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4- HB2000 Automatic H Beam Production Line

A. Subject of this Product Page on Wuxi JACK Steel Structure I H Beam Production Line:

1. Origin: This page is converted from introduction slides on I H Beam Production Line, for quick review on Usage/ Workpiece Specifications/ Strong Points/ Process Technology/ Layout and Main types of H Beam Production Equipment, being deployed in Wuxi JACK delivered I H Beam Production Line;
2. Goal: We expect this page of slides can be helpful to anyone who have interest on I H Beam Production Line and I H Beam Production Machine, and want to spend the least time to get a general picture on it, either for the purpose of successful purchase, or just plan to have an overall idea.

 

B. Extensive Use of Steel Structure I H Beam Production Line:

1. Function and Finished Working Parts of I H Beam Production Line:

1) Delivery: As its name suggests, I H Beam Production Line produces welding T/ I/ H Beam of light/ medium/ heavy duties, from the minimum 200mm web height, to the maximum 3000mm web height. This is the primary working parts applied in Steel Structure industry:

2) A piece of large welding H Beam, being manufactured from Wuxi JACK I H Beam Production Line: (Fig.1)

Fig1 I H Beam Gantry SAW Welding Machine 14

 

2. Uniqueness of Steel Structure I H Beam Production Line and Related I H Beam Production Machine:

1) New H Beam Production Equipment: Recent years, there is a kind of new generation efficient and cost effective H Beam Production Equipment: 3 in 1 H Beam Assembly Welding Straightening Integral Machine (H Beam 3 in 1 Fabrication Machine), which has many advantages in replacing traditional I H Beam Production Line, for producing light and medium duty T/ I/ H Beams;
2) I H Beam Production Line Irreplaceable Capability: Meanwhile, in the field of producing heavy duty welding H Beam, which means welding seam bigger than 12mm on finished T/ I/ H Beam, and needs to be completed with more than one time welding pass on finished working parts, the traditional I H Beam Production Line still has its irreplaceable position. This is benefitting from its 45° fillet welding, in I H Beam Submerged Arc Welding Machine:

45° fillet welding on H Beam, in Wuxi JACK I H Beam Submerged Arc Welding Machine: (Fig.2)

Fig2 I H Beam Gantry SAW Welding Machine

 

 

C. Classification on Steel Structure I H Beam Production Line:

Based on internal material transferring way among 3~ 4 working zones of I H Beam Production Machine, the I H Beam Production Line can be classified into 2 general types of automatic and semi-automatic:

1. Automatic Steel Structure I H Beam Production Line:

1) Advantages: Automatic I H Beam Production Line has the least degree of human intervention, as shown in banner of this page: Utilizing 60° / 90°/ 180° hydraulic drive Overturning Equipment and Steel Conveyor, WIP (Work In Progress) workpieces flow inside the entire I H Beam Production Line is fully automatic and safe;
2) “Disadvantage”: Automatic I H Beam Production Line involves relative larger workshop land occupation and more investment. And update on its layout involves longer time;

2. Semi-Automatic Steel Structure I H Beam Production Line:

1) Installed with 3 types of basic I H Beam Production Equipment:
 

a) H Beam Assembly and Tack Welding Machine;
b) H Beam Submerged Arc Welding Machine;
c) H Beam Flange Straightening Machine;

d) I H Beam End Face Milling Machine;
2) Material Flow: Human operation on transferring of WIP (Work in process) working parts among the above listed 3 types of I H Beam Production Machine, are carried out by operators operating on traveling cranes and travel carts, a group of Semi-Automatic I H Beam Production Line is set up;
3) Business Features: Semi-Automatic I H Beam Production Line has smaller land occupation, more flexible layout, and less investment, compared with automatic I H Beam Production Line. It is more applicable for MGPP (Multi-Generation Production Plan) on introducing I H Beam Production Line at customer site.

 

 

D. Related Product Pages on Steel Structure I H Beam Production Line:
 

For deep down exploration on technical details of Wuxi JACK I H Beam Production Line and involved I H Beam Production Equipment, please visit thematic product pages of:
1) I H Beam Production Line;
2) Automatic and Manual I H Beam Production Line;
3) I H Beam Production Equipment

 

E. General Picture on Strong Points and Technical Features of Wuxi JACK Steel Structure I H Beam Production Line:

Slides 1: Finished Workpieces Specifications and Advantages of I H Beam Production Line:

1. Specifications of Finished Workpieces from I H Beam Production Line:

1) Working Parts: Standard models of I H Beam Production Line produces 3 grades of Max. welding T I H Beam based on its models HB1500/ 1800/ 2000, which is distinguished according to H Beam max. web height: 1500mm/ 1800mm/ 2000mm;

2) Selling Volume: Of which, the 1500mm grade (HB1500) I H Beam Production Line has the widest application;
3) Special Models: Under special design, Wuxi JACK can produce I H Beam Production Line with finished H Beam up to 3000mm web height;
2. Strong Points: This page of slides also lists main superiorities of Wuxi JACK I H Beam Production Line. In general, this turnkey project builds up a modern workshop for Steel Structure manufacture at customer site;
3. Business Case: The photo in this page of slides presents a line of HB1500 heavy duty automatic HB1500 I H Beam Production Line, exported by Wuxi JACK to a Russian client in the year 2014.

1 H Beam Welding Production Line

Slides 2: The Fluent Process Flow in Wuxi JACK Steel Structure I H Beam Production Line:

1) This page of slides gives a graphic view on process technology route in producing welding H Beam, in both automatic and semi-automatic I H Beam Production Line;
2) General speaking, it goes through 5 steps, and involves operation on 5 major types of I H Beam Production Machine:

1. The 1st Step: 1st Operation with CNC Strip Plate Cutting Machine at Beginning Station of I H Beam Production Line:

1) This step is for preparing raw materials on making T/ I/ H Beams;
2) The strip steel boards cut from carbon steel plate will be applied as flange and web of welding H Beam;
 

2. The 2nd Step: Implement Assembly and Stitch Welding on Flanges and Web into T / H Beam, in I H Beam Assembly Machine:

The corresponding H Beam Production Equipment in this step is I H Beam Assembly and Tack Welding Machine:

1) In this step, first one piece of flange and web respectively will be fit up and stitch welded into T Beam;
2) Then, the WIP (Work in process) T Beam is flipped 180°, and sent into the I H Beam Assembly and Tack Welding Machine again, by means of traveling crane;
3) The 2nd piece of flange is loaded into the I H Beam Assembly Machine, to make T Beam into H Beam;
 

3. The 3rd Step: Carry Out Large Current SAW (Submerged Arc Welding) with I H Beam Submerged Arc Welding Machine:

The corresponding I H Beam Production Equipment in this step is I H Beam Submerged Arc Welding Machine:

1) In Automatic I H Beam Production Line:

a) There are 4 sets of LHC Trolley Moving I H Beam Submerged Arc Welding Machine, being deployed in a consecutive straight line;
b) Each set of the LHC Trolley Moving I H Beam Submerged Arc Welding Machine is responsible for completing 1 piece of welding seam on H Beam;
c) Every time 1 piece of welding seam is completed, the H Beam is flipped 90°, and sent to next set of LHC I H Beam Submerged Arc Welding Machine, until all the 4 pieces of welding seams are finished fabrication on H Beam;

2) In Semi-Automatic I H Beam Production Line:

a) There is 1 set of LHA Gantry Moving H Beam Submerged Arc Welding Machine, or LHT T Frame Open Structure I H Beam Submerged Arc Welding Machine, being applied for completing this task:
b) One set of the LHA/ LHT I H Beam Submerged Arc Welding Machine finishes all the 4 pieces of welding seams;
c) For this purpose, the workpiece H Beam should be flipped 4 times of 90° on supporting rack of the I H Beam Submerged Arc Welding Machine, to perform SAW on H Beam;
 

4. The 4th Step: Flange Straightening with I H Beam Straightening Machine:

The corresponding I H Beam Production Equipment in this step is I H Beam Flange Straightening Machine:

1) Flange Deformation: After the large current submerged arc welding, H Beam flanges usually is distorted upward somewhat due to heat input, which should be flattened out in I H Beam Flange Straightening Machine;
2) Longitudinal Deformation: Sometimes, the distortion along H Beam lengthways is also obvious, which should be straightened with I H Beam Horizontal Press Straightening Machine;
 

5. The 5th Step: I H Beam End Face Polishing with I H Beam End Face Milling Machine:

1) The corresponding I H Beam Production Equipment in this step is I H Beam End Face Milling Machine;
2) This step is for machining end faces of fabricated H Beam, so that these finished working parts can be jointed together for carrying out Steel Structure construction;
 

6. Material Flow among Steel Structure I H Beam Production Machine:

1) In automatic I H Beam Production Line, workpieces 60°/ 90°/ 180° rotating and transportation is fulfilled by means of moving or stationary 60°/ 90°/ 180° Hydraulic drive Overturning Equipment and Steel Conveyor. Operators work is safe and relieved;
2) In semi- automatic I H Beam Production Line, the corresponding material flow is basically completed by operators with operating on traveling cranes. So, operators need to take care on safe operation.
 
2 H Beam Welding Production Line

Slides 3: The Recommended Layout of Wuxi JACK Steel Structure I H Beam Production Line:

1. Layout and Workshop Land Occupation of I H Beam Production Line:
 

This page of slides gives suggested layout of I H Beam Production Line, which takes workshop land area in the range of 2000 m2 to 5000 m2:

The four sets of central I H Beam Production Machine in I H Beam Production Line:

1) I H Beam Assembly and Tack Welding Machine;
2) I H Beam Submerged Arc Welding Machine;
3) I H Beam Flange Straightening Machine;
4) I H Beam End Face Milling Machine;
Are installed in sequence in a straight row, so that workpieces can flow the entire machine equipment complex of I H Beam Production Line along the shortest path;


2. CNC Strip Plate Cutting Machine, which is a kind of more general purpose equipment and not confined to I H Beam Production Line use, is arranged in another span along side the 4 sets of essential I H Beam Production Machine, together with raw materials storage area;

 

3. Land Area under Such Layout of Steel Structure I H Beam Production Line:

1) The minimum required least area is: 95m length x 24m width (2 arrays of 11m span, together with 2m width walking passage) = 2280m2;
2) The ideal occupied area is: 200m length x 24m width= 4800m2.

3 H Beam Welding Production Line

Slides 4: Starting Primary I H Beam Production Machine in Steel Structure I H Beam Production Line: CNC Strip Plate Cutting Machine, plus I H Beam Assembly and Tack Welding Machine:

From this page of slides, photos of main H Beam Production Machine are pasted in sequence:

 

1. CNC Strip Plate Cutting Machine:

1) Working Nature: As mentioned previously, it is kind of universal equipment, which can be served in not only I H Beam Production Line, but also in other process technology;
2) Running Position: CNC Strip Plate Cutting Machine is deployed at start working station of I H Beam Production Line: 1st Operation zone;
3) Varied Specifications: There are numerous configurations of CNC Strip Plate Cutting Machine, divided on: Max. valid cutting width (Gantry span)/ Cutting way (Flame or Plasma)/ Cutting torch quantity, etc.;
4) Model for being applied in I H Beam Production Line: The CNC Strip Plate Cutting Machine is usually in configuration of: CG4000 (4000mm span of cutting rails), Oxygen flame cutting, 9 sets of strip cutting torches, and 2 pieces of CNC cutting torches;

 

2. I H Beam Assembly and Tack Welding Machine:

1) Significance: This is the first set of solitary use dedicated I H Beam Production Equipment;
2) Technical Specialty of I H Beam Assembly Machine is high precision: Controlled with PLC (Programmable logic controller) and A.C. inverter, accuracy and reliability of H Beam assembling process is guaranteed;
3) Sophistication: I H Beam Assembly and Tack Welding Machine is a “complicated” equipment: Hydraulic drive on workpieces alignment, PLC control on logic working, and A.C. inverter for managing on working speed control.

4 H Beam Welding Production Line

Slides 5: Central Primary I H Beam Production Machine in Steel Structure I H Beam Production Line: I H Beam Assembly and Tack Welding Machine, plus I H Beam Submerged Arc Welding Machine:

1) Central Zone of I H Beam Production Line: We paste I H Beam Assembly and Tack Welding Machine again in this page of slides, because as a tightly arranged working zone, all the I H Beam Production Machine inside I H Beam Production Line are deployed in “seamless” style, as can be seen from the 2 photos on this page of slides;
2) Way of Arrangement: As can be observed from this page of slides, the 4 sets of LHC trolley moving I H Beam Submerged Arc Welding Machine is positioned right behind Z15 I H Beam Assembly and Tack Welding Machine: The assembled H Beam will be sent to SAW welding area by way of conveyors without delay;
3) Working Site: The 2 photos in this page of slides reflect working condition at automatic I H Beam Production Line: Seldom operators work on these I H Beam Production Equipment.
5 H Beam Welding Production Line

Slides 6: Middle Primary I H Beam Production Equipment in Steel Structure I H Beam Production Line: I H Beam Submerged Arc Welding Machine and I H Beam Flange Straightening Machine:

1) Closer View: In this page of slides, the LHC trolley moving I H Beam Submerged Arc Welding Machine can be observed in closer distance and more clear view: The H Beam is laid onto a group of hydraulic drive 180° Overturning Racks in 60° position, for performing 45° fillet welding on H Beam;

2) I H Beam Flange Straightening Machine:

a) This is the 3rd set of essential I H Beam Production Equipment;
b) There are 2 general groups of I H Beam Flange Straightening Machine: HYJ series Mechanical motor drive medium duty (Max. H Beam Flange 40mm thickness, tensile strength 510 MPa), and YTJ series hydraulic cylinder drive heavy duty (Max. H Beam Flange 80mm thickness, tensile strength 600 MPa);
c) Model Here: In this page of slides (Right side photo), it is a set of HYJ-800 mechanical motor drive I H Beam Straightening Machine, which is the largest selling model in I H Beam Production Line.

 

6 H Beam Welding Production Line

Slides 7: Closing Primary I H Beam Production Equipment in Steel Structure I H Beam Production Line: I H Beam End Face Milling Machine and Hydraulic Drive 60°/ 90°/ 180° Overturning Equipment:

1. DX Series I H Beam End Face Milling Machine being Deployed at EOL (End of Line) Working Station in Steel Structure I H Beam Production Line:
 

1) Wide Application: Besides working in I H Beam Production Line, I H Beam End Face Milling Machine can also be used on performing end face machining on all kinds of available steel structure members: BOX Beam/ Cross Beam/ Pipe/ Special shape structure members... etc.;
2) Applicable Models: When being applied in I H Beam Production Line, the often selected models of I H Beam End Face Milling Machine are DX12xx (Such as DX1215), or DX15xx (Such as DX1520);

 

2. Business Case on Wuxi JACK CNC I H Beam End Face Milling Machine:

1) This page of slides (Left side photo) shows a complex of Milling and Facing Center exported from Wuxi JACK to Belarus in the year 2014;

2) The Milling and Facing Center is Composed of:

a) 2 sets of CNC-DX1540 CNC I H Beam End Face Milling Machine;
b) 2 sets of tailor made turning tables;
c) 5 sets of tailor made hydraulic drive workpiece clamp tables;


3. Overturning Equipment: This page of slides (Right side photo) also reflects on working moment of moving style hydraulic drive 180° Overturning Equipment, in a cmplex of automatic I H Beam Production Line.

7 H Beam Welding Production Line
H Beam Assembly Machine
01

H Beam Gantry Welding Machine
02

H Beam Straightening Machine
03

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