System for welding in a controlled atmosphere
The IRS 3.0 1/1 controlled-atmosphere welding system is designed for welding parts made of chemically active alloys in an inert environment, ensuring high-quality welded joints that would be difficult to achieve under traditional welding conditions.
The system features a short preparation cycle (vacuuming and filling the chamber with argon), which reduces the total welding time and lowers process costs.
The system includes a three-axis manipulator that enables optimal positioning of the workpiece during welding.
General View of the System
Main Components of the System
- Vacuum Chamber
- Chamber Lid
- Welding Power Source
- Independent Cooling System
- Rotary Vacuum Pump
- Roots Booster Pump
- Vacuum Port
- Argon Supply Port
- Air Intake Valve
- Gas Analysis System
- Glove Port
- Observation Window
- Work Table with 3-axis Positioner
System Components
Vacuum Chamber
Diameter — 1600 mm
Height (length) — 1600 mm
Chamber volume — 2.8 m3
Chamber argon filling time — no more than 5 min
Welding Manipulator
The manipulator with three degrees of freedom is designed to place the workpiece in the most convenient position for welding. Rotation, tilting, and lifting of the faceplate are performed by motor gearboxes. To prevent axis rotation, the gearboxes are equipped with brakes.
By controlling the manipulator's motor gearboxes, the operator can set any position of the positioner within the available ranges.
Number of axes — 3
Rotation speed range — 0–6 rpm
Load capacity — 500 kg
Workpiece diameter — 0–800 mm
Faceplate rotation angle — ±360°
Maximum tilting speed, rpm — 6
Faceplate tilting angle range — −30 to 120°
Overall dimensions (W/D/H) — 808/1389/931 mm
Faceplate diameter — 720 mm
Number of T-slots on the faceplate — 6
T-slot width — 14 mm
Weight — 400 kg
Rotary Vacuum Pump
Maximum water vapor pumping rate — 2.4 kg/h
Ultimate partial pressure without gas ballast — 10-4 mbar
Noise level — 75 dB
Motor power — 5.5 kW
Weight — 17 kg
Roots Booster Pump
Nominal pumping speed — 505 m3/h
Noise level — <70 dB
Motor power — 2.2 kW
Weight — 74 kg
Industrial Chiller
Cooling capacity — 8 kW
Supply voltage — 380±10% V
Mains frequency — 50/60 Hz
Number of phases — 3
Ambient temperature — 5–45 °C
Coolant temperature — 5–35 °C
Welding Power Source
Torch cooling — liquid-cooled
Primary operating power (100% duty cycle) — 14.2 kW
TIG welding current range — 3–500 A
TIG operating voltage — 10.1–30.0 V
Ignition voltage — 9.5 kV
Dimensions (with handle), L/W/H — 625/290/475 mm
Weight — 42.0 kg
System Operation
The system operates in a three-shift mode. The entire system can be serviced by a single operator.
Main operator tasks:
- installing and securing the workpiece;
- removing and unloading the finished part;
- installing consumables;
- visual inspection of the produced parts;
- writing operating programs for the system;
- monitoring program execution;
- adjusting operating programs.
The chamber is made of 304L stainless steel. The front section of the chamber is welded and includes a flange with a groove for a sealing ring to ensure airtight door closure during vacuuming.
The flat front door is mounted on a wheeled trolley and is moved manually along rail guides during opening/closing.
Pneumatic hinged clamps provide pressing of the door flange against the chamber flange. The chamber is equipped with one workstation with two glove ports, 8 inches in diameter, fitted with gloves installed on the inner side of the chamber. A viewing port with a diameter of 320 mm is positioned for convenient observation of the welding process.
The chamber is equipped with all necessary ports for connection of the vacuum system, argon supply, measurement head, lighting lamps, and glove ports. Two halogen lamps are mounted outside the chamber to illuminate the internal working space.
Gallery of completed projects
