Welding positioners are a device that holds and turns a workpiece in order so that welders can work at an appropriate angle and on a uniform surface. It can move at a rapid speed even when it is carrying weights that signify weight. The principal function of a welder’s positioner is to ensure that the piece of work is always in the correct position for welding.
It can help reduce fatigue since they can stand in a single position and complete their work. They don’t have to bend or move since the welding positioner can rotate around 360 degrees. The object or the workpiece to be welded can be adjusted to the weld positioning device. Weld positioners can be fitted with pipes or valves. This is the primary reason they find many applications in industries that employ CNC machining or fabrication of metal to create metal components or parts. This article discusses the functions, benefits, and uses of weld positioners and others.
The basic principle that drives welding positioners is identical for any workpiece, large or small. They are a kind of plane of rotation that runs perpendicularly to the ground. It is possible to place huge tools on these tabletops. But a weld positioning device is much more than an axis that rotates. Its performance is contingent on limitations on the output of static torque. It can spin at breakneck speeds while carrying a substantial volume of weight.
Points to Know When Working on Weld Positioners
Here are some tips that workers must remember when welding using a weld positioner:
Examining your center of gravity (CoG)
The center of gravity is where the weight of an item is placed. When you choose the position weld, it is essential to think about your center of gravity for the workpiece and its weight and size. This will ensure the importance of the workpiece across all axes and affect the speed of the table’s rotation. CoG can change as the welder adds components with different weights and sizes to the positioning device. This is also something that needs to be taken into consideration.
Proper attaching of workpiece
The method by which the piece of work is secured to the welding positioner is essential as it is the method if it breaks off after the work is complete. Specific tasks that require repeating to make parts used in typical applications utilize specific production fixtures. In addition, for round-shaped workpieces generally, a three-jaw tool could be used for attachment to the positioning device. Some workpieces require bolts, which must be planned out according to the size and shape of the piece.
Flat, even surface
Make sure the whole device is mounted on an even, flat surface. Otherwise, the piece could fall off, which could pose a risk. It is possible to mount the positioner vertically on a table or a stand, however, it should be adequately secured.
A Few Reasons to Use Welding Positioners
There are numerous benefits to weld positioning devices, aside from the enhanced comfort of the person using them. Here are a few:
Better quality A welding positioner increases accuracy, and this implies that there are fewer chances of errors by workers.
Safety of workers A welding positioner guarantees the safety of workers. This is because the piece being welded is adequately secured in the positioner to ensure that it is not moved. As opposed to anchoring the workpiece by chaining the essay or tying it, there is the possibility of uncontrolled movement that could be risky.
Reducing fatigue Its design welding positioner allows workers to sit in one place and work, and it can be adjusted to their height and comfort level. Therefore their strain or fatigue will decrease and will help increase productivity.
Compact footprint Weld positioning devices can be adjusted to fit in small spaces, and this can reduce the amount of clutter on the floor of production.
Semi-automatic operation Weld positioners can be utilized as a semi-automatic device by connecting it to a power source. This increases the speed and consequently the productivity of the welder.
Positioners Increase Welding Throughput
Positioners boost productivity since they eliminate wasted time across a range of aspects. The first is that welding positioners allow for a maximum arc time. Chains, cranes and other rigging equipment require lots of effort to move, and frequently welders have to wait until the piece of work is properly positioned. This could have occurred multiple times in one welding.
The use of positioners allows the welder to move the part speedily! In the case of significant factors, the positioners permit one person to do the task without having to remove several people from the component. This results in labor savings and frees workers to do other jobs.
Positioners Improve Weld Quality
The main benefit of having the proper weld positioner is that it produces consistently high-quality welds. Any movement in the component in the welding process can make it difficult to create high-quality welds if your material is secure enough to allow for sufficient welding penetration. It is also simpler to complete the weld without shifting interruptions. Welding positioners can solve numerous issues related to the quality of the weld because it rotates the workpiece at a controlled rate and speed, ensuring continuous, penetrative welding.
Retrain & Attract Skilled Welders
With the welding workforce becoming a bit dwindling, retaining and attracting skilled professionals is an enormous advantage for any company. Positioners enable welders to work more efficiently, for more extended periods and more quickly. This equipment can improve the working environment, making it much more appealing to skilled workers. Positioners for welding additionally:
Enhance morale of employees
Utilize semi-automatic functions to reduce the fatigue of workers and boost production speeds.
What are the Different Applications of Weld Positioners?
Weld positioners are widely used in a variety of industries in which welding, and fabrication are needed. Here are a few applications of weld positioners:
- Rotor position
- The rotation of components for assembly
- The mounting of equipment for welding
- Welding of wheels, shafts, pipes, shafts, and more
- Large offset loads
If you’re searching for weld positioning devices for your industrial project, make sure you purchase the right producer and distributor. Woodward Fab is one of the most prominent makers and suppliers of sheet metal fabrication equipment. Weld positioners are offered by the company with different specifications that can satisfy customers’ requirements.
Utilizing manipulators, positioners, and the best way to use them
The manipulators and the positioners are alike; however, they differ in how the workpiece is placed. Positioners hold the workpiece while a manipulator can move and hold the welding heads.
The process of using a positioner to weld begins with the mounting of a workpiece on the plate. Then, it is clamped into place. In certain situations, investing in fixturing designed explicitly for this purpose is worthwhile.
The 3-jaw chuck design of work holding is a different option. A gear drive and motor will then turn on the face plate or chuck to place the workpiece in the direction the welder demands.
Tilt actions increase the positioning options available. The tilt of the faceplate can be made possible by the worm drive, which can be either motor driven or operated manually.
Positioners with two axes (or tilt/turn, tilt/rotate or tilt/turn positioners) allow for various ways to manipulate workpieces both on horizontal and vertical Axes. They are suitable for pipe applications, such as elbows and flanges. Welding turntables are used for projects where the workpiece must rotate around the vertical axis.
Turning roll is a good choice for larger or heavier work like pressure vessels or tanks. Headstocks/tailstocks are for rotating a workpiece around a horizontal axis, and the headstock by itself could be sufficient to rotate smaller workpieces horizontally. The larger and more heavy workpieces will require the addition of an additional tailstock.
Pipe Stand offers the best range of pipe turning positioners in Australia.
Portable & Benchtop Positioners
LJ bench top positioners come with a variety feature such as 3 air purge fittings for stainless steel and TIG welding applications; 3 hollow spindle; 3 height adjustable roller cart; 3 torch mount options
The 08P-200 benchtop pipe welding positioner with 8″ outer diameter (OD), is versatile and adds functionality to your shop floor. It is lightweight at 110 lbs. Additional 39 lbs. When the chuck weight has been added.
The bench top positioner measures 14x17x20x20 inches and can hold 300 lbs. From the chuck face. It can support lighter-duty work pieces that need rotation.
The welding positioner can rotate at a speed of 0.7 to 7 rotations per hour (RPM) for controlled operation. Operators can safely and confidently turn their workpieces with this welding positioner, which has a turning force of 730 in-lbs. This allows for faster and more consistent welds.
This bench-top pipe welding positioner features an oversized turntable and a 12″ outside diameter (OD). This machine is compatible with an 8-inch chuck or a welder gripper. The machine also features a hollow spindle 3/8″ with an air purge option. The bench top positioner 08P-200 offers manual adjustment and a -15deg to 105deg handle. You can adjust the increments by 15deg.
You have a few options with the 08P-200 benchtop pipe welding positioner. The 08P-200 comes with a self-centering 8″ 3 jaw chuck. Elbow jigs are also a popular accessory for spooling applications. Outboard roller support stands are another common addition. Anti-tip feet are another popular accessory for bench top positioners
12P-800: Portable Thru Pipe Turning Positioner
The 12-P800 is a flexible thru-bore handheld weld positioner. This positioner is designed to increase productivity for lighter fabrication tasks in your shop. Its compact footprint can hold up to 1,000 lbs. The portable weld positioner comes with a 3″ hollow thru bore.
This welding positioner can turn at a constant and flawless speed of 3,000 in-lbs turning torque. The positioner can rotate workpieces at a steady speed of between 0.45 to 4.5 rotations per hour (RPM). This allows for highly controlled and consistent welding. The turntable has a 12 inch outer diameter (OD), which is compatible with a 12-inch chuck or a welder gripper.
It is versatile in its operation. The thru-bore positioner features a tilt function and a self-locking, hand crank worm gear. It has a c/w angle range of 5 to 105 degrees. This equipment was designed with safety, comfort, and convenience in mind.
The 12P800 features a fully enclosed worm-gear rotation drive and dynamic brakes. This will bring the table rotation to an immediate halt and allows for clockwise or counterclockwise table rotations. This portable welding positioner is the best in class and price.
Floor Model 12” Portable Benchtop Weld Positioners 12P-900
The 12P-900 portable benchtop model, 12-inch outer diameter (OD), bench top welder is sturdy. It is designed to be used for making cylindrical welding products such as exhaust components and pipe fittings. This positioner is perfect for spooling fabrications of lighter weldments.
It can carry a maximum load weight of 1,000 lbs. The 12P-900 is best suited for lighter weight welder tasks. It can tilt or rotate workpieces. Its powerful 3,000 in-lbs motor makes it possible to maintain a consistent rotation speed. It has a high turning torque. The variable rotation speed can be adjusted from 0.5 to 5 rotations/minute (RPM).
The 12″ OD turntable can be used with a 12 inch chuck. Concentric grooves on the table allow for easy central positioning. You can adjust the tilt range of your portable pipe turning machine to meet your needs. You can easily adjust the tilt and rotation to achieve the best angles for welding.
You can add accessories to the 12P-900 to improve performance and efficiency. The scissor lift cart is a popular accessory that allows you to move your positioner and load (1,600 lbs) easily through your shop. Pipe stands, tripod stands, and roller stands are often purchased in pairs with the 12P-900 portable welding positioner.