Reduce Fleet - Increase Productivity
Increase Productivity and Save Money by Reducing Your Welding Fleet.
Is this possible? It is if you consider the benefits of welding machines with simultaneous power generation. Using one welder/generator instead of two separate machines for your welding and power needs can save: time moving and transporting equipment, weight on your rig, and money from purchasing, maintaining and fueling half the number of units. These benefits are real; however some people doubt the quality of the power and welding arc.
Although it’s true that you get what you pay for…you don’t have to spend the most money to get the best product. However, what you spend that money on does make a BIG difference. There are many brands of welder/generator equipment available, but considering a reputable company, as well as a reputable engine manufacturer will make your purchase a positive experience. High quality, reputable brands that provide long warranties for their equipment can offer you welder/generators with excellent welding arcs and clean, stable power generation.
Now, think about the benefits of one machine for two jobs. How many man-hours and employees do you utilize just in moving and hooking-up equipment around a construction job…not to mention the hassle of getting the right equipment and power to a specific work area? What about the cost of employees securing a CDL (commercial drivers license)? And, the fuel costs of hauling and running two large machines verses one?
Consider the long term cost benefits that one machine verses two – across a fleet – can provide. Could you use smaller rigs? Would the ever-present shortage of trained operators be better served fabricating the project, instead of moving, transporting and hooking up equipment?
Let me know what you think…Post your comments and questions.
Average (Not Rated)
March 19th, 2006 at 2:49 am
I agree, even though I am small potatoes when compared to larger shops, I am a one-man-band that will travel to almost ANY field location, whether it be a boiling summer day or typical frozen Canadian winter. As a result, I can’t easily go toting two machines on one non-CDL truck without upgrading the truck a considerable amount. So, this is my specific question to Miller: is there a specific reason why Miller may not have yet produced what could be construed as more of an ultimate engine drive welder. Here’s what I’m thinking, a 350-400 amp machine with a 100%dc in DC, lower rated AC capabilities, like 250A at 60%dc, with the DC produced by similar electronics used in the Pipe Pro 304, 12KW - 15KW aux power, and some form of selectable DIG, all run by a low-rpm industrial diesel.” While I am loyally blue, this lack of the “ultimate” is not yet readily in Miller’s line-up, and there are, in my opinion, a fare sahre of small business owners who would appreciate a machine that has the grunt to repair heavy equipment while still being able to hold its own on a pipeline. What’s your take on this John?
March 21st, 2006 at 7:04 am
Great thought Stephan. I would like to know more about your process requirements to better understand your needs.
We currently have a machine that is very close to what you described - it is the PRO 300. It has an amperage range of 20-410 amps DC and can Carbon Arc Gouge w/ up to 5/16″ carbons. It is rated at 300 amps, 60% duty cycle at 104 degrees F. It has 12,000 watts peak generator power with a low speed CAT engine.
The technology is not an inverter like the PipePro, but it does use solid state technology and produces a great arc with adjustable DIG. If you wanted to AC TIG weld, its a little more expensive than an HF box, but the Dynasty 200 works great off of the 12,000 watt generator and it is the king of TIG.
To match your needs, what else would the PRO 300 need? I appreciate your feedback. It really does direct us to make sure we design the “ultimate” machine for our customers.
March 24th, 2006 at 2:49 am
John, thanks for your reply. My background is in heavy equipment. My first major working experience started as an excavator operator and so naturally when I opened my mobile welding business I started catering to this crowd. This has worked well to date, as I currently live in an area with a surplus of equipment and the accompanying developing markets to support that equipment. However, in the next couple of years, I will be moving my business into northern BC on the BC / Alberta border (great place to settle down and raise a family) into regions where not only is there heavy equipment, but also a fair share of pipeline and oilfield activity. I must admit the Pro 300 was a machine I thought very hard about purchasing when I started up my business, instead, I decided to bank some of the funds and go with the Trailblazer302, for three key reasons: (1) it is housed in a relative small and light package allowing me to carry both the welder and a 20cfm engine-driven air compressor on a modified 3/4ton truck, (2) the Trailblazer will provide 300 amps at 100% duty cycle (in CV) which works great for ¼” carbons, and (3) it has an AC output for those few times when experiencing arc blow, or if I wanted to set up a HF box for Tig.
In retrospect, I only use AC once every few months, and as much as I don’t like giving it up, I could live without it in a new machine providing that the auxiliary power in the next machine is still produced clean enough to run a dynasty 300. The reason I specify the 300 as opposed to the 200 is that some aluminum in the field gets upwards of ¼”, so the added capacity of the dynasty 300 would make those thicker jobs a little easier on equipment rather than squeezing a Dynasty 200 to do ¼” Al.
As far as the weight is concerned, while I don’t want to start packing a 1700lb welder like some of the competition are still producing, I do recognize that a larger welder will also mean a larger truck. However, I have run my weight figures and a standard 1ton dually would handle my current setup but with 1300lbs allowed for the weight of the welding machine rather than the current Trailblazer 302’s 700lbs (that’s 700lbs with fuel included).
This leaves the single greatest determining factor for my purchasing: duty cycle. I will not be able to justify the purchase of an engine drive that cannot handle at least 300amps at a minimum of a 80% duty cycle. When gouging with carbons, I am usually running somewhere in the range of a 80% duty cycle, so anything less than that and under 300 amps is not very useful for my application. Granted, when welding stick I am at a somewhat lower duty cycle, but without that capability to run ‘non-stop’ ¼” carbons, I lose a large portion of my advertising power. Customers want to hear that I can do the job faster than the next guy, not by taking short cuts, but because I carry processes like CAC-A that will save them time, and thus money. I am happy to see that the Pro 300 can produce upwards of 410amps, but without a higher duty cycle to support those current ratings, I will remain using my 300amp 100%duty cycle Trailblazer.
Also, I should recognize that the best pipe-process equipment is not necessarily needed to make to-code welds, as this could be argued in the case against upgrading the Pro 300. I will admit that I know of a welder who successfully does smaller piping with his bobcat 225, and I am confident that for the most part this Trailblazer could tread water for a while in the pipe industry. However, that said, if the technology is out there that aids in currently used processes such as downhill smaw, who wouldn’t want to have a welder that could hold up its end of the deal and perform better using that higher level of technology.
So, to your original question, I think the Pro 300 as it sits with the low-rpm CAT engine is very close to becoming the ultimate machine, allowing independent welders to handle the higher amperages of the equipment repair industry and still have DC arc with enough finesse to hold its own on the pipeline. Simply increasing the duty cycle of the Pro 300 to having at least 300 amps output at a full 32V and at 100%duty cycle and 350 amps at 60% - 80% duty cycle would make myself and many other Miller fans very happy. Want to keep us happy for life? Consider adding AC output, even if it’s just up to 250amps, it would allow for those times when you find yourself welding in a magnetized zone.
One last closing thought on price, because it is often the counter point that is brought up when us welders start talking about bigger and better machines. When we are investing $10,000 into a top quality machine that will be providing us for many years with a means to our living and professional reputation, to me, a simple 20% increase in cost for an additional 50% increase in machine versatility seems well worth the increased buy-in price for that machine.
March 29th, 2006 at 7:35 am
Stephan,
It is great to hear from someone as knowlegable as you. Great comments and thoughts. Keep your eyes on new Miller products coming out down the road. We recognize your needs and the needs of customers like you and will continue to try and exceed your needs and expectations.
By the way, the Trailblazer 302 is a very popular machine in Alberta because it does have a great pipe arc and high duty cycle.
Have a great day,
November 24th, 2006 at 10:57 am
I didnt find thing that i need…
yahoo