Fit up welding rotators, also known as hydraulic rotating rollers, are auxiliary equipment used for welding or assembly of large cylindrical workpieces (such as pipes, storage tanks, pressure vessels, etc.). They combine hydraulic systems and roller support technology to achieve stable rotation, precise positioning and efficient operation of the workpiece.
It is usually composed of a set of adjustable rotators and a set of hydraulic assembly (fit up) rotators. According to the customer's vessel pairing requirements, they can move on the track at the same time or separately, playing the role of pipe pair welding and handling.
1. Roller assembly
Usually composed of a driving wheel and a driven wheel, the motor drives the driving wheel to drive the work-piece to rotate.
The roller surface may be coated with rubber or polyurethane to prevent scratches on the work-piece surface and provide sufficient friction.
2. Hydraulic system
Hydraulic motor: drives the roller to rotate and provides smooth power output.
Hydraulic cylinder: used to adjust the roller spacing or height to adapt to workpieces of different diameters.
Hydraulic pump station: provides power for the system and adjusts the speed and direction through the control valve.
3. Support and adjustment mechanism
The roller bracket that can be raised or lowered or translated ensures the center alignment of the work-piece through hydraulic synchronous control.
Some equipment is equipped with automatic centering function to prevent the workpiece from swinging.
4. Control system
Manual or PLC automatic control to adjust the rotation speed, direction and roller position, some support remote operation.
| Item |
Specification |
| Rated load carrying weight |
80T |
| Applicable cylinder diameter |
Φ500-6000mm |
| Roller diameter x width |
Φ450*240mm |
| Roller Material |
Imported polyurethane |
| Wheel adjustment method |
Hydraulic tilt lift adjustment |
| Hydraulic cylinder stroke |
250mm |
| Oversize |
Length3600*Width990*height 905mm |
| Motor |
3kw |
| Other loading weight |
20T,40T,60T,100T,120T,150T,200T,customized |
| Rail support |
Optional |
Fit up rotator can be used in may places, such as circumferential welding (such as submerged arc welding), where the workpiece rotates at a constant speed to achieve high-quality welds; when assembling large containers in sections, it can be used for grouping and assembly, and accurately aligning cylinder sections or heads; it can also be used for inspection and processing.
How to choose the right hydraulic fit up roller frame?
1. Weight: Determine the maximum weight of the workpiece. The rated load of the hydraulic fit up rotator must be ≥1.2 times the weight of the workpiece to ensure a safety margin.
2. Diameter range: According to the minimum and maximum diameters of the workpiece, confirm whether the adjustment range of the roller frame matches.
3. Length: Long workpieces (such as more than 10 meters) need to increase the number of roller frames (such as more than 3 groups) to avoid deflection.
4. Speed requirements:
Determine the speed range (such as 0.1~1.5r/min) according to the welding or assembly process, and check the speed regulation method of the turning roller (frequency stepless speed regulation or mechanical gear speed regulation).
How many tons can a hydraulic roller rotator bear?
1). Light roller rotator
1~10 tons, used for welding or rotating small pipes and tanks, laboratory equipment, etc.
Features: manual or simple hydraulic control, rollers are mostly made of rubber or polyurethane.
2). Medium roller rotator
10~50 tons, suitable for medium-sized pressure vessels, large pipelines, steel structures, etc.
Features: electric or hydraulic drive, adjustable speed, rollers may use steel core + rubber coating to enhance friction.
3). Heavy roller rotator
50~200 tons or more, suitable for large storage tanks, ship sections, heavy machinery parts, etc.
Features: multiple sets of roller linkage, high-strength steel structure, equipped with high-power hydraulic system and safety locking device.
4. Customized roller rotator
The load-bearing capacity can reach 500 tons or even higher, mainly used for super-heavy workpieces such as nuclear power equipment and spacecraft shells.
Features: Non-standard design, may adopt split structure, composite roller or additional support system.
How about lead time?
Usually we have 5T to 100T in stock,over 100T rotator we need 10 days for production,you can send us your request then we will design for you and promise the fastest lead time.
Can the hydraulic roller rotator travel on the track?
The fixed hydraulic roller rotator is only used to fix and assemble pipes or cylinders. The movable roller rotator can add travel wheels and power devices according to your requirements to make it travel along the preset track. It is mainly used for segmented welding and large assembly.
Packaging & Shipping
√ Wuxi Lemar Machinery Equipments Co., Ltd. is a high-tech enterprise specializing in automated welding equipment and H-beam equipment. Our company has developed a series of professional equipment such as CNC cutting equipment, Beveling equipment, welding equipment, etc.
√ On the basis of continuously absorbing advanced technologies and processes domestic and abroad,our products are widely used in pressure vessels, petrochemicals, power stations, heavy machinery, ships, steel structure buildings and other industries.Most of the products have reached advanced international levels.
√ Lemar Machinery has won the praise of users with the corporate spirit of "motivational and enterprising, honest and trustworthy", and is wi ling to work hand in hand with friends from all walks of life to realize its vision.
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