With the continuous improvement of the level of industrial automation, orbital welding machines are increasingly used in the field of stainless steel pipe welding, and have become the core equipment for many manufacturing companies to improve welding quality and efficiency. Especially in industries such as food, medicine, chemicals and semiconductors that have extremely high requirements for welding cleanliness and precision, automatic orbital welding machines are gradually replacing traditional manual welding with their precise control and high-quality welding effects.
However, although the orbital welding machine has powerful performance, it operates under high temperature, high pressure and high energy environment. If it is not operated properly, it is very easy to cause safety accidents. Therefore, mastering the safe operation specifications of the orbital welding machine is not only related to personal safety, but also to the service life of the equipment and the stability of production efficiency.
This article will systematically analyze the various safety details that should be paid attention to when using the orbital welding machine to help operators effectively avoid risks and ensure the safety and smoothness of the operation process.
1. What is an orbital welding machine?
The orbital welding machine is a high-precision equipment used for automatic welding of annular welds such as stainless steel pipes. It mainly uses a preset track system to make the welding torch move at a uniform speed along a circular path to achieve fully automatic melting welding. It is widely used in industries with high requirements for welding quality and hygiene level, such as clean pipeline systems in pharmaceutical factories, food processing pipelines, and petrochemical fields.
Core advantages include:
High welding consistency
Reduced human errors
Beautiful weld formation
Suitable for mass production
Because of its many advantages, orbital welding machines are frequently used, but also bring higher safety management challenges.
2. Ten safety precautions when using orbital welding machines
2.1 Personnel training and safety education
Technicians operating orbital welding machines must undergo systematic training and be familiar with the equipment structure, control system interface, and welding parameter settings. At the same time, they should master the emergency handling process for common faults.
It is recommended that companies organize welding safety training courses regularly to strengthen employees' awareness of electrical, heat source, and high-pressure gas-related hazards and enhance overall safety awareness.
When operators use stainless steel welding equipment for welding operations, they must wear the following protective equipment: welding masks (anti-glare and ultraviolet), high-temperature resistant gloves, fireproof work clothes, protective shoes, and protective glasses (for equipment commissioning and cleaning) to avoid safety hazards caused by arc light, splashing metal, and high-temperature burns.
2.2 The working environment is well ventilated
A large amount of metal smoke and harmful gases will be released during the welding process, especially when stainless steel welding may produce toxic substances such as hexavalent chromium and ozone. Therefore, the workplace of the orbital welding machine must be equipped with an efficient exhaust system or smoke exhaust device to ensure air circulation and prevent operators from inhaling harmful gases.
2.3 Check the power supply and grounding system before welding
As an automatic orbital welding machine that relies on electric drive, electrical safety is of vital importance. Before welding, it must be confirmed that:
The power cord is not damaged or leaking
The equipment housing is reliably grounded
All interface cables are firmly fastened
The welding power output is stable and there is no current fluctuation
Poor grounding can easily cause electric shock accidents and even damage the precision control system.
2.4 Keep the welding area dry and free of oil
Orbital welding machines are generally used in clean places, but they may also be contaminated by water vapor, coolant or oil stains during daily operation. If there is moisture or conductive liquid in the equipment base, pipes or operating table, it is very easy to cause electrical short circuits or arc instability, and in severe cases, it may also cause electric shock accidents.
Before welding stainless steel pipes, be sure to clean and dry the work area and remove surface oil and moisture.
2.5 Correctly install and tighten the track clamp
The track clamp is an important component of the automatic track welding machine, and its stability directly affects the accuracy of the welding track. When installing the clamp, you must do the following:
Fit tightly with the pipe without shaking
The closed end interface of the track is not misaligned
The bolts are locked in place
If the track is not centered or installed loosely, it will cause defects such as weld offset, cracks, and weld penetration.
2.6 Develop a complete welding process specification
For stainless steel pipes of different diameters, wall thicknesses, and materials, matching welding process parameters such as current, voltage, speed, gas flow, wire feeding speed, etc. should be formulated and set in the program by experienced welding engineers to avoid misoperation.
Standardized parameters not only improve welding quality, but also effectively avoid equipment overload or loss of control.
2.7 Monitor the operating status of the equipment
During the welding process, the operator should pay attention to the control panel data, welding audio changes, weld formation, etc. Once an abnormality such as arc instability, current jump, alarm prompt, etc. occurs, the equipment should be immediately stopped to troubleshoot the fault.
The equipment provided by high-quality orbital welding machine exporters is usually equipped with a real-time monitoring system and fault alarm function. Users should learn to correctly read and respond to various system prompts.
2.8 Regular cleaning and maintenance of welding equipment
If the equipment is not cleaned for a long time after welding, it may cause:
Cooling system scaling
Carbon deposition and blockage of the conductive nozzle
Short circuit of the control panel
Gas channel blockage
Therefore, it is recommended to clean the welding head and fixture after each welding, maintain the wire feeding system and gas interface weekly, and check the cable insulation and power supply status monthly. Regular maintenance is the core means to extend the life of the equipment.
2.9 Power-off operation process in emergency situations
The welding site must be equipped with an emergency power-off button and marked conspicuously. Once spark spray, equipment overheating or human electric shock occurs, the emergency button should be pressed immediately to cut off all power.
At the same time, the operation site needs to be equipped with safety facilities such as fire extinguishers and explosion-proof blankets, especially when flammable gas welding (such as hydrogen-assisted) is involved.
3. It is also important to choose a safe and reliable orbital welding machine exporter
High-quality orbital welding machine exporters should not only provide the equipment itself, but also provide the following supporting services:
