheral devices such as circumferential and longitudinal manipulators or weaving slides etc.

Adapting existing fully established modular designed components assists the development of new applications for our customers. Thanks to our integrated axis controls, the process controller enables the customer to adapt and control existing positioners and other mechanical components.

Our Multi-Process Welding System

Multi-process know-how of POLYSOUDE technicians assures the customer that the best solution will be chosen for his application. Depending on the quality, productivity and working conditions... different scenarios can be developed in partnership with the customer. Where required, solutions can be demonstrated and tested in our laboratory in order to check and validate the process.
Our orbital systems are able to handle TIG, plasma, JMAW and FCAW processes. Also combinations of these processes are possible; each case must be analyzed separately according to customer needs.
An other positive factor for multi-process applications is that today multi-process power sources are becoming more and more available in the market, therefore resulting in lower cost solutions.
Description of the MIG-MAG orbital multiprocess welding systems
The process controller is at the heart of the welding system. The controller integrates all components and receives the operator interfaces.
Different power sources can be connected to the system. In this way it is possible to choose the best adaptation and welding process that the application requires. The system incorporates a standard "robot interface" and control circuitry for the power source and cooling system used. Within this interface the process controller commands all the functions of the power source. This architecture allows for a single unique umbilical connection to the welding system for rapid connection /disconnection.
Two operator interfaces are available. A powerful Windows based software that we call "POW" permits on-line and off-line program development & editation. Many advanced functions help to optimise welding parameters during research & development phases. Operator personnel can use the remote control during welding cycle for fine tuning adjustments.
The welding carriage is composed of different modular parts that are tailored to the application.
Two versions are available for the MIG-MAG welding process.
A standard version has been developed for conventional applications with a fixed working area. The process controller, PC, printer, robot interface and connection module is assembled in a single control unit comprising of individual racks.
A mobile version is designed for quick erection of the complete system for site and field applications.
Less than 5 minutes are needed to connect the different parts together.

MIG–MAG WELDING SYSTEM For semi-automatic orbital welding General Architecture The MIG – MAG system comprises 4 sub-assemblies: • A robust carriage which is clamped onto a guide ring. The guide ring is of a quick connecting type. The carriage supports the filler wire spool and 3 slide assemblies (weaving, vertical motion, angular motion of the head, rapid oscillation module). • A power source which is connected to the cooled torch through the process controller. • A Numerical Control (NC) unit which is interfaced on one hand with the power source and on the other hand with a laptop P.C. for programming of the welding sequences. • A remote control linked to the process controller for adjustment of welding parameters . Depending on your preference for the power source, three types of systems can be connected with the best today’s welding technology. Please refer to the technical specification for detailed information. Application Fields The MIG-MAG system is designed in two different versions depending where the work has to be done: standard or mobile. For the mobile version, the Power Source and the NC are implemented in an easily transportable robust rack. The bug can operate in any position for pipe or any other component welding. Current application sectors examples: • Onshore underground pipes • Vessels • Chemical industry piping • Tubular structures Process The welding processes are those available from the power sources and from the filler wire suppliers. Advantages of the MIG – MAG The MIG – MAG orbital welding system offers a host of advantages: • high deposit rate: welding up to more than 3 kg/hour • improved quality of the welding • improved repeatability • no licensed welding operator required • improved working conditions Options • Angular motion of the torch • Quick oscillation
	Welding bug

	19’’ Standard version

	Mobile version

	Remote control