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KL -134 electron beam welding machine with “sliding” gun
- Vacuum chamber design incorporates the dual wall providing greater vacuum integrity with
lighter overall weight. High structural stiffness insures motion system of high accuracy and
repeatability
- Welding control with real time automatic seam tracking and observation RASTR secondary electron
emission system.
- Beam analysis system allows the operator to determine actual beam operating conditions prior to
beginning weld development and reduce weld parameter development time.
- Lanthanum Hexaboride cathode are used for long service life of more than 40 hrs, prevents “beam
walking” when the focus position is changed
- CNC +PLC of all machine systems.
MACHINE DESIGN AND DATA
One door allowing workpieces to be loaded into vacuum chamber. Work table has electric drive and is placed on the rails of the platform. The electron beam gun is set on the displacement “sliding”mechanism for moving along Y-Y axes with the accuracy of linear positioning ± 0,1 mm. Screws in ball-and-screw pairs, linear guides of all linear modules are covered by metal shields to protect them from depositions. Machine is equipped with universal rotator containing horizontal or vertical rotation axes.
CONTROL SYSTEM
Control System is based on open architecture principles that provide PC use at all control levels and realization of the following features:
- programmable three coordinate axes movement (two axes of linear movement and one axis of rotator) with linear and circular interpolations;
- simultaneous movement and control of welding focusing and deflection currents;
- operating in a fully automated mode, a semiautomated mode with user defined start and stop locations, and a manual mode, including jog function;
- sequencing blocks of programmed data together into master programs;
- automatic deflection teaching using RASTR system providing exact beam position on the joint;
- data logging of all control commands and parameters including welding parameters both in graphic and tabular formats
- diagnostics tools for trouble-shooting faults or errors.
SOFTWARE ARCHITECTURE
High software program controlled by ÎS Windows 2000 provides operator interface for all operating procedures and diagnostic protocols printing out.
Low software program controlled by ÎS QNX 4.2 provides control of equipment in all operational modes.
Main technical parameters of KL-134 machine
| Overall Machine sizes ( L×W×H), mm: |
6 975 × 4 890 × 2 702 |
| Weight, t |
15 |
| Vacuum chamber internal sizes ( L×W×H), mm:
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2 020 × 1 100 × 1 200 |
| Working pressure in chamber, Torr |
8·.10-5
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| Chamber and gun pumping time, minutes, max |
20 |
| EB gun “sliding”movement along Y-Y, mm |
500 |
| EB gun traveling speed along Y-Y, mm/s |
0,16÷33 |
| EB gun positioning accuracy, mm |
0, 03 |
| Work table traveling speed along X-X, mm/s |
0,16÷33 |
| Work table positioning accuracy, mm |
0, 03 |
| Maximal load capacity of work table, kg |
500 |
| Rotator faceplate diameter, mm |
650 |
| Maximal load capacity of rotator, kg |
300 |
| Faceplate rotation speed, rpm |
0,04÷10 |
| Radial runout of rotator faceplate, mm |
±0.05 |
| Face runout of rotator faceplate, mm |
±0.1 |
Maximal sizes of workpieces , mm:
- on rotator with horizontal axis: Ø = 800, L= 950
- on rotator with vertical axis: Ø =1000, L= 860 |
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Seam visualization and tracking system
RASTR: tracking accuracy, mm
magnification, times |
±0.1
5 |
Electron Beam Equipment ELA-60/30
(gun, power supply and control system):
Accelerating voltage, kV
Accelerating voltage stabilization, %
Welding current range
(with 0,125 mA programmable step)
Beam current stabilization, %
Working distance range , mm
Focus current stabilization, %
Beam oscillation frequency for sine form, Hz.
Beam pulsing frequency at pulsing welding, Hz
Cathode life-time, hours
Beam deflection angle at maximal power, degree |
60
±1
0…500
±1
50±500
±0.5
1…2000
1…600
40
±3° |
General technical characteristics:
Consumed power, kVA, max
Cooling water flow rate, l/hour
Cooling water temperature at inlet, Ń°
Cooling water pressure, kg/cm2
Compressed air pressure, kg/cm2, min |
110
1 600
20…25
3…4
6 |
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# 26 
1999– 2008 PWI