Circle Welders – Automated Welding & Machines to Match
Dedicated welding equipment, such as automated circle welders or rotary welding equipment, are great additions to any welding/fabrication operation. Our line of premier Welda-Round machines offer options for manufacturing projects of almost any alloy or welding method. Automated circle welding systems are designed to be economical and repeatable.
Some major benefits of circle welders are:
- Higher levels of production than manual process and even robotic systems
- Lower installation costs than other automation cells
- Highly repeatable welding output
- Easy to set up, operate and maintain
- Takes up minimal shop floor space
Let’s get into our rotary welder offerings, some of their standard features and how you can customize each piece to fit your welding projects.
MODEL 300 – MIG Circle Welder
This is the most popular circular welding system in the welding industry today! With a 75-pound head clamping force, this machine is heavy duty yet compact. Each 300 Model Welda-Round has the latest automated welding digital controls and technology for easy setup and operation.
- DC rotation drive
- Adjustable operation console
- CNC machined tooling arms
- MORE…
MODEL 350 – Rotary TIG Circle Welder
The Model 350 is a high capacity rotary welder that is capable of a single revolution weld cycle in a matter of seconds. It has high-frequency protection as well as drive delays and overlap controls. This robust TIG welding machine has a 360-degree rotation torch, perfect for any demanding job.
- Adjustable 8-inch vertical stroke
- Standard air-cooled torch
- 300 amp and 70% duty cycle
- MORE…
MODEL 500 – Port Welder
The larger and more robust Model 500 port welder offers extreme welding rigidity and accuracy. The duel torch system and a 100-pound clamping force are all situated on a heavy-duty frame. It’s the perfect machine for larger weldments and all other circumferential welding projects.
- 500 Amp duty cycle
- 50-550 IPM integral wire drive
- .7 to 14 RPM rotation speed
- MORE…
MODEL 550A – Aluminum Rotary Welder
Ultimate wire feeding capability for aluminum spud welding. When welding aluminum special care must be taken to properly feed soft aluminum wire. The 550A was developed using a slip ring assembly allowing the wire spool to rotate with the torch. This eliminates whip or twisting of the aluminum wire to prevent weld defects.
- Flexible configurations for headers and other pressure vessels
- Can be configured for all Arc Welding Processes
MODEL 600 – Fitting Welder
For unbeatable speed and quality, the Model 600 fitting welder is exactly what every modern welding shop needs. The arc time on this machine is drastically reduced as the rotating torches can travel 180-degrees and has an adjustable overlap. With a hefty 750-pound head clamping force, the model 600 Welda-Round is an all-star piece of welding equipment.
- Floor mounted operator console
- Fabricated tooling arm
- Wire drives
- MORE…
Rotary Welder & Circle Welder Machines Made in Wisconsin USA
All of our standard circle welders can be fully customized for your unique requirements. Bancroft Engineering designs and builds welding equipment out of Waukesha, WI—specializing in stand-alone machines to fully robotic automated systems.
Ready to learn more about a customized welding system for your company? Call us at 262-786-1880, or email: sales@bancrofteng.com to get started.
Trade-In Trade-Up Welding Machine Program
Is your Bancroft Welda-round starting to show signs of aging? Do you think it might be time to replace your old Bancroft welding machine and trade-up to a newer, more efficient model that can truly fit your needs?
We recently had a customer approach us with this exact situation. We started our normal process of quoting them a new machine and/or to rebuild their existing equipment. They responded with, “I like the rebuild idea, but we cannot afford the downtime.”
Bancroft Rotary Welding Machines
This got our sales team thinking! “We either need to stock a refurbished 300 Welda-round so we can send it to our customer and trade them for their current machine. OR, can we send a new machine at a discount and take their old machine in on trade?”
The answer? Our new Trade-In Trade-Up Program! Trade-in your old Welda-round and your new rotary welding machine will come with all the same options as your current machine plus give you the capability to add on more features to suit your needs.
We hope our new Trade-In Trade-Up offering will significantly help our existing customers. Here are a few big perks for utilizing this new program:
- Use the latest and greatest in automated welding technology
- Ensures you’ll get a great price for your former or out-dated machine
- Eliminates the inconvenience of downtime
- Removes the hassle of waiting for the older machine to be sold, uninstalled and moved out of the way
Get Started with the Trade-In Trade-Up Welding Machine Program
To trade-in your old welding machine, simply send us a picture of it. Within 48 hours you will receive a quote that will include your trade savings. We guarantee a minimum of $5,000 in savings regardless of your machine’s condition!
Included in this program, Bancroft will offer FREE shipping of your old equipment back to our plant in Waukesha, WI.
For complete details, call: 262-786-1880 or email us at sales@bancrofteng.com.
Automated Welding Equipment: To Replace or Not to Replace?
It can be difficult to know if you’re making the right decisions when it comes to automated welding equipment expenses. How do you know if it’s the right choice to purchase a new piece of equipment or continue to repair an old one? We’re here to help ease that decision process. Read on to learn if you should or should not replace your current automated systems.
First, can you afford downtime?
If you’re running five welders and one goes down, that’s a much different situation than if you’re running one or two and lose one—that’s at least half of your production lost! Some businesses can’t afford downtime, while others prefer to maintain older equipment.
Next, assess what life is still left in your current automated welding equipment
It’s important to understand what the annual maintenance costs are of all your current welding systems. Tracking those costs over time is one of the best indicators of the longevity of a machine. It’s safe to say that almost all machinery will inevitably wear out. Knowing what you’ve invested into the machine over the past few years will give you a baseline of where it’s at when you’re looking at making the decision to either replace it with a new system or retrofit the welding equipment completely.
For example, if a machine is 15-20 years old and in the past decade all you’ve done is routine maintenance, it’s more likely you’ll soon face a major repair. So, it might be a good time to look into buying a new piece of equipment. However, if you have an older machine you recently overhauled or refurbished, it’s probably better to hold onto it and reap the benefits of your investment.
Finally, are the critical electronic components still available?
In today’s innovative manufacturing world, electronic manufacturers are making components obsolete and discontinuing production of system components earlier and earlier. Make a list—or ask the manufacturer for a list—of the critical components. A quick internet search will take care the rest.
Still not sure?
If you decide it’s time to replace your welding equipment or retrofit an older machine, give Bancroft Engineering a call and let us make the next 20 years worry free!
Bancroft Engineering, located in Waukesha WI has years of experience designing, building and updating automated welding equipment for every sized project.
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Google vs. Bancroft + Happy Holidays!
GOOGLE, What do people most frequently ask about welding?
- What does it take to be a welder?
- Are welders in demand?
- Why do welding rods stick?
- How long does it take to become a welder?
- Do welders make good money?
- What is the highest paid welding jobs?
GOOGLE, What are the most difficult questions to answer about welding?
- Is it better to use fixed welding automation or a robot?
- Can an air-cooled robotic MIG gun be used instead of a water-cooled gun?
- What is the benefit of touch sensing?
- Do I need a seam tracking system?
- What type of payback can be expected from an automated welding system?
GOOGLE, Is there an expert that can help me make decisions about welding automation?
While Google might have the answers to the simple questions, let Bancroft answer the more complicated welding automation questions! We take the time to understand your welding requirements and offer advice that is customized to your needs. Bancroft Engineering offers a wide range of standard welding equipment such as weld lathes, synchronized drive lathes, linear welding systems, seamers and more. We also offer custom equipment and robotic welding cells to fit any part size, weight or geometry.
Get in touch with us today to get ALL of your automation questions answered
Should You Upgrade to a Longitudinal Seam Welder?
If you are currently using a manual process to do your linear welding then this article is for you. We have highlighted the benefits of upgrading to a Bancroft longitudinal seam welder and show you how it can improve your welding process. No matter what type of parts you are seam welding, automation can help you to increase your productivity while decreasing welding errors.
For many industrial applications, it is necessary to form the material into cylinders or rectangular tubes within the part production process. The edges are then welded together to form a rigid structure. Instead of holding the edges in alignment and manually tack welding, longitudinal seamers provide the aide of automation.
Automated longitudinal seam welders offer many benefits and also help to eliminate common problems such as:
- Leaks around tack weld areas
- Uniformly chilling of the joint to prevent distortion and oxidation
- Dimensional accuracy and repeatability problems
Welded linear seams are uniform across the entire length and can be done using a variety of welding methods:
- MIG
- TIG
- Submerged Arc
- Plasma
- Laser
A longitudinal seam welder gives the operator repeatability with the touch of a button. Seamers increase production while providing consistent quality welds from piece to piece. These machines are cantilevered from one end to allow loading and unloading of open and closed sections directly to the mandrel arm.
Seam welders can be used for external or internal welding applications. Below is a photo example of an internal process:
There are many ways to weld a seam. Browse our website for more information and give one of our engineering experts a call. We can walk you through the options and help you decide what equipment will improve your welding process the most.
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Looking to Automate Your Welding Process?
Pondering between fully or semi-automatic welding systems?
Fully automated robotic welding strives to completely remove the need for skilled labor to produce welds. Everything is done by the machine itself from setup to production—all the way down to the cleaning of the welding torch. While the initial equipment investment tends to be higher, there are many advantages to fully automatic welding over manual welding:
- Produces more consistent welds
- Ideal for large volume production
- Higher quality welds
- Improves worker safety
- Reduces production cost
A popular alternative to fully automatic welding is semi-automatic welding systems. These machines generally require an operator to load and unload product. Depending on the job, semi-automatic systems can be as efficient and many times easier to operate than a robotic system.
Bancroft offers a wide variety of equipment for both fully-automatic and semi-automatic welding. Both types of equipment offer processes that are much quicker and more effective than manual welding. It also produces better, more consistent welds than welding by hand. There is an even greater benefit if larger welds are involved, multiple passes are needed, or higher part quantities are being produced. Automated equipment is also ideal for industries where weld strength plays an important factor, as the welds are of higher quality.
Bancroft is always ready to start a completely custom machine design and also has a variety of standard semi-automatic welding equipment in stock including welding positioners, Welda-rounds, and weld-lathes.
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Rebuilding Your Aging Welding Equipment
Using outdated or broken welding equipment can be hurting your company’s productivity, quality, ROI and more. The cutting-edge technology that was out 5-10 years ago is far behind the welding equipment of today. Rebuilding your current, outdated machines can improve welding performance and give you the reliability your company needs.
Bancroft does more than offer new welding equipment—we can rebuild and update your old and worn out machinery, whether you purchased it from us to begin with or not.
Benefits of Rebuilding Your Aging Welding Equipment:
- Saves money
- Extends equipment life
- Decreases downtime
- Increase welding quality
- Optimizes power efficiency
- Decrease training time
- Expands machine’s versatility
During the rebuilding process, Bancroft will make aesthetic improvements, replace any worn parts, inspect the machine for future problems and update all welding components that may have become obsolete.
Featured below are the before pictures of our 300 Welda-Round that has been in use for many years. This machine has just been updated by Bancroft.
The photos below are what it looks like after the upgrade was completed.
How old is your welding equipment? Today’s state-of-the-art welding technology will make your equipment run more efficiently and create an immediate payback.
Give us a call and we can help you make your welding equipment look and function like it’s brand-new!
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Take Advantage of Section 179 Expensing in 2018
If you’re in the market for automated welding equipment of any kind, there has never been a better time to invest in innovation from Bancroft Engineering. There is still time to order and have your machine delivered by the end of the year. Our schedule is filling up quickly, so act now!
We would like to remind our customers that Section 179 of the United States Internal Revenue Code (26 U.S.C. § 179) has been restored to a write-off of up to $1,000,000 for 2018. To qualify, the equipment must be:
- Installed and placed in service during the same tax year
- More than 50% of the use of the equipment must be used for the business
In addition, a bonus depreciation is extended through 2018 for all businesses who have purchased over $2.5 million in equipment. This bonus depreciation is 100% in 2018!
How does all this work? Our accountants have provided us with the following examples to help explain it:
Section 179 deduction is not a complicated tax code, it is one of the few government incentives available to small business. When a company buys equipment, whether by a cash purchase or by financing it, the company typically spreads the expense over several years through depreciation. For example, if a company buys a machine for $100,000, the company can expense about $20,000 per year through depreciation for 5 years. Section 179 allows that company to expense the entire $100,000 during the current tax year if there is sufficient income to offset the expense, thereby accelerating the tax savings.
Section 179 Expensing Example:
- Cost of Equipment After All Bancroft Discounts: $150,000.00
- Section 179 Deduction: $150,000.00
- Total First Year Deduction: $150,000.00
- 35% Savings on Equipment Purchase: $52,500.00
- Lowered Cost of Equipment After Tax Savings: $97,500.00
Remember! Our calendar is almost full for 2018. Contact us today to get your welding machine shipped by the end of the year so you can take advantage of Section 179 expensing. Visit www.section179.org for more details.
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Is it Time to Automate your Welding Process?
Bancroft Engineering offers both semi-automated machines and fully-automated systems to help with all your welding needs. From our Welda-Rounds and Weld-Lathes to vision-guided robotic systems, we have the equipment to improve your process. When you automate your welding process, it can improve quality, productivity, lower your labor costs, and increase the reliability and consistency of your operation.
How repeatable are the welds you are making?
If your weld process is repeatable, a semi-automated system would be perfect for you. It produces at least 2 times the output as a skilled welder, which can drastically reduce labor costs. Making the switch can eliminate mistakes and there are also tremendous savings in scrap material.
What is the value of the product before the weld?
If the value of the product is very high before the weld is made, considering either a semi or fully automated system could prevent costly mistakes. Both systems eliminate mistakes caused by human error. They produce the highest quality weld every single time and offer much faster speeds.
What is your budget?
Prices for both semi and fully automated systems have dropped significantly in recent years. Robotic systems now have a lower initial investment, increase productivity and can produce an ROI in less than a year. Set up times are minimal, and mistakes are non-existent.
Are you better than the competition?
As technology advances, so do our competitors. Are they using automated systems? If you want to beat out your competition, you can easily become more productive and profitable by having the best equipment in the industry.
Next Step?
Contact the knowledgeable sales team at Bancroft Engineering to see how our products can benefit you!
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Samples, Prototypes, Production Welding & Fabrication
Video Above of a Model 300 Welda-Round Producing a Customer Sample
At Bancroft Engineering, LLC we pride ourselves on our knowledge and experience in all aspects of welding. Along with specializing in the manufacturing of customized automated welding machinery, we utilize our in-house equipment to work on everything from prototypes and samples, to small and large production runs.
Prototyping and samples can be overwhelming and time-consuming. From selecting the correct gas and wire to dialing in the correct parameters. Let one of our weld engineers do the work for you. With the manufacturing of samples, we provide a cycle time study and return on investment numbers to assist your engineering and purchasing department.
If you already have your process and part design figured out but you don’t have the volume for your own welding machinery or production welding just isn’t in your business plan, Bancroft always has Welda-rounds and Weld-Lathes powered up and production ready. Let Bancroft create an innovative solution for you.