Welding Rotator – The Ultimate Guide

A Welding Rotator is an auxiliary welding machine commonly used to weld round objects.

It will enable you to minimize tension, job toil, and manufacturing costs. They aid in the conservation of resources, allowing you to save money.

SENLISWELD is one of the world’s largest welding rotator manufacturers. With over 20 years of industry expertise in construction, we have been pleasing our clients by offering a broad selection and quality-driven products.

In this FAQ guide, we have covered everything you need to know about Welding Rotators.

What is a Welding Rotator?

A welding rotator is auxiliary welding equipment, it rotates the cylindrical workpiece normally. It will save your labor cost and make the welding quality better.

According to the adjustment method, it is divided into self-aligning rotator and conventional rotator. There are some other types, for example,fit-up rotator, tank rotator, track wheel rotator, and so on. It depends on your workpiece and requirement.

Welding rotators consist of 5 parts:

1. Base foundation
2. Wheel roller
3. Motor and bearing
4. Electric box
5. Remote control

If it is a fit-up rotator, there will be some hydraulic system and hydraulic station. Your request will all be accomplished by SENLISWELD.

A welding rotator consists of one driving wheel and one idler wheel, the 4 wheel rollers support and rotate the workpiece. The material depends on your workpiece.

You could control the speed through the remote hand control or foot panel, it can rotate forward and reverse.

Self-aligning Welding Rotator

Conventional Welding Rotator

What Is The Working Principle of a Welding Rotator?

A Welding Rotator is an efficient welding machine used to increase welding efficiency and decrease the manufacturing rate.

In those situations when you have to handle heavy round objects for welding, it plays a crucial role. All performance of the Weld Rotator depends on its wheel roller and engine. You need to load the round object on the machine.

Once the object is all set to rotate, the machine then starts the automated welding process. There is a thing to be noted that the Welding Rotator is normally suitable for round objects welding because of its rotating movement.

If you try to weld any object on the Welding Rotator, then it will be hard for you to adjust the angle.

Self-aligning Rotator

What is the Use of Welding Rotators?

The welding rotator is generally used for the assembly, sharpening, and welding of tubing, tanks, oil tanks, and other containers.

A welding rotator may be used in combination with a column and boom and a SAW device to obtain in and out longitudinal welding. It consists of a self-adjusting rotator.

As a result, this unit has advantages such as compact construction, limited cubage, lovely form, lightweight, and easy operation.

The unit may do all types of auto or manual welding. It’s able to enhance welding accuracy, reduce welding labor, and increase productivity.

What is the Self-Aligning Welding Rotator?

Self Aligning Welding Rotator

This type of welding rotator can work on several sizes of metal works without adjusting or changing the focus of the wheel.

The self-aligned rotator can be used for rotating cylindrical parts such as fuel drums, pressurized containers, silos, oil tankers, pipelines, etc.

It increases the value of productivity, velocity, and the effectiveness of your work, either using automatic welding or manual welding. They have a very crucial function in steel construction as they help to reduce crane operations and functions.

Self-aligning rotators are made of two units. These two units consist of one drive unit and one idler unit. The quantity of drive and the quantity of the idle units can be modified and altered depending on the terms of the welding operation to be carried out.

What is the Conventional Welding Rotator?

Conventional Welding Rotator

The size of the Conventional Rotator varies from 2 to 500 tons with greater loads and larger diameter ranges, for both Polyurethane wheels with excess disk and all steel wheels depending on the performance.

The structure and rotator base are carefully crafted to ensure proper balance to support the weight of the vessel or workpiece.  Both the drive and idler frames are outfitted with heavy-duty designed and machined wheel braces that protect the roller axles and bearings.

Features of Conventional Welding Rotator

• Rotators may be found in a range of applications such as pressure vessels, heat exchangers, boilers, pipe welding, and so on.
• More productive and reliable options for expanded power in energy, engine, shipbuilding, and other sectors, etc.
• Rapid development and efficiency enhancements
• Welder exhaustion may be minimized.
• There is no need to employ a crane for work management.

What is the Fit-Up Welding Rotator?

Fit Up Welding Rotator

This type of welding rotator uses the hydraulic pump station. It takes into consideration the welding operation to be done. If the welding operation requires specificity, then the best fit welding rotator is one that can specifically carry out the operation.

What is the Small Welding Rotator?

Small Welding Rotator

This small welding rotator is used for small-sized welding works such as pipes, rotating cylindrical objects, etc. The small welding has capacities ranging from 2 tons and below. The diameter is usually below 500mm.

Sound and well-constructed small welding rotators are available for sale at SENLISWELD. You can have the best delivered to you according to the requirement of you.

What You Should Know About a Welding Rotator?

1. A welding rotator is a mechanism that uses friction or rotating to weld tubes, pressure vessels, metal pipelines, and other objects without changing the circumference of the wheel. Welding products may be medium or heavy in weight.

2. The loading capability will vary from 1 ton to 500 tons. To avoid bearing damage, some welding rotators have a car wiper engine and cables. While others have a manual metal knob.

3. It is made up of three parts: the idler, the motor, and the electrical controls.

4. The welding rotator’s frame and structure are assembled to ensure precise and consistent alignment to withstand the pressure of the metal substance being worked on.

5. They are all equipped with bearings to minimize friction. The gear also aids in rotational transmission. The speed controller controls the machine’s speed.

6. The welding rotator’s voltage may be adjusted. Depending on the production’s requirements and the numerous locations where the production is located. For example, in Nigeria, the voltage is 230 volts, while in Angola, it is 220 volts, and so on. You may also adjust the voltage to particular locations.

7. The rollers are usually constructed of PU content, although steel materials are required for greater tonnage.

SENLISWELD enables you to enjoy stress-free, quick, and easy welding to help in efficient development and quality craftsmanship by providing the best fit personalized welding rotator for your job.

What Is The Difference Between a Self-Aligning Rotator And a Conventional Rotator?

The primary difference between a self-aligning rotator and a conventional rotator is the manual and auto-handling factor.

• Self-Aligning Rotator: A self-aligning weld rotator is the best option to weld a variety of objects without the need of adjusting the angle and rotating wheel. This Welding Rotator adjusts and aligns the object automatically and performs welding performance at a high rate.

The working procedure of the self-aligning weld rotator depends on the two power units.

The first power unit is the idler and the second one is the drive unit. You can adjust the quantity of both units according to the object and welding procedure to be carried out.

• Conventional Rotator: The Conventional Weld Rotator is a heavy-duty manual handling Welding Rotator. The most out-ranking feature of this Welding Rotator is the weight load capacity. Handling heavy objects is like a cup of tea for the conventional Welding Rotator.

For efficient rotating of objects, the wheel of the Conventional Welding Rotator is Polyurethane.

The same as the Self-Aligning Rotator, the Conventional Rotator also has two working units; Idler and Drive.

Both these working units are fitted with the wheel roller. All these together perform a high-class performance with less welder exhaustion.

Conventional Rotator

Self-Aligning vs. Conventional Rotator – Which One To Buy?

Okay, so you are confusing between Self-Aligning Rotator and Conventional Welding Rotator, can’t decide which one to buy? Well, no doubt, both these Welding Rotators are rock stars in their shoes.

• Self-Aligning Rotator: The Self-Aligning Rotator is an efficient automated welding machine. In self-Aligning, you only need to load the object, and the rest is on the machine’s shoulder. By adjusting the quantity of the working units, you can weld any round object efficiently.

• Conventional Rotator: The working procedure of the Conventional Rotator is the same as the Self-Aligning Weld Rotator, but the conventional Welding Rotator is for manual aligning of the objects.

The two working units, along with the polyurethane wheel roller, perform high-quality welding. The best part about the Conventional Weld Rotator is you can weld objects of any size without the fear of wear and tear.

If you want to enjoy auto aligning, use the Self-aligning Welding Rotator. But if you are satisfied with the manual aligning of the objects, invest in the Conventional Welding Rotator.

What is the Mechanism of Operations in Welding Rotators?

Theoretically, this sounds difficult, but the welding rotator has a basic operating process.

The welding rotator works by rotating the substance to be operated on, which is normally a cylindrical object. The welding process will take place when the rotation is in motion.

This essentially ensures that the welding rotators retain and move cylindrical items. The welding operators execute their duties without needing to adjust their location. They continuously turn the vessels themselves, liberating them of crane and tension.

What are The Structural Parts of the Welding Rotator?

Welding rotators have several structural parts that are quite distinct from others due to the design of the welding rotator. Generally, the structural parts of a welding rotator include;

• The rotating vessel, usually wheels – this is the part that turns or rotates the cylindrical vessels and circular materials to be worked on.
• The idler – this part that supports the rotation of the device and as such can alter the direction of the output shaft.
• Motor speed regulator – this is known as the transmission device in some welding rotators. This part controls the velocity of the rotation.
• Rotating wheel border – this part upholds the wheels. This is also known as a rotating wheel frame.
• The remote controller – foot pedal control or hand remote control, they are used to modify and adjust the speed when needed.
• The power motor – the DC motor is mostly used but some welding rotators use an AC motor. This part supplies power to the machine and also aids in speed regulation.
• The electric box – these are the integral parts and as such are needed for the effective running of the welding rotator. Other features can also be added to the machine at the request and requirement of the customer or company.

What is the Characteristic Advantage of a Welding Rotator?

Some characteristic advantage of the structure includes:

• The welding rotator can be assembled according to the weight of the material, the distance between two ends of the material and the length of the material to be worked on.
• The in-built motor speed regulator gives room for an increase or decrease in the speed of the welding operation. It leads to the welding at your pace and causes the speed to be stable.
• Due to the adjustable and modifiable structure of the welding rotator, it can work on various ranges of distance and diameters.
• The variable components of the welding rotator allow for its wide usage and application.

What Can You Use a Weld Rotator For?

The welding rotator can be used for several applications, some of them includes:

• It is used to congregate and weld cylindrical materials.
• You can use welding rotators for Metal Inert Gas welding
• It can be used for Sub-Arc Welding
• They can also be used for Tungsten Inert Gas Welding etc.

What Can a Welding Rotator Do for You?

Self-aligning Rotator

• It serves as an automated welding device. It’s more like welding on the go, especially for cylindrical objects, tankers or pipelines, and other rounded objects. It lets you weld without too much handling which minimizes stress.
• It handles both light and heavy-sized materials. The size of the device to be used depends largely on the size of the material and the welding job to be done.
• It makes your welding experience faster and efficient as you can comfortably control the speed of the welding rotator.
• Weld rotators can be used to work on pressure vessels, pipelines, oil tankers, heat exchangers, etc.
• Welding rotators, as a result of their characteristics, increases the quality of production, minimizes handling, and reduces the crane of handling.

How Welding Rotator Makes Your Welding Process More Efficient?

Take an example. If you hire laborers to do the welding task, then have you an idea of how much they will cost? You need to pay each labor separately, which will cost a pretty high amount altogether.

While on the other side, a welding rotator is less expensive than the laborer’s cost and is highly efficient in performance. So, it is pretty simple.

If you hire laborers for welding work, then there are 50% chances that there will be an error in the output. While on the other side, Welding Rotator is an expert in performing accurate work at less cost.

Following are the benefits you will enjoy with the Welding Rotator;

• Less Time Consumption: Labor takes more time in getting the work done. If you have an automated Welding Rotator you can get the task done in no time.
• High-Production Rate: Of course, the welding tool will produce more production rate than the laborers do.
• Error-Free Work: This is the most satisfying benefit. By having a Welding Rotator you have the surety that the work will be error-free no matter what.

The only possible chances of error in the Welding Rotator are due to improper handling.

So, in general, the benefits of a welding rotator are as follows:

• Since there is a substantial reduction in the physical movement of the welding material, it allows you to conduct accurate, right, and reliable welding operations.
• Welding rotators improve the efficiency of welding processes, reducing the operator’s and the operation’s operating time.
• It enables an uninterrupted welding process with relaxation.
• It protects both you and your welding materials. It is constructed in such a way that it would not damage or produce damages.
• It improves output speed, value, and efficiency.
• It improves the effectiveness of the results of your welding process.
• Welding rotators help you save money by growing the level of your performance in proportion to your input.

How To Select the Best Welding Rotator for Your Welding Operations?

Self-aligning Rotator In Workshop

While there are welding rotators that may be used for basic welding operations, there are several items to remember when choosing a welding rotator that is appropriate for your workpiece.

• Have a look at the product that would be worked on. Consider the vessel’s scale and strength. If you know the scale of your circular vessel, you can get a quote from Senlis Weld as soon as you send us your message.
• Assess the device’s durability and c Evaluate the welding rotator’s loading capability.
• Try welding rotators that are set up to operate for the voltage in your current spot. This is important since the current of welding rotators varies depending on the location you are in where the welding process is performed.
• Know the machine’s certification. Choose welding rotators that are qualified and accredited in your field. For example, the United States requires UL certification for its operations. CE qualification is required in certain European nations.

How to Maintenance Welding Rotators?

Welding rotators are typically powerful, and as such, maintenance cannot be overlooked.

Here are a couple of ideas for maintenance:

• When using any unit, such as a welding rotator, search it for loose screws, nuts, and nails. Before you use the machine, tighten the screws.
• Before starting a new project, make sure there are no weld bits or remains on the unit. This can result in an obstacle in the system.
• Keep an eye out for odd and unexpected noises and movements from the unit, as well as unpleasant scents. Until you use it, do the required repairs.
• Ensure that the welding operation’s job load is appropriate for the welding rotator in usage. For hard welding products, do not use a welding rotator with a lower capacity.
• Choose SENLISWELD for the latest technical repair advice for you.

How To Avoid Accidental Damage During Transportation?

You can effortlessly avoid accidental damages during transportation by using proper safety protocols. The safety protocols you need to apply;

• Wearing proper leather gloves: Always follow the general rule of thumb, and apply your safety first. Either you are welding round objects or any irregular shape object; make sure that you are wearing welding leather gloves for your hand protection.
• Handling tool: There are a lot of Welding Rotator handling tools available in the market, make sure that you are using one while performing the welding process.
• Eye protection: How can you neglect the importance of eye protection in the welding process? Either you are a welding expert, or a beginner, wearing eye protection is a must. Wear high-quality eye protection so that the rays don’t pass it.

• Transporter: Once the welding process is done, don’t try to move the object yourself. Use a transporter to move the object effortlessly and conveniently.

So, if you apply the mentioned safety protocols perfectly, then we guarantee, you can perform and transport safely during welding.

Is a Welding Rotator Same as a Welding Positioner?

Many people get confused with these two terms and also for the fact that they have few similarities. They both rotate spherical and cylindrical welding materials but differently. They increase the efficiency and effectiveness of your welding operation.

Welding Positioner: Some objects are complex in shape that you have to wonder how to weld and position them. A Welding Positioner is a welding tool used to rotate, move, and hold two complex shape objects for the deep and precise weld.

The welding rotator is quite similar to a welding rotator but they are not the same. The welding positioner is a device that carries out its welding operation by grasping and limiting the motion of the welding material at a fixed point but rotating it according to the degree of the angle.

Due to this structure of the welding positioner, it can be used for any shape and form of welding material. However, for welding rotators, the case is different. The welding rotator tends to be operational only on spherical or cylindrical welding materials due to the constant rotary movement of the wheels.

Either you want a Welding Rotator or a Welding Positioner, SENLISWELD has everything for you.

What is the Pricing of a Welding Rotator?

The pricing of welding rotators is not strictly dictated by the machine’s selection. The price of a welding rotator may be determined by its scale, functionality, activity, and user-customizable choices.

SENLISWELD offers low-cost welding rotators that can be tailored to the specifications and achieve the required results.

Where to Find the Best Welding Rotator Manufacturer?

There have been several Manufacturers that have shown up. As a result, there are just a few reliable manufacturers to purchase high-quality welding rotators from.

However, it is preferable to obtain your welding rotators from a reputable manufacturer rather than making an indecisive order. All and every business loves quality assurance from the product they are buying. This is what you get from the SENLISWELD manufacturing company.

Over the past 20 years and more, we have obtained several comments from individuals and businesses about the significant increase in their pace of output as a result of their sole decision to purchase their welding rotators from the finest – SENLISWELD.

What Problems Will You Face If You Buy a Used Welding Rotator?

The common issues you will face on buying a used Welding Rotator are;

• Slag Inclusions: Slag Inclusion is the trapping of non-metallic particles in the metallic weld surface. These non-metallic particles destroy the weld quality and make the surface rough. The common reasons for slug inclusions are the less efficient welding machine and technique.
• Improper deep fusion: Used Welding Rotators are less efficient in performance. On the parts of the object where you have to weld a deep fusion for a strong joint, used Welding Rotator lag in performance.
• Cracks: We have also noticed that the surface of the object weld by a used Welding Rotator is also rough and cracky in texture.

What are the Common Applications for Heavy-Duty Welding Rotators?

• Welding of heavy, dense dishes stops on an automatic basis.
• Containment vessel part cladding.
• Wind tower production line
• Tandem close gap welding stations for stiff pressure vessels.
• The base for a wind electricity plant.
• Rotor housings, pulleys, and other parts are used in the shipbuilding and coastal industries.

What Steps Are Included in the Welding Procedure?

The welding method consists of a series of operations that include introducing the work material to the welding system (or vice versa), generating linear movement between the work material and the welding machine, monitoring the weld quality, such as rpm, orientation, voltage, and so on, and re-positioning the work material for another weld.

The term “automated welding” refers to the process of automatically monitoring the relative motion of the weld head and the work material.

Advanced machining methods include metal inert gas (MIG), tungsten inert gas (TIG), and submerged arc welding (SAW).

The key advantages of automatic welding are increased efficiency as a result of shorter cycle periods and consistent performance as a result of a lower degree of weld flaws as a result of more direct monitoring of the welding operation.

On the negative hand, welding configuration is limited to flat parallel lines, and setting time is augmented.

Do you need assistance deciding on the best welding rotator for your task? Want to make the welder more relaxed while boosting performance?

Welding rotators are available in a variety of sizes and holding capacities at Senlis Weld. We carry the whole line.

Do You Want To Increase Quality of Production?

SENLISWELD is a manufacturer of welding rotators of various sizes, loads, and capacities with more than 20 years of experience in manufacturing best-suited performing welding rotators.

We provide assured advice and guidance on the purchase, use, and servicing of all welding rotators, which increases the quality of your manufacturing, the output of your craftsmanship.

This makes your clients rejoice and obtain service, and increases your likelihood of acquiring bigger offers in the long term.

Welding Rotator Automation

At SENLISWELD, you can own satisfying welding rotators that enable you to operate without worrying about the performance of the machine or the result of your output because confidence and high quality are part of our hallmarks to best serve you.

When it comes to dependability and timely distribution of all types of welding rotators, SENLISWELD is your best bet.

We are the welding rotator company from whom you would like to purchase your welding machines because we have the most reliable and powerful welding rotators, tailored to your specifications.