The Welding Electrode Manufacturing unit consists of Wire straightening and cutting machines, Mixers, Briquetting press, extruder, wire feeder, conveyor and Baking Oven.

2. MANUFACTURINGPROCESS FOR WELDING ELECTRODES
PLANT

3. WIRE DRAWING MACHINE
In these machines, Wire rod of size 5.5mm or 6.35 will be
drawn to required standard size 2.5 mm, 3.2 mm, 4.00 or 5
mm.

4. WIRE STRAIGHTENING AND CUTTING MACHINE
These machines straighten and cut coils of wire into the
required standard length. The tolerance on length is accurately
maintained.

5. DRY MIXER
 The powders which constitute the flux are mixed together in
the mixer so that the constituents are blended into a
homogeneous batch.

6. WET MIXER
 In this machine the dry mixed flux and binding agent
(Potassium / Sodium silicate) in measured quantity are mixed and
kneaded to get a wet paste and this wet paste will be transferred
to briquetting press.

7. BRIQUETTING PRESS
 The paste obtained from the Wet Mixer machine is
compressed into cylindrical cakes which can be fed neatly into
the extrusion cylinder.

8. WIRE FEEDER WITH WIRE HOPPER
 This equipment can be set and reset with ease for different diameters and lengths of
electrodes. One complete set of change over parts is provided to enable production of
2.50mm, 3.15mm, 3.25mm, 4.00mm and 5.00mm change over parts consist of pickup rollers,
wire guides, guide tubes mouth pieces. All change over parts are made out of hardened and
tempered alloy steel. The wire feeder system is driven by a train of gears through a gear
box. The speed of the wire feeding is Variable .

9. EXTRUDER
 The extruder is equipped with a hydraulic cylinder, hydraulic pump, pressure control
valve and directional control valve. The piston has a fast return stroke to enable fast raffling
of the paste cylinder. The paste cylinder has dia meter of 150 mm and the stroke of the
paste piston is approximately one meter the following is the mechanism of operation of the
wire feeder / extruder.The pieces of wire which are fed from the wire feeder at high speed
pass through the Die block and thereafter through the coating die. Simultaneously the paste
is compressed through the press block, takes a right angle turn and covers the space
between the coating die and the wire. Thus the bare gets the coating.

10. CONVEYOR
The conveyor takes over the coated electrode from the transfer belt and performs the following
operation….
1. Spacing the electrodes apart
2. Aligning the electrodes
3. Brushing the holder ends
4. Grinding the arc striking ends
After the above operations are done, the electrodes are taken over by a slower belt from where they
are manually lifted and placed on trays. The quality of workmanship and the alignment of various
moving parts will be such as to maintain a low rejection level on the conveyor.

11. BAKING OVEN
 The baking oven is of the walk-in type so that the trolleys can be pushed
in and out. A spare set of trolleys is provided as standard accessory and the
oven is manufactured specially to cope with the feed drying of electrodes.

12. DE – COATING MACHINE
 This equipment enables the coating of rejected / damaged electrodes to
be separated from the core wire so that both the wire and the flux may be
recycled.

13. PACKING TABLES
 These tables enable quick manual packing of electrodes, segregation of
damaged electrodes and filling up of good electrodes in polythene bags /
cartons.

14. MICROMETER FOR CONCENTRICITY MEASUREMENT
 This instrument can measure the concentricity of the semi-dry green
coating on the electrodes to an accuracy of 0.10 mm.

15. CHEMICAL & MECHANICAL LAB
 A complete set of laboratory equipment for wet analysis and mechanical
testing equipment comprising of Rockwell hardness tester & charpy / lzod
impact tester and universal testing machines may be provided as optional
extras.

16. FURTHER DETAILS:-
M/S.OMEGA WELDROD SYSTEMS
Fac: 1/455 G,Aachan Kulam Road,
Neelambur,Coimbatore 641062,
Tamilnadu, INDIA.
Tel: 91-422-2934005
Email:weldomega@gmail.com
Web:www.omegaweldrod.com