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Overlay

The Encompass Gen II MIG Overlay System is a full function (vertical and horizontal travel, AHC, oscillation and wire) weld system designed for multi-pass GMAW welding. This weld system is designed for the automatic welding of plate surfaces in a box configuration of 9’ by 3’ in two (2) configurations, boiler and vessel modes. In boiler mode the system is designed to weld in a vertical application, oscillating horizontally across the weld bead. In vessel mode the system is designed to weld in a horizontal application, oscillating horizontally.

Mounting of the weld system is quickly accomplished via utilization of a box travel beam and rack system that can be mounted in both vertical and horizontally applications. The carriage, index beam and torch travel assemblies are modular in design and can be quickly installed on the travel beam. This arrangement allows quick and easy maintenance or adjustments of the assemblies without complete removal of the system.

An intelligent servomotor for the low torque end requirements, to traverse the carriage assembly quickly along the vertical beam, drives the vertical travel axis. This motor is a complete servo motion control system with integrated multi-axis motion control, amplifier and feedback controller. The oscillation, torch height, wire feed and horizontal travel axes of the weld system utilize DC high torque smart stepper motors with integrated motion controller and micro-stepping drive.

Both travel axes incorporate a two-speed travel jog system that allows for precise torch positioning as well as rapid traverse in order to position the carriage assembly quickly and precisely during both weld and setup modes.

The MOS utilizes a low voltage power supply that provides power for the mechanical system and distributed process control for multi-pass welding.

EMI also provides an optional “Cone and Dome” subsystem for the MOS when used for vessels cone or dome applications.

there are two different versions of that machine.  A Gen II and a Gen III

Machine Motions

VERTICAL TRAVEL AXIS The vertical travel axis is used to traverse (move) the carriage assembly across the material to be welded in the vertical direction.
HORIZONTAL (INDEX) TRAVEL AXIS The horizontal travel axis is used to traverse (move) the index beam assembly across the material to be welded in the horizontal direction.
AUTOMATIC HEIGHT CONTROL (AHC) This axis is utilized to control the distance between the weld wire and the weld surface.
OSCILLATOR (OSC) This axis is used to position the torch assembly across (perpendicular to the weld joint) the weld surface. The oscillator is used to “weave” the torch during the weld process.
WIRE FEEDER This assembly is responsible for delivering and metering the filler weld wire at the desired rate when welding.

General Specifications:

WEIGHT (W/OUT WIRE, CABLES & VERTICAL BEAM) 125 pounds
VERTICAL BEAM LENGTH 10 feet
HORIZONTAL INDEX BEAM LENGTH 60.75 inches
OVERALL HEIGHT OF WELD SYSTEM 16-17 inches
MINIMUM ID FOR INTERNAL VESSEL WELDING 30 inches
MINIMUM OD FOR EXTERNAL VESSEL WELDING 48 inches

WELD SYSTEM PERFORMANCE:

AHC TRAVEL 6 inches
INDEX WIDTH 0 – 6 inches
OSCILLATOR PIVOT 0 – 360 degrees
WIRE SIZE 0.045” Standard
WELD VOLTAGE 10 to 38 volts, 1-volt increments
WELD CURRENT 0 to 300 amps, 5 amp increments
WIRE SPEED 50 to 600 inches per minute, 5 ipm increments
TRAVEL SPEED 0 to 100 inches per minute, 1 ipm increments
OSCILLATOR WIDTH 0 to 100, 1 increment
OSCILLATOR SPEED 0 to 100, 1 increment
OSCILLATOR IN DWELL TIME

1. MAX – 20 tenths of a second (2.0 sec)

2. MIN – 0 tenths of a second

3. INC – 1 tenth of a second (0.1 sec)

OSCILLATOR OUT DWELL TIME

1. MAX – 20 tenths of a second (2.0 sec)

2. MIN – 0 tenths of a second

3. INC – 1 tenth of a second (0.1 sec)

PRE-PURGE TIME 3 seconds
POST-PURGE TIME 3 seconds
BURN BACK TIME 0 to 200 ms, 1 ms increments
AHC RESPONSE 1 to 30, 1 increment
INDEX WIDTH 0.01-inch increment
TRAVEL RETRACTION SPEED 185 inches per minute
PENDANT 12”L x 7”W x 5”D
POWER SUPPLY CONTROL BOX 13”L x 8”W x 6”D
WELD MODE SELECT Via pendant
NUMBER OF CONTROLLED AXIS 5 (horizontal & vertical travel, oscillator, AHC, wire feed)
TYPE OF MOTION CONTROL 1 Integrated DC servo motor & 4 Integrated DC stepper-motors
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