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Bug-O Mechanized Cutting & Welding Systems

Bug- O Systems – Empowering People to Transform the Welding and Cutting Industry

Bug- O Systems is a Family-Owned business founded in 1948. The company has grown and evolved to become an Industry leader in the design, manufacture, and application of portable mechanization products for the cutting and welding industry. Our products are designed to give our customer an excellent return on their investment. From the St. Louis Arch to Disney Cruise Ships and Pipelines all around the world, Bug-O’s modular system of components can be configured to fit virtually any application.

We welcome the opportunity to discuss any application that challenges you today. We can make recommendations and would be pleased to setup a demonstration in your facility so you can see firsthand how Bug-O’s Systems can save you time, money and increase your quality.

Why Choose a Mechanized Process?

Increased Production

The machine replaces the operator’s hand to control the process. Continuous welding, no stopping and starting.

Improve Quality

Precise speed and path control improves appearance and quality. Decreases defects and costly rework.

Reduce Material Handling

Take the machine to the work. Work in all positions.

Reduce Distortion

Regulate travel speed. Provide uniform heat input.

Improve Worker’s Environment

 Reduce operator fatigue. Remove operator from welding / cutting fumes.

TABLE OF CONTENTS 

  • Pages 3-32 (Please Click Here)
  • Circle Cutting pg. 33
  • HOB-O pg. 33
  • Plasma Circle Burner pg. 34
  • Plasma Circle Burner with Remote Control pg. 35
  • Oxy-Fuel Circle Burner for Square or Beveled Hole Cuts pg. 36
  • CB-3 / CB-3H pg. 37
  • Pipe Cutting & End Preparation pg. 38
  • Programmable Pass Through Pipe Cutting Machine pg.38
  • Programmable Dual Function Elbow and Saddle Cutter pg. 39
  • .Programmable Pass Through Pipe Cutting Machine pg. 40
  • Pipe Coupon Cutting Machine pg. 41
  • Programmable Pipe Cutter pg. 42
  • Pre-Programmed and Custom Cuts pg. 43
  • Custom Mechanization pg. 44
  • High Capacity Modular Drive System pg. 44
  • All Position Overlay System pg. 45
  • DCW-5 pg. 46
  • DCW-18 pg. 47
  • MM-5 pg. 48
  • Girth Welders pg. 49
  • Accessories pg. 50
  • Automatic Height Control pg. 50
  • Racking Groups pg. 51
  • Panographs pg. 51
  • Torch Support / Holders pg. 52
  • Rails pg. 52
  • Magnets & Their Accessories pg. 53
  • Carriages & Vacuum Supports pg. 53
  • Batteries pg. 53
  • CONTACT US

Circle Cutting

HOB-O®

The DC HOB-O® lightweight hole borer is easily carried to the work, and is quickly centered on the workpiece. All that you need is a single center punch mark. Set the hole radius on the built-in scale, light the torch, start your cut and hit the switch to make smooth accurate holes in any position; virtually eliminating the need for grinding and touchup. This flame-cutting machine will cut holes from 1" to 8" (25 mm to 200 mm) inside diameter and from 14 1/2 to 48" (368 mm to 1220 mm) outside diameter. When mounted with magnets, each magnet foot is covered with a shield to protect it from direct flame and heat.

Features:

• Lightweight and portable, can be taken to the work piece
• Easy setup • Cuts holes from 1-8" (25-200 mm) inside diameter
• Can cut and bevel holes with precision
• Cuts holes from 14 1/2 - 48" (368-1220 mm) outside diameter
• Made in USA

Kits

HOB-O®
HOB-2303 (120 VAC) HOB-2323 (240 VAC) HOB-2313 (42 VAC)

HOB-O® w/ Magsquare Feet HOB-2303-MSQ (120 VAC) HOB-2323-MSQ (240 VAC)

HOB-O® w/Blind Area Kit Combo HOB-2204 (120 VAC) HOB-2224 (240 VAC) HOB-2214 (42 VAC)

HOB-O® Blind Area Kit
HOB-2080

The blind area kit makes smooth accurate holes in any position, virtually eliminating the need for grinding and touch-up. Note it must be used with an 18" machine barrel torch and a DC HOB-O® in order to cut holes from 8" up to 14 1/2" (203 to 368 mm)

HOB-O® w/ Blind Area Kit
Combo w/ Magsquare Feet

HOB-2204-MSQ (120 VAC)

Plasma Circle Burner

The CB-1P is designed for cutting beveled holes in lightwall pipe or vessels. This machine is supplied with an air plasma power source (specified by customer), torch and 50' (15 m) leads. It will cut beveled holes in light wall pipe or vessels with wall thickness up to 5/16" (7 mm). An automatic rise and fall cam controls the torch position for saddle cut holes up to 2/3 of the work diameter. The cables and air hoses supplying the unit pass through slip rings and O-rings enabling the machine to operate continuously in either direction without cable or hose wrap up. The CB-1P must be mounted on a carriage or fixture.

Features:

• Plasma process
• Rise and fall cam 5” (127 mm)
• Burning diameter of 1-12” (25-305 mm) bevelled holes
• Application type – thin wall, small diameter pipe
• Must be mounted on a carriage or manipulator
• Made in USA

CB-1P Circle Burner
CBO-1020

Plasma Circle Burner with Remote Control

The CB-1PR is designed for cutting bevelled holes in light wall pipe or vessels with wall thickness up to 5/16" (7 mm). An automatic rise and fall cam controls the torch position for saddle cut holes up to 2/3 of the work diameter. The cables and air hoses supplying the unit pass through slip rings and O-rings enabling the machine to operate continuously in either direction without cable or hose wrap up. The CB-1PR is supplied with a Hypertherm® Powermax® 65 or 85 (specified by customer) plasma power supply, 180 degree plasma machine torch and 50' (15 m) control cable / torch lead. The CB-1PR Plasma Circle Burner requires 120/50-60/1 to operate and must be mounted on a carriage or fixture. The remote pendant has the following controls: speed display, speed control, travel direction, overlap timer, cycle start, manual/auto switch, on/off switch, pilot light and quick stop.

Features:

• Remote control
• Plasma process
• Rise and fall cam 5” (127 mm)
• Burning diameter of 1-12” (25-305 mm) bevelled holes
• Application type – thin wall, small diameter pipe
• Must be mounted on a carriage or manipulator
• Made in USA

CB-1PR Circle Burner with Remote
CBP-2020

Oxy-fuel Circle Burner for Square or Bevelled Hole Cuts

The CB-2 is mounted on a special frame with a releasable permanent magnet base specially designed for use on vessels and large diameter pipe. The CB-2 includes variable speed rotation, 2-hose oxy-fuel machine torch, adjustable tip adapter, vertical and horizontal torch adjustment and rise and fall cam.

Features:

• Oxy-fuel process
• Mounted by a manually operated magnet
• 1.5”-42” (38-1067 mm) bevelled holes • Rise and fall cam 0-7” (0-178 mm)
• 4”-48” (102-1219 mm) square cut
• Application type – vessels, large diameter pipe
• Made in USA

CB-2 Circle Burner
CBO-2000

CB-3 / CB-3H

The CB-3 Circle Burner uses the oxy-fuel cutting process for single pass, square or beveled hole cuts. It is designed for use on vessels, large diameter pipe, domed heads and flat plate. The CB-3 includes a 2-hose oxy-fuel machine torch, adjustable tip adapter, variable speed rotation, vertical and horizontal torch adjustment and rise and fall cam. The CB-3 must be mounted on a column and boom, manipulator or fixture.

The CB-3H Circle Burner has the same features as the CB-3 and includes a hillside kit. This hillside kit is for single rise and fall motion per revolution of the machine to provide the motion required to follow the contour of an offset pipe-to-pipe weld.

Features:

• Oxy-fuel process
• Must be mounted to a carriage or manipulator
• 1.5"-42" (38-1067 mm) beveled holes • Rise and fall cam 0-7" (0-178 mm)
• 4"-48" (102-1219 mm) square cut
• Application type - domed heads, vessels, large
• Adjustable vertical and horizontal torch positioning system
• Made in USA

CB-3 Circle Burner
CBO-3000 / CBO-3010

Pipe Cutting & End Preparation

Programmable Pass Through Pipe Cutting Machine

The SE-2PTD is used to cut saddles, offset saddles, laterals, miter cuts and holes on pipe. A second (selectable) program is used for cutting customized shapes in pipe. Also available is Windows based software for programming. This machine can be configured for oxy-fuel, plasma or both. The SE-2PTD eliminates the need to make templates or to layout complex cuts.

Features:

• Dual programming capabilities
• Pipe weight capacity of 375 lbs. (170 kg)
 • Pass through cutting diameter from 1-4" (25 mm to 100 mm) O.D.
• Speed range of 3.75 rpm
• Pipe cutting diameter when externally chucked from 4-14" (100-355 mm) diameter
• Made in USA

SE-2PTD SEO-4250-OX 120V
Oxy-Fuel SEO-4252-OX 240V Oxy-Fuel

SE-2PTD
SEO-4250-PL 120V
Plasma SEO-4252-PL 240V Plasma

Programmable Dual Function Elbow and Saddle Cutter

The SE-4PD provides dual programming capabilities enabling the user to make saddle cuts, offset cuts, laterals, miters, holes and shapes in pipes thus eliminating the need to make templates and layouts. Also available is Windows based software for programming. The SE-4PD can accommodate pipe sizes ranging from 1"-12" (25-305 mm) in diameter and is available for plasma and oxy-fuel cutting.

Features:

• Oxy-fuel or plasma process
• Pipe weight capacity of 375 lbs. (170 kg)
• Dual programming capabilities
• Speed range of 0.2-3.7 rpm
 • Can accommodate pipe sizes ranging from 1- 12" (25-305 mm) in diameter
• Made in USA

SE-4PD
SEO-4520-OX 120V Oxy-Fuel
SEO-4522-OX 240V Oxy-Fuel

SE-4PD
SEO-4520-PL 120V Plasma
SEO-4522-PL 240V Plasma

Programmable Pass Through Pipe Cutting Machine

The SE-4PTD is used to cut saddles, offset saddles, laterals, miter cuts and holes on pipe. A second (selectable) program is used for cutting customized shapes in pipe. Also available is Windows based software for programming. This machine can be configured for oxy-fuel, plasma or both. The SE- 4PTD eliminates the need to make templates or to layout complex cuts.

Features:

• Dual programming capabilities
• Internal chucking of pipe (for short lengths) up to 20" (500 mm) diameter.
• Pass through cutting diameter from 4-123/4 " O.D. (100-325 mm)
• Rotation speed 0.2-3 rpm
• Pipe weight capacity of 375 lbs. (170 kg)
• Made in USA

SE-4PTD
SEO-4400-OX 120V Oxy-Fuel
SEO-4402-OX 240V Oxy-Fuel

SE-4PTD
SEO-4400-PL 120V Plasma
SEO-4402-PL 240V Plasma

Pipe Coupon Cutting Machine

The PCC-1 is used for cutting pipe to a desired length or for beveling the edge of a pipe for weld prep. The machine features a self centering speed chuck capable of gripping 0-8" O.D. pipe and 3-11" I.D. pipe. A racking group supports a plasma or oxy-fuel torch which can be setup for square or beveled cuts up to 12” in length. The variable speed control on the PCC-1 can be adjusted from 1-6 rpm. A rotary ground is included on the plasma version and a quick action manifold is supplied on the oxy-fuel version.

Features:

• Available for oxy-fuel or plasma in a 110 volt model
• Capable of cuts up to 12" (305 mm)
 • Variable speed control from 1-6 rpm
• Speed range of 1-6 rpm
• Able to grip 0-8" O.D. and 3-11" I.D. pipe
• Plasma model includes a rotary ground and the oxy-fuel version is supplied with a quick action manifold
• Made in USA

PCC-1
100-0388 110 Volt

Programmable Pipe Cutter

The MM1 is a computer controlled machine that automates the cutting of profiles, holes and shapes on pipe with diameters from 4-16" (102-406 mm). It rotates the pipe on its roller bed with a three jaw chuck while simultaneously moving a cutting torch back and forth along the pipe’s axis. Pre-programmed shapes such as saddle, hillside, lateral and miter cuts can be made by simply selecting the type of cut from the menu, then entering the diameters of the pipes being processed and pressing the run button to cut your pipe. Also available is Windows based software for programming.

Features:

• Available for oxy-fuel or plasma process
• Speed is .2-3 rpm
• Cutting diameter of 4-16" (100-406 mm)
• Pre-programmed shapes such as saddle, offset saddles, laterals, miter cuts, and holes can be made
• Eliminates the need for templates, layouts or calculations
 • Irregular shapes can be plotted, programmed and saved for future use
• Can cut pipe lengths from 3-38" (76 mm -11.6 m)
• Made in USA

MM-1
SEO-3500 120 VAC
SEO-3502 240 VAC

Pipe Cutting and End Preparation - Pre-Programmed and Custom Cuts

PC Option
BUG-6140

CAD Interface
BUG-6240

Wireless Serial Connection Set for use with PC Option
BUG-6220

Custom Mechanization

High Capacity Modular Drive System

Bug-O offers a Modular Drive System with more than double the standard carrying capacity. The High Capacity MDS can carry up to 140 lbs. (64 kg) vertically, and is compatible with all standard MDS components. The High Capacity MDS provides the required power to carry the feeder, wire, and cables to mobilize the complete welding system. For full load carrying capacity, the High Capacity Modular Drive System must travel upon heavy duty rail (call factory for details).

Features:

• One complete traveling welding platform
• Compatible with all standard MDS components
• Capable of carrying up to 140 lbs. (64 kg.) vertically (rating includes a 100% safety factor)
• Allows for all inclusive welding process application (Bug-O tractor, suitcase feeder, wire and all electrical connections)
• Larger diameter, 1.125" (28.5 mm) chrome moly pinion
• Made in USA

High Capacity MDS
MPD-1000-HICAP 120 VAC
MPD-1002-HICAP 240 VAC

All Position Overlay System

The All Position Overlay System is designed for pulp digesters, boiler tube walls or any vessel or surface that requires overlay repair. The system will travel at a regulated, precise travel speed producing consistent uniform overlay patterns. A welding current sensor monitors and controls the welding torch height on pitted or irregular surfaces. The system can be customized for job specific applications on circumferences or flat walls and can be configured to handle a variety of operating windows. The entire system is portable and can be broken down into small pieces for moving thru small manholes or openings.

Features:

• Customizable for job specific applications
• 2-120 ipm (51-3048 mm/min) travel speed
• Portable system that can be taken to the work
• Full pendant control
• Pendulum weaver included along with welding torch height control
• Cycle select module can be pre-set for continuous cycle, bi-directional stop at limit or rapid return at limit to start position
• Can be adapted for horizontal/step-up welding
• Made in USA

Close-up view

Overlay System

DCW-5

Bug-O addresses the need to utilize the latest advancements in pulsed MIG and submerged arc process control for its circle welders. This Circle Welder System is now available for Digitally Controlled Welding Power Sources. All digital control signals can now be passed to a continuously turning wire feeder for advanced process welds. Now you can have all the power and arc characteristics that the new digitally controlled power sources can deliver, along with no hose or cable wrap-up regardless of direction or rotation.

The DCW-5-L Circle Welder, equipped with Lincoln Electric® Power Feed 84® wire feeder, is capable of welding 1-12" (25.4- 304.8 mm) diameters. This machine can be used for GMAW, GMAW-P or FCAW welding process. There are eight user memories for complete welding procedure recall, and pre-programmed auto settings to simplify process procedures.

The DCW-5-O Circle Welder, equipped with OTC-DAIHEN AF-4012 wire feeder, provides OTC patented wave pulse process with 1-12" (25.4-304.8 mm) diameter range.

Features:

• GMAW, GMAW-P, FCAW advanced weld process control
• No hose or cable wrap-up regardless of direction or rotation
• All digital control signals passed to a continuously turning wire feeder
• Rise and fall cam with 5" (125 mm) of travel
• Rotation speed .5-5.9 rpm
• Made in USA

DCW-5

DCW-18

The DCW-18-L Circle Welder, equipped with Lincoln Electric® MAXsa® 10 Controller for Power Wave® AC/DC 1000® is capable of welding nozzles with a diameter range of 10-50 inch diameter. The machine is set up for sub arc process. Features of the machine include eight procedure memories and user friendly controls.

The DCW-18-M Circle Welder, equipped with Miller® Digital interface for use with Miller® Digital series power sources. It is capable of welding nozzle diameters from 10-50" and is set up for SAW process.

Features:

• GMAW-P and SAW process control
• No hose or cable wrap-up regardless of direction or rotation
• All digital control signals passed to a continuously turning wire feeder
• Rise and fall cam with 7" (177.8 mm) of travel
• Rotation speed of .06-.72 rpm
• Made in USA

DCW-18

MM-5

The MM-5 is a computer-controlled machine that automates the cutting of profiles, holes, nozzles and shapes on pipe with diameters from 4" to 39.375" (10-100 cm). It features built in Auto Height Control for plasma cutting process. The MM-5 rotates the pipe on its roller bed with a three jaw chuck, while simultaneously moving a cutting torch back and forth along the pipe’s axis. Pre-programmed shapes such as saddle, hillside, lateral and miter cuts can be made by simply selecting the type of cut from the menu, then entering the diameters of the pipes and pressing the run button to cut your pipe. There is no need for templates, time consuming layout or calculations. In addition, irregular or custom shapes can be plotted, programmed and saved for future use.

Features:

• Available for oxy-fuel or plasma cutting process in 120 and 240 volt models
• Eliminates the need for templates, layouts or calculations
• Built in automatic height control for plasma cutting process
• Pre-programmed shapes such as saddle, offset saddles, laterals, miter cuts, and holes can be made
• Cutting diameter of 4" - 39.375" (10-100 cm)
• Irregular shapes can be plotted, pre-programmed and saved for future use
• Made in USA

MM-5
SEO-5000 120 VAC
SEO-5002 240 VAC

Girth Welders

Bug-O Systems offers Automatic Girth Welders for tank fabrication applications. They are convertible for both bottom up and top down construction. Bug-O Girth Welders are also capable of being used as a pair to construct a dual sided girth welder. Special models can be built per customer’s request.

Unlike other girth welders on the market, the BGW (Bug-O Girth Welder) Series comes standard with a Dual Drive System and other features unique to our machines. This self-propelled submerged arc welding system can reduce field storage tank welding time by 40% by increasing arc on time and reducing weld defects. The models run directly on the tank and carry the operator, eliminating the need for scaffolding while ensuring operator comfort and safety. The Girth Welders, due to their modular design, are applicable for top down or bottom up constructed single or double wall storage tanks. They are designed for internal and external welding. There are four standard units and our design allows us to offer custom-built units for special applications.

Features:

• Dual drive motor system
• Laser site guide
• Efficient flux recovery system
• Ergonomic operator cabin
• Integrated control panel
• Adjustable weld head and flux belt support system

Girth Welders

Automatic Height Control

Accessories

Automatic Height Control

Automatic Height Control is a compact easy to use accessory, designed to maintain a constant welding torch-to-work distance. This control can be used with SAW, FCAW and GMAW welding. It includes a solid-state control box and a motorized slide which will bolt onto any standard Bug-O Systems carriage or fixture. It can be used for a wide variety of welding applications where precise control of welding current is critical. This system requires a constant voltage (CV) power supply for operation.

(Included in All AHC Systems)
CAS-1550

AHC for Universal Bug-O-Matic
 BUG-6553

AHC for Free Standing Torch Support Integration
CAS-2100

AHC for MDS Pendulum Weaver System
CAS-2060

AHC for MDS Linear Weaver System or MDS Straight Line System
CAS-2050

Panographs

Racking Groups

Welding Groups, with rack and pinion adjustment, align a welding gun to the weld joint.

Cutting Groups utilize rack and pinion to adjust and align a cutting torch with the cut line.

Machined Rack Welding Group
MDS-1040

Machined Rack Cutting Group
MDS-1050

Dual Torch Welding Group
MDS-1075

Dual Torch Cutting Group
MDS-1090

Panographs

Panograph Welding Groups maintain consistent tip to work surface distance. Rack and pinion adjustment positions a welding gun to the weld joint.

Panograph Cutting Groups maintain consistent tip to work surface distance. Rack and pinion adjustment positions a cutting torch gun to the cut line.

Panograph Torch Floater
PAN-1000

Mechanical Corner Follower
PAN-2145-L, R 

Double Torch Panograph
PAN-1072

Welding Panograph
PAN-1008

Mechanical Seam Follower
PAN-216

Torch Supports / Holders