McLease FLANGEENDWELD PRO: Automated Pipe to Flange & End Cap TIG Welding System
Executive Summary
McLease presents the **FLANGEENDWELD PRO**, an advanced Automated Pipe to Flange & End Cap TIG Welding System for critical pressure component fabrication. Manufactured in India under global technical collaboration, it ensures precise, high-integrity welds. Features flexible financing (no CIBIL), 15-year service/spares assurance, AI-powered RAMC, and online support for enhanced productivity and unwavering reliability.
1. Introduction to Pipe to Flange & End Cap TIG Welding
Welding flanges and end caps to pipes are critical operations. Manual TIG struggles with consistency. Automated systems provide precise, repeatable, and high-speed solutions for these crucial joints, ensuring uniform weld quality, full penetration, and superior aesthetics, essential for safety, efficiency, and compliance.
2. McLease FLANGEENDWELD PRO: The Automated Solution for Critical Joints
Our private label system combines robust Indian manufacturing capabilities with cutting-edge global technical collaboration, engineered for unparalleled performance in automated production of critical pipe assemblies.
2.1. Key Features:
High-Performance TIG Power Source
- Advanced inverter-based DC Pulse TIG (GTAW), optional AC
- Digital control for stable arc, precise current
- Wide current range (e.g., 5-600 Amperes)
- Brands (Components/Technology): ESAB, Lincoln Electric, Fronius tech
Automated Welding Torch & Manipulation
- Mechanized TIG torch on robust manipulator (e.g., column & boom)
- Integrated AVC for precise arc length
- Optional oscillation for wider weld beads
- Integrated liquid cooling
Precision Pipe Positioners / Rotators
- Heavy-duty, servo-driven rotators or headstock/tailstock
- Smooth, concentric pipe/flange rotation
- Brands (Components): Apex, Bonfiglioli, Panasonic, Yaskawa, Siemens drives
Automated Wire Feed System (Optional)
- Integrated cold wire feeder
- Precise & consistent filler metal delivery
Intelligent Control System
- Advanced PLC-based CNC system
- Intuitive touchscreen HMI
- Stores hundreds of weld programs
- Brands (Components): Siemens, Schneider Electric, Delta, Panasonic
Precision Clamping & Fixturing
- Robust, custom-designed pneumatic or hydraulic clamping
- Securely holds pipes, flanges, end caps; minimizes distortion
- Quick-change tooling
Integrated Purge Gas Management
- Automated internal purge gas delivery & control
- Optimal inert atmosphere for high-purity root passes
Integrated Cooling System
- High-capacity, closed-loop water chiller
- Cools power source & torch, maximizing duty cycle
- Brands: Gem Orion, S&A, Hexacool, Teyu
2.2. Advantages & Benefits:
- **Superior Weld Quality & Consistency:** Full-penetration, defect-free welds with excellent aesthetics.
- **High Repeatability:** Ensures every weld meets exact specifications.
- **Increased Productivity:** Significantly faster than manual TIG.
- **Reduced Rework & Scrap:** High precision minimizes defects.
- **Cost Efficiency:** Optimizes consumables, reduces labor costs.
- **Code Compliance & Traceability:** Meets stringent industry codes with data logging.
- **Enhanced Safety:** Automated process reduces operator exposure.
- **Material Versatility:** Welds Carbon Steel, Stainless Steel, Duplex, Inconel, etc.
2.3. Uses / Applications:
- Pressure Vessel Manufacturing (nozzles, manways, end caps)
- Heat Exchangers (tube-to-flange, tube-to-header)
- Process Piping (high-pressure/purity systems)
- Boiler Manufacturing (components)
- Storage Tanks (nozzles, connections)
- Shipbuilding (high-integrity piping)
- Nuclear & Aerospace (high weld quality applications)
2.4. Technical Specifications (Typical Configuration):
| Parameter | Specification |
|---|
| **Welding Process** | DC Pulse TIG (GTAW), optional AC TIG (for Aluminum) |
| **Power Source Output** | 5-600 Amperes (configurable) |
| **Input Power** | 3-Phase, 415V AC, 50/60Hz |
| **Pipe/Tube OD Range** | 50 mm to 1500 mm+ (customizable) |
| **Flange/End Cap OD Range** | Compatible with pipe OD range, standard/custom flanges |
| **Wall Thickness Range** | 1 mm to 25 mm+ (multiple passes for thicker sections) |
| **Travel Speed** | 50 to 1000 mm/min (programmable) |
| **Wire Feed Speed** | 0-10 m/min (programmable, for cold wire feeder if included) |
| **Control System** | PLC-based CNC controller, Touchscreen HMI |
| **Torch Cooling** | Integrated Liquid Cooling |
| **Shielding Gas** | Argon, Argon/Helium Mix (99.999% purity recommended) |
| **Purge Gas Management** | Automated internal purge gas control |
| **Clamping System** | Pneumatic / Hydraulic chucks and fixtures |
2.5. Recommended Components / Brands (Readily Available in India):
Our FLANGEENDWELD PRO integrates components from renowned and reliable suppliers, ensuring quality and competitive pricing.
Welding Power Source
- ESAB, Lincoln Electric, Fronius
Control System (PLC/HMI)
- Siemens, Rockwell Automation, Schneider Electric, Delta
Servo Motors & Drives
- Panasonic, Yaskawa, Siemens
Pneumatics/Hydraulics
- Festo, SMC, Parker, Janatics
Sensors & Relays
- Omron, SICK, Banner Engineering, Teknic
Cooling System (Chiller)
- Gem Orion, S&A, Hexacool, Teyu
Cables & Connectors
- LAPP, Polycab, Phoenix Contact
Welding Consumables
- Esab, Lincoln Electric, Ador
2.6. Limitations:
- High Initial Investment: Due to specialized automation.
- Joint Preparation Criticality: Demands highly precise & consistent joint preparation.
- Setup Time: Significant for new component sizes.
- Deposition Rate: TIG is slower than MIG/MAG for very thick sections.
- Consumables: Requires high purity shielding gas & electrodes.
3. Why Choose McLease for Your FLANGEENDWELD PRO?
McLease empowers your business with an unparalleled ecosystem of financial flexibility, long-term support, and seamless digital integration that no manufacturer alone can provide:
- **McLease Private Label Quality:** Acquire a top-tier system, meticulously manufactured in India with global expertise.
- **Zero Upfront Payment:** Book your FLANGEENDWELD PRO with no advance until delivery, easing initial capital outlay.
- **15-Year Service & Spares Assurance:** Experience unmatched long-term peace of mind. We guarantee service & genuine spare parts for 15 years.
- **Flexible Finance, No CIBIL Check:** Acquire this advanced machine without rigid bank loan requirements; tailored leasing based on your capacity.
- **AI-Powered Remote Support (RAMC):** Minimize costly downtime. Our innovative Remote Annual Maintenance Contracts leverage AI for preventive insights.
- **Seamless Online Support Hub:** Effortlessly manage your machine! Order spares, raise requests, and utilize various payment modes, including "Pay Later" options.
- **Complete Ecosystem Advantage:** Holistic solution – advanced technology, flexible financing, unmatched long-term service, and digital support.
4. Commercial Aspects & Financial Solutions
Indicative cost of a standard McLease FLANGEENDWELD PRO system starts from approx. **INR [Insert Indicative Price - e.g., 50 Lakhs - 1.5 Crore depending on complexity]**. Final pricing based on configuration.
McLease offers comprehensive acquisition models:
- **Outright Purchase:** Competitive pricing.
- **Flexible Leasing Options:** Tailored lease agreements to optimize capital expenditure & cash flow.
- **Buy Back / Sell Back Options:** Clauses for future arrangements.
- **Innovative Financing:** Solutions without CIBIL/CMR checks, including potential raw material financing.
Don't compromise on the integrity or efficiency of your critical pipe assembly welds!
Contact McLease today to discuss your specific requirements and receive a customized proposal for your McLease FLANGEENDWELD PRO Automated Pipe to Flange & End Cap TIG Welding System.
Elevate your fabrication capabilities with McLease – where precision automation meets unmatched support and flexible finance.