The welding of long structural beams is an important and often difficult process. Manual welding systems for this process are inefficient, slow and result in varying weld quality. Time spent on post weld rework costs metal fabrication businesses valuable time and money. Fabricators often try different forms of automation to improve productivity and throughput, though often the gains prove to be modest and the new processes may still fall short in terms of weld quality.
Praxair’s ProStar™ PRSGWS gantry systems represent an automated solution that will improve productivity while maintaining or improving weld quality. Complete with two welding stations, joint-seam tracking, process viewing camera systems and torch adjustability, ProStar gantry welding systems apply a continuous sub-arc weld for maximum deposition of weld metal at faster travel speeds, reducing operating costs and improving productivity. Because both sides are welding at the same time, the gantry system helps balance distortion. In addition, the ability to use twin sub-arc torches on each side increases deposition rates (up to 80 pounds per hour for both torches) and the ability to use dual tandem sub-arc torches increases deposition rates further ( up to 140 pounds per hour for both torches).
Built with the operator in mind, ProStar gantry systems feature a user-friendly touchscreen HMI with an aviator-style joystick, allowing the operator to control every part of the system, including the gantry and welding power sources. Additionally, a moving, high-back operator's seat is set low to the floor and offers comfort and proximity to the work area.
Simple to customize and built to order to suit each customer’s unique requirements, users can select HMI to custom control options, sub-arc or open arc camera systems and probe or laser seam tracking systems. They can also specify onboard twin or tandem SAW or GMAW/MIG configurations, flux delivery, recovery and heating systems. Available options also include induction or ﬂame preheat systems and onboard MIG welding systems for manual welding requirements.