Electron beam welding plant "ELU-20RS"

Electron beam welding plant "ELU-20RS"

Description

Установка «ЭЛУ-20РС» для прецизионной электронно-лучевой сварки, пайки и локальной термообработки

Detailed information PDF
The ELU-20RS unit is designed for precision electron beam welding, brazing and local heat treatment in a vacuum of bodies of revolution made of structural steels, aluminum and titanium alloys.

The unit includes:
- Vacuum chamber;
- Vacuum chamber lighting system;
- Electron beam gun;
- Electron beam gun manipulator;
- Loading platform;
- Welding manipulator;
- Power unit;
- Vacuum system;
- Cooling system;
- Locking system;
- Welding point monitoring system;
- Joint search system;
- Automated control system for the process complex;
- Control system for the monitoring of documented results of the program execution;
- Operator workstation;
- Technologist workstation;
- Control panel.

Vacuum chamber.
The vacuum chamber is a welded structured corps of rectangular cross-section. The vacuum part of the chamber is made of non-magnetic stainless steel. The chamber walls are made with the necessary lathing to meet the requirements of rigidity and stability.
Six inspection hatches at least are provided for visual control of the welding process to ensure easy observation.
The design of the chamber and inspection hatches provides protection for the operator from unused X-ray radiation.

Manipulator of the electron beam gun.
The electron beam gun (EBG) manipulator is designed for the positioning of the EBP relative to the welded product, as well as for its moving during welding.
The movement electric motors are located directly on the manipulator units.

Welding manipulator.
The welding manipulator is a transport module with two rotators installed on it alternately: with a horizontal axis of rotation (HAR) and with a vertical axis of rotation (VAR).

Loading platform.
The loading platform is designed for loading and unloading welded parts with assembly and welding equipment onto the welding manipulator and organizing transport movements of the welding manipulator to the working chamber and back.
The platform has a rigid connection with the vacuum chamber to prevent displacement of the guides during operation of the unit.

Power unit.
The technological complex includes a power unit consisting of:
- Electron beam gun with an indirectly heated cathode made of LaB6;
- Turbomolecular pump;
- High-voltage power source 60 kV, 40 kW;
- Control stand;
- Videomonitoring device.

Operator's workplace.
The operator's workplace has a control panel that moves along the camera.
The control panel contains the control panel and the operator's panel of the control system, and the video surveillance system monitor.
The operator's panel contains a video monitor showing the current phase of the technological process on the screen, the operating modes of the control system, the main monitored parameters, emergency messages, etc.

Technologist's workplace.
The technologist's workplace includes a table with a personal computer, printer and monitor to prepare and edit programs, documenting the welding process, and analyze the oscillograms of the monitored welding parameters.

Control system of the automated electron-beam technological complex.
The control system is designed to control:
- Vacuum system;
- Mechanical system;
- Electron-beam unit;
in the modes:
- Manual control (setup);
- Automatic control according to a given program;

Mnitoring system of welding zone .
Welding zone monitoring is provided both directly through the portholes and on the video monitor.
Joint search system.
The joint search system is designed to ensure alignment of the beam with the joint of the welded parts.

System of the documenting of the results of control program execution.
The goal is to create a welding process passport for a specific assembly – an electronic document (file) that records the parameters of the welding process performed during the execution of the control program.

Cooling system.
The cooling system continuously cools the vacuum equipment of the unit, the cathode and optical parts of the electron gun to temperatures that ensure their normal operation for a long time.

Control panel.
An additional remote control is located near the sliding door of the working chamber to control the chamber door, the transfer of the transport module from the chamber to the loading platform and back, adjustment transfers of the welding manipulator and the EBP manipulator.

Technical data

Working volume of the vacuum chamber, m3
17
Inner dimensions of the chamber (L*W*H), mm
4000*2100*2100
Power consumption, kW
140
Load capacity of rotation manipulator with horizontal/vertical axis, kg
1300 / 1300
Dimensions of welded parts on a manipulator with a horizontal axis of rotation (Ø*D), mm
600*2700
Dimensions of welded products on a manipulator with a vertical axis of rotation with a vertical gun position (Ø*D), mm
1400*600
Dimensions of welded products on a manipulator with a vertical axis of rotation with a horizontal gun position (Ø*D), mm
1950*1600
Operating pressure in the chamber, Pa (mm Hg)
1,3*10-2 (l*l0-4)
Operating pressure in the electron beam gun, Pa (mm Hg)
6,6*10-3 (5*10-5)
Time to reach operating pressure in the vacuum chamber and electron beam gun during repeated pumping, minutes
≤30
Visualization of the junction area
Video camera or secondary electrons
Method of combining a beam with a joint
Recording the trajectory by points, then automatically aligning the beam with the joint by deflecting the beam or moving the gun
X-ray radiation level at a distance of 100 mm from the installation surface, µGy/h (µR/s)
≤1,0 (0,03)
Overall dimensions (L*W*H) mm
12000*7000*4500
Range of changes in electron beam current, mA
1 - 1000
Accelerating voltage instability, %
±0,5
Electron beam gun accelerating voltage, kV
60
Electron beam gun power, kW
40
Rated voltage of three-phase supply network 50 Hz, V
400
Number of simultaneously controlled coordinates
4 (X, Y, Z, А or С)
Longitudinal movement of the electron gun manipulator (X), mm
2700
Transverse movement of the electron gun manipulator (Y), mm
900
Vertical movement of the electron gun manipulator (Z), mm
800
Rotation of the tuning manipulator (XZ), °
0 - 90
Detailed information PDF
Video
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