It doesn't get any smaller or more effective than this: The HX 16 Orbital Weld Head for compact cooling systems sets new standards
It's all in the name of the new orbital weld head from Orbitalum Tools GmbH in Singen, Germany: HX 16. HX stands for heat exchanger and for the welding of pre-mounted elbows in tight pipe bundles of heat exchangers into a pipe coil. At present, there is no other solution as effective as this one in the world.
Traditionally, complex heat exchangers for cooling systems were made of copper, and the pipe elbows for it were soldered. The high price of copper prompted manufacturers to switch over to stainless steel for production (material number 1.4402, DIN XCrNiMo 17-12-2, US standard AISI 316). Stainless steel can only be joined economically, reliably and in high quality with tungsten inert gas (TIG) welding in conjunction with mechanized orbital welding. All open orbital weld heads or closed weld heads commonly available on the market require lots of space for being positioned between the individual pipes of a pipe bundle, which would reduce the effectiveness of the heat exchanger and enlarge its size.
A pipe spacing of only 24 millimeters is sufficient for the HX 16 from Orbitalum for extremely easy positioning and clamping thanks to its outer diameter of only 60 millimeters. This minimum dimension has since become the "industry standard", as design engineers from every well-known air-conditioning technology manufacturer in Germany, Italy, France and India design their air-conditioners accordingly, i.e. stainless-steel pipes with an outside diameter of 15 to 16 millimeters (wall thickness of 0.5 to max. 1 millimeter). Only the length of the elbows varies depending on the manufacturer's design, which is why Orbitalum supplies the weld head in three different lengths.
The ingenious orbital weld head scores points in the areas of economy and efficiency when compared to conventional weld heads. A "wall" with pipe outlets can be fully fitted with elbows before joining and then welded in any order. For conventional orbital weld heads, the principle of fit elbow, weld, fit elbow, weld etc. applies, always starting from the center of the pipe sheet and working outward. If quality testing reveals a faulty weld later on, all elbows must be disconnected and new ones must be welded on in the worst case scenario (fault in the middle of the bundle) due to the accessibility factor. With the HX head, only the affected elbow would have to be replaced. This design-based advantage also makes the Orbitalum system the ideal tool for unbeatably cost-effective repairs. The head is only 1.5 kilograms in weight. In contrast to open weld heads with a cumbersome hose assembly, all connections for power, gas and cooling water are permanently integrated in the HX.
All orbital welding power sources from Orbitalum automatically detect the head and its properties so that the operator only has to call up his or her specified jointing program and start the joining process before beginning to weld.
To increase productivity, the operator can work with up to two HX heads on one machine in an alternating fashion, which reduces manufacturing times and downtimes considerably.
For this purpose, only the optionally available Orbitwin Switching Unit is required. By pressing the respective start button of the weld head being used, the previously assigned program is automatically called up from memory. The weld head which is not being used is locked in the interim and can be positioned for the next welding task in advance.
Orbitalum Tools GmbH is a world leader in the provision of complete solutions for orbital metal pipe cutting, beveling and welding technology.