Purely Electrical Powered Torch Cleaning

In automated arc welding, torch cleaning affects both the cost and productivity of the whole process. To positively influence both factors, the eReam innovative torch cleaning system from SKS Welding Systems (Kaiserslautern, Germany) offers striking benefits. Its all-electric drives save considerable amounts of energy compared to pneumatic drives, are easier to control, comply with the applicable safety regulations and offer good monitoring capabilities.

This system is currently available in two standard versions. An easy-to-handle cleaning of the gas nozzles, reliable operation and system integration are among the basic features of eReam. Low energy costs are another asset of the system. Compared with pneumatically driven torch cleaning devices, the cost of energy is much lower: for 50 (1,000) cleaning cycles per day, for instance, they are only 11 percent (1.5 percent). The same ratios apply to the CO2 emissions in connection with the system’s operation.

The fact that the milling unit, the spraying unit, and the optional wire cutter are electrically driven also means that there are measurable and controllable electrical values. This allows for the monitoring of the safety-relevant functions, rendering the safety devices and precautions redundant that are required in the welding cell for operation with compressed air. These are sometimes more expensive than the torch cleaning station itself. The higher costs associated with the complexity of the supply of compressed air are no longer required. As the functions of eReam are digitally/electronically controlled without any additional components or software, they are easy to integrate into common welding robot controllers and PLCs of automation systems.

The cleaning process is program-controlled. First, the robot moves the torch to the eReam unit. Centric clamping avoids damage to the gas nozzle. The material removal during milling is dependent on force using the mill torque as a control variable. Compared to the travel-dependent and often off-center milling with air-driven tools, this saves material, time and energy – and avoids errors. While a pneumatic system provides no feedback if a milling unit is jammed and stops, eReam is able to identify this status. It moves the milling head back and restarts the process.

The electronically controlled pump ensures that only the amount of anti-spatter liquid needed is sprayed on the torch. Instead of manually refilling the anti-spatter liquid, the operator changes only an externally-mounted container. This is another step towards a clean welding cell. For shops that desire an electrically driven wire cutter, this version is optionally available. With both versions, SKS is setting new standards in the field of torch cleaning with the proven milling method.

SKS North America, 2040 Austin Drive, Suite B, Troy, MI 48083, 248-519-5079, Fax: 248-519-5080, www.sks-welding.com.