Core Machines of Wuxi JACK I H Beam Welding Line, Producing Steel Structure Parts for Customer in Flexible Way!

Based on welding H Beam production process technology, main machines in Automatic and semi-automatic I H Beam Welding Line are listed as below:

1. CNC Strip Plate Cutting Machine:

1) Position: Installed at start working station of I H Beam Welding Line, this machine is for cutting out strip boards from carbon steel plate;
2) Usage: The strip boards will be served as flange and web of delivered H Beam in subsequent stations of I H Beam Welding Line;
3) Relationship: Which means, output of CNC Strip Plate Cutting Machine is input of I H Beam Assembly Machine;

4) Workpieces: Long narrow plates to be used in I H Beam Assembly Machine, raw materials of workpieces in I H Beam Welding Line: (Fig.1)

2. I H Beam Assembly Machine:

1) Position: This is the 1^st dedicated core machine in I H Beam Welding Line;
2) Function: I H Beam Assembly Machine assembles flanges and web into T Beam and H Beam with 2 times of operation;
3) And perform CO₂ stitch welding on assembled T/ H Beam simultaneously;

4) Workpieces: T Beam assembly and tack welding in I H Beam Assembly Machine: (Fig.2)

3. I H Beam Gantry Welding Machine:

1) Task: I H Beam Gantry Welding Machine is for fulfilling SAW (Submerged arc welding) on the assembled H Beam, delivered from I H Beam Assembly Machine;
2) Welding Position: In I H Beam Gantry Welding Machine, SAW is implemented in 45° filet position;
3) Welding Passes: Based on stipulated size of welding toe, SAW can be carried out more than single pass on H Beam;

4) Double torches 45° filet SAW welding in I H Beam Gantry Welding Machine: (Fig.3)

4. I H Beam Straightening Machine:

1) Position: I H Beam Straightening Machine is deployed at EOL (End of line) station of I H Beam Welding Line;
2) Function: I H Beam Straightening Machine is for straightening upward deformed flanges of H Beam;
3) Necessity: Such flange deformation is caused from SAW in the preceding I H Beam Gantry Welding Machine;

4) Vertical H Beam being flattened through I H Beam Straightening Machine in I H Beam Welding Line: (Fig.4)

5. Steel Structure H Beam Overturning Equipment in I H Beam Welding Line:

1) Role: Overturning turning equipment rack are applied in automatic I H Beam Welding Line, seldom being used in semi-automatic line;
2) Variety: At different stations, there are 3 grades of overturning rack in I H Beam Welding Line: 60°/ 90°/ 180°;
3) Function: These Overturning turning equipment racks transport and flip welding H Beam WIP (Work in process) among stations of I H Beam Welding Line;

4) 180° Overturning turning equipment rack in I H Beam Welding Line: (Fig.5)

6. General review on superiorities of Wuxi JACK I H Beam Welding Line is briefed in summary web page:” Slides on Wuxi JACK I H Beam Welding Line”.

The Lefthand Scrolling Photos: Working moments of Wuxi JACK I H Beam Welding Line and its Equipment

Basic Capability of Equipment in I H Beam Welding Line:

1. Every machine in I H Beam Welding Line can either work individually, or as part of the line;

2. In this way, customer can purchase I H Beam Welding Line not only in the form of integral group, but also select any single or several equipment: CNC Strip Plate Cutting Machine, I H Beam Assembly Machine, I H Beam Gantry Welding Machine, I H Beam Straightening Machine;

3. This helps customer purchase I H Beam Welding Line and equipment in flexible MGPP plan.

1. Role of CNC Strip Plate Cutting Machine in I H Beam Welding Line:

1) Preparing Flange and Web: CNC Strip Plate Cutting Machine cuts carbon steel plate into long narrow strips with definite width and length, which will be used as flange and web for H Beam production in I H Beam Welding Line, shown in right hand photo;
2) Wide Use: CNC Strip Plate Cutting Machine is not sole purpose equipment only for I H Beam Welding Line use. Instead, it is a general purpose machine, applied as basic 1st operation equipment in all manufacturing facilities;
3) Position: CNC Strip Plate Cutting Machine is positioned at starting station of I H Beam Production Line, preceding to I H Beam Assembly Machine;

2. Assorted Specifications of CNC Strip Plate Cutting Machine:

There are full range of specifications to choose from:
1) Wide Models: From CNC-CG3000 (Means max. valid cutting width is 3000mm) to CNC-CG10000;
2) Often selected models are CNC-CG5000 and CNC-CG6000;
3) Cutting Functions: In one set of CNC Strip Plate Cutting Machine, it has either flame or plasma cutting, or both cutting functions;

3. Recommended Configuration of CNC Strip Plate Cutting Machine in I H Beam Welding Line:

When applied in I H Beam Welding Line, the CNC Strip Plate Cutting Machine is usually CNC-CG4000 model:
1) With max. cutting rail span of 4000mm;
2) Max. cutting length of 15m;
3) Equipped with 1 or 2 sets of CNC cutting torch;
4) 9 sets of strip cutting torch;
In this way, the CNC Strip Plate Cutting Machine can be applied in both I H Beam Welding Line, or elsewhere purpose;

4. Technical Parameters of CNC-CG4000 CNC Strip Plate Cutting Machine:

1. Function and Working Steps of I H Beam Assembly Machine in I H Beam Welding Line:

1) Function: I H Beam Assembly Machine fits up flange with web into T Beam;

2) Then flip the T Beam 180°, and assemble the 2nd piece of flange onto the T Beam;
3) In this way, welding H Beam comes into being in the I H Beam Assembly Machine;
4) Welding Mode: During assembling, CO₂ Gas Shielded stitch welding is performed on assembled T/ H Beam, to solidify such assembled T/ H Beam;

2. Working Mode of I H Beam Assembly Machine I H Beam Welding Line:

This is the most complicated equipment in I H Beam Welding Line:
1) Assembly Style: To get a reliable assembly, I H Beam Assembly Machine assembles flange and web in two stages, performed at input conveyor and central working area respectively;
2) Drive: The flanges and web alignment assembling operation is driven with hydraulic oil cylinders;
3) Welding Current: In I H Beam Assembly Machine, CO₂ stitch welding is fulfilled with outsourced GMAW welding power supply, with output welding current in the range of 100A ~ 500A;
4) Logic Control: The entire working process of I H Beam Assembly Machine is controlled with PLC (Programmable logic controller), and managed with operating panel;

3. Classification on I H Beam Assembly Machine with Tack Welding based on Configuration of I H Beam Welding Line:

1) Control Manner: There are automatic and manual I H Beam Assembly Machine;
2) CO₂ Welding: Can be either manually with welder, or automatically with machine;
3) Workpiece Size: There are three standard specifications of Z15/ Z18 / Z20 models, which produces H Beam in the largest web height of 1500mm/ 1800mm /2000mm;

4. Technical Parameters of Z Series I H Beam Assembly Machine with Tack Welding:

1. Usage and Working Mode of I H Beam Gantry Welding Machine in I H Beam Welding Line:

1) Output: I H Beam Gantry Welding Machine performs large current SAW (Submerged arc welding) on the assembled H Beam, subsequent to I H Beam Assembly Machine, delivering completely fabricated H Beam;
2) Quantity: There are 4 pieces of welding seams in one piece of welding H Beam. Correspondingly, there are 4 sets of LHC model I H Beam Gantry Welding Machine in automatic I H Beam Welding Line: One machine completes one welding seam;
3) In semi automatic I H Beam Welding Line, 1 set of LHA or LHT model I H Beam Gantry Welding Machine is adopted. H Beam needs to be sent into the machine 2 times, with one time of H Beam 180° overturning in the process;
4) Welding Seam: In I H Beam Gantry Welding Machine, H Beam can be welded back and forth 2 ~ 3 times in 45° orientation, delivering full penetration big toe welding seam;
5) SAW Welding Power Supply: In I H Beam Gantry Welding Machine, SAW Submerged arc welding is performed with 2 set of SAW power supply. The corresponding welding current ranges from 300A to 1000A;

2. Classification on I H Beam Gantry Welding Machine:

Differing on mechanical structure, there are 3 types of I H Beam Gantry Welding Machine, being applied in automatic and semi automatic I H Beam Welding Line respectively:

1) LHC Model Column Trolley I H Beam Gantry Welding Machine:

a) Application: Used in automatic I H Beam Welding Line. Seldom used as individual running I H Beam Gantry Welding Machine;
b) Feature: There is 1 piece of welding torch equipped in 1 set of the LHC, welding one seam on H Beam specifically;

2) LHA Model I H Beam Gantry Welding Machine:

a) Application: LHA is applied as individual working I H Beam Gantry Welding Machine, deployed in semi automatic I H Beam Welding Line;
b) Feature: There are 2 pieces of welding torch in 1 set of LHA I H Beam Gantry Welding Machine, welding 2 pieces of H Beam simultaneously;
c) 2 Sub Groups: Based on operator position, LHA I H Beam Gantry Welding Machine can be further divided into: LHAZ Middle control, and LHAC Lateral control;
d) Standard Models of LHA I H Beam Gantry Welding Machine: LHA4Z/ LHA5Z/ LHA55Z/ LHA4C/ LHA5C;

3) LHT Model T Structure I H Beam Gantry Welding Machine:

a) Structure Features: Same as LHC, LHT has open structure. So, one model fits on all sizes of workpieces;
b) Meanwhile, same as LHA, LHT has 2 sets of welding torch in 1 set of the I H Beam Gantry Welding Machine;
c) Application: LHT is also developed for semi-automatic I H Beam Welding Line, works as an individual operating I H Beam Gantry Welding Machine;

3. Technical Parameters of I H Beam Gantry Welding Machine:

Below are technical parameters of LHC Column trolley structure I H Beam Gantry Welding Machine:

1. Function and Role of I H Beam Straightening Machine in I H Beam Welding Line:

1) Position: This is the third set of core equipment in I H Beam Welding Line, following I H Beam Assembly Machine and I H Beam Gantry Welding Machine;
2) Usage: I H Beam Straightening Machine is for flattening upward deformed H Beam flange after SAW welding, or length direction deformation. These deformations are caused from heat input generated in SAW of I H Beam Gantry Welding Machine;

2. Working Mode of I H Beam Straightening Machine:

1) Working principle of HYJ and YTJ series I H Beam Straightening Machine: (Fig.1)

2) Indicated in the above, working elements in I H Beam Straightening Machine are 3 pieces of solid straightening rollers: 2 pieces in the higher level, and 1 piece in the bottom level;
3) During work of the I H Beam Straightening Machine, the 2 top straightening rollers move downward, exerting heavy pressing force onto top surface of H Beam flange, attaining straightening purpose;

3. 2 Main Series of I H Beam Straightening Machine:

1) HYJ Series Motorized I H Beam Straightening Machine:

a) Application: This is the most widely used series, accounting for over 50% application. It can be viewed as default model of I H Beam Straightening Machine applicable for I H Beam Welding Line;
b) H Beam Orientation: H Beam stands in vertical position;
c) Straightening Force: Operation in I H Beam Straightening Machine is driven with motor reducer;

d) H Beam position and straightening process in HYJ motorized I H Beam Straightening Machine: (Fig.2,3)

e) Straightening Capacity: Flange thickness range is 6 ~ 40mm, for Q235 carbon steel;
f) Standard Models: Differing on straightening working speed, there are 2 models of HYJ-40 and HYJ-800 I H Beam Straightening Machine;

2) YTJ Series Hydraulic Oil Cylinder Drive I H Beam Straightening Machine:

a) H Beam Orientation: YTJ series also has upright H Beam in standing;

b) Straightening Force: Comes from hydraulic oil cylinder in YTJ I H Beam Straightening Machine: (Fig.4)

c) Straightening Capacity: YTJ belongs to heavy duty I H Beam Straightening Machine, with max. 80mm flange thickness for Q345 carbon steel;
d) Standard Models: YTJ-40/ YTJ-50/ YTJ-60/ YTJ-80, corresponding to max. H Beam flange thickness of 40mm/ 50mm/ 60mm/ 80mm, Q345 material;

4. Technical Parameters of Vertical I H Beam Straightening Machine: