Automated Seam Welding of Trailer Tanks and More

Miller Electric Mfg. Co. (Appleton, WI) has integrated the welding automation systems from Jetline Engineering (Carol Stream, IL) into the Miller® brand, including their LWI Internal Longitudinal Seam Welders for welding flat sheets or tanks with diameters larger than 55 in (1,400 mm). These are ideal for trailer tank fabricators:

• The standard designs offer welding lengths that range from 72 in (1,825 mm) to 300 in (7,600 mm) and can accommodate a minimum part diameter of 55 in (1,400 mm). This machine will accommodate any maximum diameter that a shop can conveniently handle.
• For seam welding cylinders, tanks, flat sheets with GTAW, PAW, GMAW and SAW processes.
• Designed for large diameter cylinders, tanks, and heavy wall plate.
• The sturdy base structure takes place of the mandrel.
• Carriages use hardened bearings and precision DC motor with tach generator feedback.
• Various speed ranges and speed holding accuracies are available.
• Copper backing bars and reversible copper finger tips are standard.
• Comes standard with 9700T microprocessor motion controller.

Options include:

• A 9900 Computer Based Controller.
• Hydraulic tilting tabletop and/or hydraulic centering plate stops.
• Dual-ARC (PAW+ GTAW) and Tandem SAW processes can increase productivity and make single pass welds on 3/8 in thick metals possible.
• Elevating rollers and part loading conveyors.
• VMS (video monitoring system) and operator podium.
• Wireless remote control for finger operation.

Miller Electric has also introduced their new Millermatic® 350P auto body aluminum repair system, a complete welding package designed to provide high weld quality and simplify repairs on aluminum vehicle body panels and beds, such as those used in trucks. This turnkey system addresses the challenges posed by welding thin gauge aluminum, such as warping, distortion and burn-through. It builds on the trusted performance of the popular Millermatic 350P MIG power source and can also be used to Pulse weld with silicon bronze, steel and stainless steel wires. Providing all the components needed for making aluminum vehicle body repairs in a single optimized package simplifies the process of aluminum welding, particularly for welding operators who are not as familiar with this material or the challenges it can pose.

https://youtu.be/s4PWPj0krL8

The Millermatic 350P auto body aluminum repair system also features the components necessary to meet the specifications set forth by Ford and the Assurance Performance Network for completing weld repairs on the Ford F-150 aluminum body truck. These specifications require a 220 V power source with Pulsed MIG capabilities dedicated to aluminum welding, using .047 in (1.2 mm) 5554 series aluminum alloy wire. The package includes:

• Millermatic 350P, a 200/230/460V power source for single- or three-phase power.
• 8 in spool of .047 in (1.2 mm) diameter Hobart® 5554 aluminum wire for superior weld quality.
• Bernard™ Q200 aluminum MIG gun, customized with a 12 ft long cable, plastic liner and a 30 deg head tube for superior aluminum wire delivery.
• .047 in (1.2 mm) aluminum Centerfire™ Contact Tips for consistent electrical conductivity and arc starting.
• .047 in (1.2 mm) U-groove drive rolls for improved aluminum wire feeding.

This system provides 300 amp output at 60 percent duty cycle with improved low-end Pulse MIG programs dedicated for aluminum welding. The low-end wire feed speed capabilities have been reduced from 105 ipm to 75 ipm, resulting in less heat input to reduce burn-through and warping when welding on aluminum body panels. This repair system offers an aluminum Pulse Hot Start™ that automatically provides more power to eliminate “cold starts” inherent with welding this material. It features line voltage compensation that provides constant output even in the presence of fluctuations in input power. A Fan-On-Demand™ cooling system operates only when needed to cool the power source, reducing power consumption and minimizing the opportunity for contaminants to be drawn into the machine.

Miller has also added the new CAT 2nd Edition graphic to their Digital Infinity Series lineup of welding helmets that feature the largest viewing area in the industry. These welding helmets provide a viewing area of 13.4 sq in and headgear with an oversized comfort cushion that offers extensive adjustability settings and improved support for better fit and comfort. The helmets also feature four arc sensors and four modes: weld, cut, grind and X-Mode. Exclusive InfoTrack™ technology allows the lens to track arc time.

Miller Electric Manufacturing Co., 1635 W. Spencer Street, PO Box 1079, Appleton, WI 54912-1079, 920-734-9821, www.millerwelds.com.