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Self Aligning Rotator: The Ultimate FAQ Guide

With the different kinds of welding rotators available in the market, it must be difficult for you to determine which one you should opt for in your factory.

For this purpose, we plan to introduce Self-Aligning Welding Rotators to you in order to ease the choosing process for you.

We suggest you continue reading this guide as it contains all the features and benefits that Self-Aligning Welding Rotators offer and if you feel like they would suit your work requirements, you should purchase one instantly.

We have compiled some of the most common queries as well as unknown facts regarding Self-Aligning Rotators and we hope that they help in enabling you to make the correct decision for your business.

What is a Self-Aligning Rotator?

Self-Aligning Rotators offer a robust and rugged design with long-lasting and reliable rollers that perform the task of rotating the workpiece during the welding process.

Self-Aligning Rotators do not require you to manually adjust the wheels before the welding process and automatically align the welding rollers onto the workpiece.

Self-aligning welding rotator

Due to their self-aligning characteristic, you can even use Self-Aligning Welding Rotators on irregular or uneven surfaces.

Self-Aligning Welding Rotators also save up time and labor costs and are extremely efficient in performing their job as they have a low probability of errors and save you from over-exerting yourself.

With the help of Self-Aligning Welding Rotators, you can choose to either perform manual welding or automatic welding, whatever seems to be convenient for you.

What can You Use Self-Aligning Rotators for?

Self-Aligning Welding Rotators are basically used to serve the purpose of ensuring that your workpiece remains in place while it is being rotated in order to perform the welding process thoroughly.

You can use Self-Aligning Welding Rotators for the purpose of rotating cylindrical vessels such as fuel drums, pressure vessels, pressurized containers, heat exchangers, silos, boilers, oil tankers, generators, wind towers, pipelines, etc.

You can mainly use them in automatic welding of round or ring metal. The surface of the vessel does not matter in Self-Aligning Welding Rotators and you can even operate unevenly surfaced workpieces on it.

Self-aligning welding rotator drawing

What are the Different Parts of a Self-Aligning Welding Rotator?

Self-Aligning Welding Rotators are sold in a complete set that consists of multiple parts that make up the entirety of a Self-Aligning Welding Rotator and enable it to perform effectively.

Self-Aligning Welding Rotators are made up of two units: one drive unit and one idler unit. You can purchase as many drive units and idler units as you desire, depending on the activity that you need to carry out.

Self-Aligning Welding rotators consist of trunnion brackets that serve the purpose of supporting the wheels in order to automatically align them according to the change that occurs in the diameter of the workpiece.

Your supplier would provide you with a whole set of Self-Aligning Welding Rotators consisting of the following equipment:

• 1 Power and 1 Idler turning roll
• 1 Electric control system
• 1 control panel
• 1 remote pendant

Different parts of a self-aligning welding rotator

How do Self-Aligning Welding Rotators Operate?

The Self-Aligning Welding Rotator is made up of three simple components that operate together to ensure that the functions are performed properly. The main support unit, as well as the motorized drive, are examples of these components.

When you place the workpiece on the rollers, the rubber-tired rollers that are part of the support unit perform the job of absorbing the loading shock.

The roller-tired rubbers are often designed to protect the workpiece during the welding process. An overload disk made of steel protects the wheels from damage and shock.

The equipment’s operation is ensured by the motorized drive. You can also include additional features such as foot-controlled levers, pendant controls, digital screens, and anti-drift components to guarantee that the workpiece remains stable and does not move.

What Benefits do Self-Aligning Rotators Offer You?

Self-Aligning Welding Rotators are known for their added benefits that set them apart as compared to other kinds of welding rotators. Some of the advantages that they offer you are as follows:

● Increase in productivity

Self-Aligning Rotators are much faster as compared to manual welding devices and visibly increase the production rate of your factory.

Since you can control the speed of your Self-Aligning Rotator according to your production rate, you are able to perform the welding process at a much steady pace which allows you to take up huge orders and also not fall behind on your work deadlines.

Self-Aligning Welding Rotators also do not waste any material, time, or minerals, and perform their job thoroughly which is why they are known to increase your productivity.

● Reduction of labor fatigue

Manual welding processes are straining and require the labor to over-exert themselves in order to acquire the desired results.

However, since Self-Aligning Rotators are usually operated by a single person and are completely automated machinery, they reduce labor fatigue and allow them to rest.

Even if labor is used to perform the task of welding while the Self-Aligning Welding Rotator is rotating the workpiece for a thorough performance, it does not burden the labor as they have to usually stay in one place and do the welding while the Self-Aligning Welding Rotator ensures that it is done with accuracy.

Welding is a hazardous and exhausting job and you should only perform it through the use of automated machinery such as Self-Aligning Welding Rotators.

● Safety requirement

Self-Aligning Rotators are constructed with consideration of all safety requirements and are specifically designed to offer protection to the labor. They are immune to all sorts of potential hazards in the workplace and prevent injuries and accidents.

You can also take extra precautions to enhance the safety elements in Self-Aligning Welding Rotators such as ensuring that all the parts are perfectly fitted and there are no loose screws.

● Consistent accuracy

Self-Aligning Rotators operate with the help of certain algorithms due to which they are able to provide you with consistent results and since they have no room for errors, there is preciseness and accuracy in their performance.

Compared to manual welding, Self-Aligning Welding Rotators offer you a far more thorough job and ensure that the welding process is performed with finesse and swiftness.

Due to their low rate of potential errors, Self-Aligning Welding Rotators remain in demand throughout the automation industry.

● Cost reduction

It does not require you to hire labor for the adjustment of the workpiece during the welding process as they do not require any manual alignment.

They save up huge sums of labor costs and gain more profit with the increased production rate. They also do not waste any minerals, hence there is no loss of resources.

It is better to invest in Self-Aligning Welding Rotators than investing in labor costs.

What Kind of Characteristics do Self-Aligning Rotators Offer You?

Self-Aligning Welding Rotators offer you the following characteristics:

• No manual adjustment required
• Decreased rate of time consumption
• Improved quality of products
• Lesser job handling
• Variable speed rotation
• Economic price range
• Hydraulic facility

How Much of a Load can You Put on Self-Aligning Rotators?

The capacity of handling weights in Self-Aligning Welding Rotators depends upon the size of the rotator itself. Different sizes of Self-Aligning Welding Rotators would offer you different weight capacities.

You can not put a bigger load on your Self-Aligning Welding Rotator as compared to its actual size. For instance, if your Self-Aligning Welding Rotator is weighed 50 tonnes, you should ensure that the load you are putting on it is lesser than that amount.

There is a wide variety of Self-Aligning Rotators that can handle a load ranging from about 5 tons to 800 tonnes.

What Kind of Material Suits Better for Self-Aligning Rotators?

Thin-walled vessels are better suited as workpieces for Self-Aligning Welding Rotators as they provide you with better traction and allow the rotator to rotate freely.

The four-point suspension in Self-Aligning Welding Rotators acts as a great advantage for thin-walled vessels and allows them to be loaded easily without any sort of damage caused to either the vessel or the rotator and ensures maximum support.

What Functions can Self-Aligning Welding Rotators Perform?

Self-Aligning Welding Rotators are responsible for performing the following functions for you:

• The idler unit of Self-Aligning Welding has certain limitations such that they can only rotate in some specific directions being forward, stop, or reverse.
• Just as the idler unit, the driving unit of Self-Aligning Welding Rotators can also only perform the function of moving forward, stopping, or moving in reverse.
• The rotation speed also matters in Self-Aligning Welding Rotators and they perform an efficient job in maintaining it and keeping the pace of the production output steady.
• Self-Aligning Welding Rotators also possess the function of emergency stopping the welding process in case of any hazard or error.

Functions of self-aligning welding rotator

What is the Average Speed that Self-Aligning Welding Rotators Offer You?

One of the most beneficial features of Self-Aligning Welding Rotators is that their speed can be controlled and you can either increase it or decrease it according to your factory’s production rate.

The average speed of Self-Aligning Welding Rotators usually reaches about 6 to 60 meters per hour, irrespective of the size and motor power of the rotator.

You can also increase this range to reach your desired speed and perform the welding task at a faster pace.

You can use the electromagnetic step-less speed control in order to adjust the speed of your Self-Aligning Welding Rotator.

In What Industries can You Use Self-Aligning Welding Rotators in?

Self-Aligning Welding Rotators are most commonly used in large-scale welding factories that require maximum efficiency and safety in the workplace.

The following workplaces necessitate the use of Self-Aligning Welding Rotators in their premises and you are essentially required to perform the welding process through automated machinery here:

• Pipe manufacturing industries
• Chemical petrol industries
• Wind power fabrication
• Offshore and onshore gas industries
• Chemical & fuel storage tank fabrication
• Conventional power industries
• General and other fabrication industries
• Welding repair industry
• Any heavy cylindrical job

Self-aligning welding rotator in factory

What Makes Self-Aligning Rotators a Better Alternative for You as Compared to Conventional Rotators?

In a Self-Aligning Welding Rotator, when you mount a pipe or vessel onto the sections of the wheel brackets, their self-aligning mechanism allows the wheels to automatically align themselves, regardless of ovality, to match any diameter within their radius.

However, in conventional rotators, you need to manually adjust the wheel brackets around the frames to match the different diameters within their radius.

The top wheels of the Self-Aligning Welding Rotators either possess clutches or are free-wheeling, allowing you to mount the vessel into the sections of the wheel brackets without any risk of damaging the transmission drive due to improper loading.

On the other hand, since conventional rotators lack clutches, they are more likely to cause harm to the transmission drive if you load a vessel improperly on the rollers.

The workpiece is usually supported on four wheels with Self-Aligning Welding Rotators, which enables positive rotation, particularly when accommodating welded joints on the workpiece, and is also less prone to leaving dents on the workpiece if it is a thin-walled vessel.

Conventional rotators are more time-consuming as compared to Self-Aligning Welding Rotators and do not produce goods at such a quick pace.

Conventional welding rotator

Can You Hire a Self-Aligning Rotator on a Short-Term Basis?

Self-Aligning Welding Rotators can be purchased from the manufacturer directly if you require one in your workplace; however, you can also hire them on a short-term basis if you have a specific job to perform.

SENLISWELD offers Self-Aligning Rotators that are up for hire as well as purchase. You can also hire Self-Aligning Welding Rotators in as much quantity as you want.

Delivery of self-aligning rotator

What Are Some Tips You can Apply for the Maintenance of Self-Aligning Rotators?

When you are performing inspection or maintenance of your Self-Aligning Welding Rotators, you need to make sure that the motor is turned off and the power plug is removed.

Following are some tips you need to necessarily apply in order to extend the life span of your Self-Aligning Welding Rotator.

• You need to fill the speed reducer with 30# oil and replace it every month for the first few months, and after every half month subsequent to that.
• You should ensure that rubber rollers do not come into contact with oil or are exposed to elevated temperatures.
• In case the bearings of your Self-Aligning Welding Rotators have failed, the earth connecting cable cannot be attached to the rotators.
• There are certain requirements of Self-Aligning Welding Rotoatrs regarding the surroundings which you need to follow. They include that there should be no contact with rainwater or no presence of corrosive gas and the temperature should be as per the requirement mentioned in the instruction manual.
• Stay on the lookout for any sort of odors, noises, or vibrations in your Self-ALigning  Rotators.

Self Aligning Welding rotator in rail

What is the Maximum and Minimum Diameter of Self-Aligning  Rotators that You can Get?

Without adjusting or changing drive shafts, the self-aligned rotator may rotate workpieces with diameters ranging from 500mm to 3500mm.

The pipe diameter varies according to the size of the Self-Aligning Welding Rotator. For instance, the pipe diameter of a small-sized one which is 5 tons, will range from about 250mm to 2500mm.

While the pipe diameter of a large-sized one which is 100 tons, will range from about 1000mm to 6300mm.

The roller diameter also depends on the size of the Self-Aligning Welding Rotators but it is fixed for different sizes. For instance, the roller diameter of a small-sized Rotator which is 5 tons will be 250mm.

Whereas, the roller diameter of a large-sized Rotator which is 100 tons will be 240mm.

Self-Aligning Welding Rotator with a capacity range of about 3 tons to 500 tonnes of weight

How Long is the Warranty Period for Self-Aligning Rotators?

Warranty periods amongst different manufacturers vary depending on the quality of their products.

Most manufacturers often offer one year of warranty to their clients, in which you can report any faults or accidents that involve your Self-Aligning Welding Rotator and the manufacturer will offer you compensation for them.

A warranty entails that the manufacturer takes responsibility for its product and thus increases the trust between the client and the manufacturer. It is also proof that the product is tested and can perform your job in an efficient manner.

We suggest you only deal with manufacturers that are willing to provide a suitable warranty period for their machinery.

In What Price Range can You Purchase a Suitable Self-Aligning  Rotator?

The price range of Self-Aligning Welding Rotators varies amongst different manufacturers depending on their size as well as the material used in their production.

Self-Aligning Welding Rotators are considerably economical and serve you with good results in the long run and also do not require you to spend much money on maintenance and repairs as you can easily do them yourself.

You can easily find Self-Aligning Welding Rotators in the price range of about $2,000 to $30,000 for a single machine.

Customized Self-Aligning Welding Rotators are also available for you; however, they will cost you a bit more as compared to the standard ones.

How can Self-Aligning Rotators Upgrade Your Business?

Self-Aligning Rotators are currently in great demand due to their added benefits and people are willing to invest a great deal of money in them as they provide unmatchable results at a quick pace.

Due to this, they are bound to bring in a ton of profit for you and your business and enable you to make further developments.

You can also purchase different kinds of welding rotators for your factory through the profit you gain which will enable you to be on top of the competition as you will be able to perform all kinds of welding jobs.

Self-Aligning Rotators also increase the production process of your goods and enable you to take in large orders and work well with deadlines. You can also take more orders due to their production output.

We hope this guide cleared out all your queries regarding Self-Aligning Rotators and you are now completely aware of their pros and cons.

The purpose of this guide is to help you in the difficult process of determining which welding rotator to opt for and we hope you have made up your mind regarding the decision now.

If you want to contact us further in case of any queries or in order to purchase Self-Aligning Rotators, our team is ready to assist you further. You can also check out our purchasing guide by clicking here.