When considering orbital welding for tube or pipe, a usual concern is over the complexity of learning how to program a machine to perform accurate, consistent welds.
Calculating a Weld Schedule
An orbital weld schedule can be developed with reference to these calculations.
- Tube O.D. x 3.141 = Circumference
- IPM (4 to 7) ÷ Circumference = RPM
- Time: (60 sec. ÷ RPM) + Rotation Delay + Overlap
- Level 1 Amps: 1 amp/.001” wall thickness (316L)
- Last Level Amps: 80% of Level 1 Amps
- BCK Low Amps: 30% of Level 1 Amps
- Rotation Delay: Normally 1 to 2 seconds
As you can see, this manual method could take time, effort, and a certain amount of mathematical skill to master. To simplify the orbital welding process, auto programming options were developed.
Auto Programming for Orbital Tube Welding
Today, most fusion orbital welding power supplies have auto-programming software. This allows welders to operate the tube welding system with little to no programming training. A program is instantly generated after the necessary inputs are entered.
Note that though auto programming can quickly generate weld schedules, they are not necessarily perfect. Often, minor adjustments need to be made, but they provide a great baseline to go off – saving you time and material while testing weld schedules.
If using auto programming to create a new weld on a Magnatech system, the weld will automatically be created based on the users’ choice of weld mode, head model, tube diameter and wall thickness, material type, and the number of weld levels desired (see screens below). After the weld is created, the user can review and edit the weld from the Weld Operation screen.
Auto Programming for Orbital Pipe Welding
Though most fusion systems have this technology, most manufacturer’s multi-pass pipe welding systems do not.
Magnatech has developed a unique auto-programming for orbital pipe welders.
Even an inexperienced user can enter the pipe’s OD, wall thickness, and material to generate a weld program. The power supply stores up to 100 programs and can transfer programs using a USB flash drive.
After the weld program is created, you can modify the parameters of a program as needed in two different modes: Edit and Scaling.
Edit: The edit mode allows users to make changes at any point in the cycle.
Scaling: The scaling mode allows a percentage change for the entire program.
If you seek manual control, a pendant can be used. It can be used away from the machine for remote use. These pendants have a waterproof, rugged design sealing a silicone rubber keypad.
Use auto programming to quickly create quality welds without complexity. Need further help in understanding power supply programming? Contact us to talk about equipment demonstrations and training.
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