JH-1280 In-Situ Hardfacing & Automatic Air Carbon Arc Gouging Workstation
Integrated 1250A Workstation for On-Site Wear Component Repair
An integrated automated repair system developed by JINHUA for heavy industrial wear-component maintenance. The JH-1280 integrates the hardfacing control system directly into the welding power source.
This design reduces external cables and components, making the system easier to transport, install and operate during on-site maintenance. With a welding current range of 60–1250 A, wireless parameter adjustment and modular aluminum guide rails, the JH-1280 is particularly suitable for on-site repair of roller presses and other large wear components.
Main Applications
The JH-1280 is designed for industrial maintenance applications, with typical industries including cement, mining, steel, power generation and heavy equipment maintenance.
Typical industries include:
Cement / Mining / Steel / Power generation / Heavy equipment maintenance
On-site repair — in-situ hardfacing and gouging of large industrial wear components.
Integrated Hardfacing & Gouging
One machine platform supports both material removal and rebuilding. The workstation supports automatic hardfacing and automatic air carbon arc gouging, and provides multiple programmable welding patterns.
Automatic Air Carbon Arc Gouging
The gouging system automatically feeds the carbon electrode and moves along the programmed repair area. It can be used to remove:
- Damaged overlay
- Cracked weld metal
- Old hardfacing layers
- Defective welding areas
- Material requiring preparation before rebuilding
Automatic Hardfacing
After surface preparation, the workstation can switch to hardfacing mode and deposit new wear-resistant material according to the programmed welding path.
This creates a more efficient repair workflow:
- Gouging
- Surface Preparation
- Hardfacing
- Rebuilding
Remove & Rebuild on One Workstation
One machine platform supports both material removal and rebuilding, so the same equipment covers gouging through to final overlay welding.
- Automatic air carbon arc gouging
- Automatic hardfacing
- Programmable welding patterns
- Same guide rails and carriage for both processes
Programmable welding patterns
The JH-1280 provides multiple programmable welding patterns, which are described in detail in the following section.
- Circular welding
- Straight-line welding
- Oscillation welding
- Horizontal strip welding
- Grid welding
The workflow runs from gouging and surface preparation through to hardfacing and rebuilding, using the same workstation.
Integrated JHM-1280 Power & Control System
A major feature of the JH-1280 is the integration of the welding control system into the main power source.
Compared with traditional systems using separate control cabinets, this provides:
- Fewer external cables
- Faster installation
- Easier transportation
- Simplified equipment connection
- Fewer connection points
- Easier on-site maintenance
The JHM-1280 provides a welding current adjustment range of 60–1250 A with a rated duty cycle of 100%, making it suitable for continuous industrial hardfacing applications.
JHM-1280 power source — welding control integrated into the main power source.
Multiple Automatic Welding Modes
The JH-1280 supports several programmable welding trajectories. These welding modes allow one workstation to adapt to different wear conditions and workpiece geometries.
Circular Welding
Suitable for circular and cylindrical repair areas.
Straight-Line Welding
Used for conventional linear hardfacing passes.
Oscillation Welding
The torch moves laterally during travel to increase welding bead width and surface coverage.
Horizontal Strip Welding
Suitable for repeated horizontal hardfacing passes.
Grid Welding
Creates programmed grid-type wear-resistant patterns for specific industrial applications.
Lightweight Modular Guide System
The JH-1280 is built around aluminum alloy guide rails, keeping the workstation light enough to transport and install on site.
The JH-1280 consists mainly of:
Aluminum alloy guide rails
The horizontal and vertical guide rails are manufactured from aluminum alloy. This provides:
- High structural strength
- Lower equipment weight
- Easier transportation
- Faster on-site installation
- Easier disassembly after maintenance
Standard Effective Travel — Horizontal Travel: 1500 mm. Vertical Travel: 600 mm. Customized travel dimensions are available.
Modular aluminum guide rail — horizontal and vertical rails assembled around the workpiece.
Quick-Install Traveling Carriage
The traveling carriage uses an aluminum alloy structure. The carriage wheel mechanism is designed for easier installation and removal from the guide rail.
This is particularly useful for maintenance teams that frequently move the equipment between different repair locations.
Traveling carriage — aluminum alloy structure with quick installation and removal from the guide rail.
Automatic Wire & Carbon Electrode Feeding
A high-torque wire feeder and a dedicated carbon electrode feeding mechanism cover both hardfacing and gouging operation.
Automatic Wire Feeding
The hardfacing wire feeder uses a high-torque stepper motor and customized feeding mechanism. The system supports real-time wire speed adjustment.
- Welding Wire Diameter — Ø2.4–3.2 mm
- Wire Feeding Speed — 0–7000 mm/min
Stable wire feeding helps maintain consistent deposition during continuous hardfacing.
Automatic wire feeder — high-torque stepper motor with real-time wire speed adjustment.
Automatic Carbon Electrode Feeding
For automatic gouging, the workstation uses a dedicated carbon electrode feeding mechanism.
- Carbon Electrode Diameter — Ø13 / Ø16 mm
- Electrode Feeding Speed — 0–500 mm/min
The feeding speed can be remotely adjusted according to the gouging process.
Carbon electrode feeder — dedicated mechanism for automatic air carbon arc gouging.
Wireless Remote Control
The JH-1280 provides extensive wireless operation capability. The operator can adjust major process parameters while observing the actual repair area.
The remote controller can operate:
- Vertical movement
- Horizontal movement
- Forward / reverse travel
- Wire feeding
- Wire retraction
- Carbon electrode feeding
- Carbon electrode retraction
- One-button start / stop
- Wire feed speed adjustment
- Electrode feed speed adjustment
- Welding voltage adjustment
This is particularly valuable during on-site work where the welding head may be installed inside or around large industrial equipment.
Flexible Voltage Control
The welding voltage control system supports several operating methods. This allows the operator to select the most convenient control method according to the maintenance environment.
- Remote control
- Local control
- HMI control
Wireless control — remote adjustment of movement, feeding and welding voltage.
Precision Motion Control
The guide system provides controlled horizontal and vertical movement. Controlled travel helps improve welding trajectory consistency during automatic hardfacing and gouging.
Positioning Accuracy
Horizontal Travel Speed
Vertical Travel Speed
Typical Roller Press Repair Process
An eight-stage on-site workflow, from inspection of the worn surface through to the finished overlay.
Inspect the Worn Surface
Evaluate the worn area, damaged overlay and required repair thickness.
Install the JH-1280
Mount the aluminum guide rails around the workpiece.
Automatic Gouging
Remove damaged or unsuitable hardfacing material where required.
Prepare the Surface
Inspect and clean the gouged repair area.
Switch to Hardfacing Mode
Install the welding configuration and select the required welding pattern.
Set Parameters
Adjust the welding parameters before starting the automatic cycle.
Automatic Hardfacing
The machine performs the programmed welding cycle.
Repeat if Required
Additional layers or repair areas can be welded according to the final profile.
Technical Specifications
Motion, feeding and power source data for the JH-1280 in-situ hardfacing and air carbon arc gouging workstation.
Motion & Feeding System
| Parameter | Specification |
|---|---|
| Horizontal Effective Travel | 1500 mm, customizable |
| Vertical Effective Travel | 600 mm, customizable |
| Positioning Accuracy | ±0.1 mm / 1000 mm |
| Horizontal Travel Speed | 0–3000 mm/min |
| Vertical Travel Speed | 0–1000 mm/min |
| Wire Feeding Speed | 0–7000 mm/min |
| Carbon Electrode Feeding Speed | 0–500 mm/min |
| Welding Wire Diameter | Ø2.4–3.2 mm |
| Carbon Electrode Diameter | Ø13 / Ø16 mm |
JHM-1280 Power Source Specifications
| Parameter | Specification |
|---|---|
| Model | JHM-1280 |
| Rated Input | 3 Phase, 380 V, 50 Hz |
| Welding Current Range | 60–1250 A |
| Rated Duty Cycle | 100% |
| Input Capacity | 65 kVA |
| Input Current | 115 A |
| Voltage Adjustment | 18–44 V |
| Open-Circuit Voltage | 80 V |
| Dimensions | 815 × 366 × 788 mm |
| Weight | Approx. 95 kg |
Electrical configuration can be customized according to the destination country’s industrial power supply.
Customizable configuration
- Horizontal and vertical guide lengths can be customized according to the workpiece.
- Electrical configuration can be customized according to the destination country's industrial power supply.
Main Advantages
Seven practical advantages for maintenance teams repairing large wear components on site.
Integrated Design
Power source and hardfacing control are integrated into one system, reducing external connections.
Hardfacing + Gouging
One workstation supports both automatic overlay welding and air carbon arc gouging.
Portable for On-Site Maintenance
Lightweight aluminum guide rails make transportation and installation easier.
High-Current Output
Up to 1250 A welding output supports demanding industrial hardfacing applications.
Multiple Welding Paths
Circular, straight, oscillation, strip and grid welding are available.
Wireless Parameter Adjustment
Operators can remotely adjust motion, wire feeding and welding voltage.
Customizable Travel
Horizontal and vertical guide lengths can be customized according to the workpiece.
JH-1280 vs. JH-350 Series
Both systems can be used for industrial wear-component rebuilding, but they are positioned differently.
| Feature | JH-1280 | JH-350 Series |
|---|---|---|
| Main Positioning | Integrated on-site workstation | Modular hardfacing/gouging family |
| Power + Control Integration | Yes | Depends on model |
| Maximum Welding Current | 1250 A | Depends on power source |
| Hardfacing | Yes | Yes |
| Automatic Gouging | Yes | Available |
| Wireless Voltage Control | Yes | Depends on configuration |
| Welding Modes | Circular / Straight / Oscillation / Strip / Grid | Customized by model |
| Guide Structure | Lightweight aluminum | Modular aluminum |
| Main Advantage | Integrated high-current field workstation | Flexible model selection |
Tell Us About Your Repair Application
For a technical proposal, please provide the following information.
- 01 Workpiece type
- 02 Workpiece dimensions
- 03 Worn area photos
- 04 Wear depth
- 05 Existing hardfacing material
- 06 Required overlay thickness
- 07 Required hardness
- 08 Welding wire specification
- 09 Need automatic gouging: Yes / No
- 10 Required horizontal / vertical travel
- 11 Factory power supply
- 12 Destination country
JINHUA engineers will evaluate the application and recommend the appropriate JH-1280 configuration.
Request a Technical Proposal
Send your workpiece details and worn area photos — JINHUA engineers will recommend the appropriate JH-1280 configuration.
Worn area photos and workpiece drawings can be sent by email or chat after submitting.
Frequently Asked Questions
Common questions about the JH-1280 workstation, the JHM-1280 power source, feeding systems and welding modes.
It is mainly designed for automatic on-site hardfacing and air carbon arc gouging of large industrial wear components, especially cement roller presses.
Yes. The JH-1280 supports both automatic hardfacing and automatic air carbon arc gouging.
The JHM-1280 power source provides an adjustable welding current range of 60–1250 A.
The standard wire feeding system supports approximately Ø2.4–3.2 mm.
The specified standard sizes are Ø13 mm and Ø16 mm.
Yes. The standard horizontal effective travel is 1500 mm and vertical travel is 600 mm, but customized dimensions are available.
Yes. The wireless controller supports remote welding voltage adjustment as well as wire/electrode feeding and machine movement.
The workstation supports circular, straight-line, oscillation, horizontal strip and grid welding.