Linear welding Automat AWL 2050.25 LIFT

AWL 2050.25 LIFT is an industrial machine designed for longitudinal welding under high hourly workloads. It can operate in manual or automatic mode and includes advanced productivity-enhancing functions. The LCS06 control system provides sophisticated process control, including communication with the welding power source.

The machine is supplied only as a custom-made solution. Due to the complexity of the system, a detailed consultation of the customer’s requirements is always necessary. The final technical design and project feasibility are determined individually according to the product parameters, application and production program.

AWL 2050.25 LIFT welds on a copper backing bar and provides double-sided clamping of weldments up to 2050 mm long. Controlled weld-root protection is provided by forming gas using the CascadeGas system.

The machine is designed for TIG AC/DC and Plasma AC/DC welding of alloy and non-alloy steels, CrNi steel, copper, aluminum, titanium, galvanized steel, aluminized steel and other materials.

The central steel block is supported by two ergonomically shaped supports and contains the electronic components and cooling system. Both force arms are fixed to the central block, which also holds the welding mandrel. The arms are designed as welded steel half-shell structures with controlled flexibility. The left arm carries the linear guide of the welding head.

The weldment is pneumatically pressed against the welding mandrel by gear levers with transversely adjustable CuCrZr pressure segments. Stainless-steel segments can be supplied as a custom solution, particularly for aluminum welding and improved cooling after welding.

The machine is mounted on a robust welded structure containing the control electronics. An electronically controlled hydraulic lifting system enables the processing of weldments with diameters up to 2500 mm. The mechanism moves on linear guides along a robust central column with two stabilizing supports and uses a hydraulic cylinder with a stroke of 1490 mm.

A welding-fume extraction channel is integrated directly into the machine structure without negatively affecting the welding process. This solution is especially beneficial when welding galvanized materials. The extraction connection has a diameter of 100 mm.

Steel operating platforms allow comfortable and safe machine operation when welding large-diameter components. The platforms are fixed to the machine base, rise together with the machine and are equipped with safety railings.

The welding mandrel is made of low-alloy steel with high flexural strength. It carries a precisely machined, internally liquid-cooled CuCrZr backing bar with an integrated CascadeGas system. A stainless-steel backing bar can also be supplied as a custom solution for aluminum welding.

Gas management consists of three independent circuits:

* shielding gas for the welding torch, * gas for post-cooling the weld, * forming gas for weld-root protection.

The CascadeGas system automatically activates individual forming-gas sections according to the current position of the welding torch. Gas is supplied only where required, reducing forming-gas consumption by up to 80%. All gas circuits are equipped with precise flow meters and control valves.

The welding head has a pneumatically controlled torch holder. In the parked position, the torch is horizontal, allowing easy visual inspection of its components. Longitudinal movement is provided by a backlash-free drive consisting of a servomotor, planetary gearbox and belt drive.

Technical movement parameters:

* repeatable positioning accuracy: 0.2 mm, * welding speed: 10–300 cm/min, * rapid traverse speed: 600 cm/min.

The machine can be equipped with the HST CREATIVE CW 07 cold-wire feeder. It is fully controlled by the LCS06 system and provides extensive adjustment of feeding parameters, including wire-feed reversal.

The LCS06 control system was developed specifically for linear welding automats. It controls the complete machine, supports communication with the welding source and provides advanced automatic functions, including UP/DOWN control logic.