A. Application of Metal Structure BOX Beam Production Line:

1. Important Workpiece: BOX Beam is a kind of widely applied steel structure working parts, which, thanks to its high intensity benefitting from square cross section, plays primary roles in industries of: Bridge Building/ Metal Structure/ Road Paving/ High Rise Building Construction;

2. Wuxi JACK Automatic Line of BOX Beam Production Machine:

1) Task: The automatic BOX Beam Production Line introduced in this product section is for high efficiently producing BOX Beam in high quality:

The batch of BOX Beams of different sizes produced from Wuxi JACK automatic line of BOX Beam Production Machine: (Fig.1)

2) Superior Machine Group: The BOX Beam Production Line designed and produced by Wuxi JACK company was developed on the basis of advanced process technology both domestic and abroad, advanced welding technique, and years of experience accumulated:

4 sets of Wuxi JACK LHC12 model SAW BOX Beam Welding Machine fabricate out BOX Beam in automatic stream line: (Fig.2)

3) Strong Points: This line of machine and equipment on BOX Beam production has the strong points of complete configuration, high automation, high efficiency, user friendly operation;

3. Production Output of Wuxi JACK Welding BOX Beam Production Line:

1) For semi-automatic line, its annual output of single shift can be above 5000 Ton;

2) For fully automatic line, its annual output of single shift can be above 12,000Ton;

3) Turnkey Project for Customer: The reasonable process technology and reliable machine performance makes this automatic line takes lead both in China and Overseas market: We design and produce not only every type and model of BOX Beam Production Machine: but also conventional A.C. inverter control and CNC BOX Beam End Face Milling Machine as finished machining:

4)  A piece of large of large size 1,500mm height BOX Beam being finished end face milling from Wuxi JACK CNC-DX2020 CNC BOX Beam End Face Milling Machine: (Fig.3)

B. Technical Brief on Wuxi JACK Welding BOX Beam Production Line:

The production on welding BOX Beam involves rather complicated process technology, mainly on assembly and welding, with series of sub-steps in each step:

1. Varied Types of BOX Beam Assembly Machine:

From internal baffle plate assembly, to U Beam, to finished BOX Beam:

1) Step 1: From cut plate to internal baffle plate: (Fig.4)

2) Step 2: From internal baffle plate to U Beam: (Fig.5)

3) Step 3: From U Beam to BOX Beam: (Fig.6)

2. Rich Assortment of BOX Beam Welding Machine:

One of the salient features with welding BOX Beam production is its integrated nearly all types of common seen welding mode in the process of fabrication:

1) CO₂ tack welding during baffle plate/ U Beam/ BOX Beam assembly;

2) Twin arc CO₂ back welding after BOX assembly;

3) Electroslag welding of either consumables type, or electrode type, for finished welding on internal baffle plates;

4) Finished twin arc or triple arc SAW welding on external welding seams of BOX Beam;

All the above listed welding involves advanced welding technique adopted at different work stations of Welding BOX Beam Production Line;

3. Accordingly, different types of BOX Beam Production Machine are deployed at different work station of the automatic line, according to process route on assembly and welding;

4. Wuxi JACK Leading Position: The reasonable process technology and reliable performance of each machine, makes sure automatic line takes lead both in China and overseas market;

5. Conventional Sizes of BOX Beam Produced from Welding BOX Beam Production Line:

C. Process Route and Major BOX Beam Production Machine:

1. Cut out beam strip and baffle end plate: CNC Strip Flame Cutting Machine;

2. Marking: Platform, for determining position of baffles and cut holes;

3. Beveling of beam main plate: Edge milling Machine or semi-automatic cutting      machine;

4. Pre-setting hole for electroslag weld：Manual gas cutting torch;

5. Multiple Steps of BOX Beam Assembly Machine:

1) Assemble and tack welding of internal Baffle plate;

2) Tack weld of baffle with flange: Input conveyor roller table of U Beam BOX Beam Assembly Machine:

Wuxi JACK GZ12 model machine for internal baffle plate assembly: (Fig.7)

3) U Beam assembly：Assembled into U Beam，then pressed tightly and performed with tack welding;

4) 90° tilt on U Beam: Movable 180°hydraulic tilting rack, flipped to both sides;

5) Baffle plate welding: Manual welding machine, on the basis of technology requirement;

6) Tack weld of liner plate：Manual welding machine;

7) Assembly of Cover plate of BOX Beam: Assembled with U Beam Box Beam Assembly Machine, then pressed tightly and performed with tack welding:

Wuxi JACK UBZ12 for assembly and tack welding on U Beam and BOX Beam: (Fig.8)

6.  Multiple Stations of BOX Beam Welding Machine:

1) 90° tilt on BOX Beam: Movable 180°hydraulic tilting rack;

2) Backing of welding seam: Cantilever type backing CO₂ BOX Beam Welding Machine:

Wuxi JACK XQ12 model machine works at customer site: (Fig.9)

3) 180° tilt on BOX Beam：Movable 180° hydraulic tilting rack;

4) Backing of weld seam: Cantilever type backing CO₂ BOX Beam Welding Machine;

5) Electroslag welding of internal baffle plate: Cantilever type Electroslag BOX Beam Welding Machine:

Electroslag welding on internal baffle plate, with Wuxi JACK XD15 model machine: (Fig.10)

6) Transferred and flipped to cutting station：Movable 90° hydraulic tilting rack;

7)  Test on welding seam: Ultrasonic testing instrument;

8)  Clearing of riser, sprue of electroslag：Carbon arc gouging;

9) Transfer and flip to original position: Movable 90°hydraulic tilting rack;

10) Transferring BOX Beam to SAW (Submerged Arc Weld) area：Conveyor;

11) BOX Beam Moved to SAW station：Movable 180°hydraulic tilting rack;

12) BOX Beam finished welding on one side：Cantilever type SAW BOX Beam Welding Machine，it moves till completion of welding operation:

Wuxi JACK LHE12 model gantry structure machine welds out BOX Beam: (Fig.11)

13) BOX Beam Flip：Movable 180° hydraulic tilting rack;

14) BOX Beam finished welding on opposing side：Gantry type SAW BOX Beam Welding Machine, it moves till completion of welding operation;

15) BOX Beam Moved to middle conveyor：Movable 180°hydraulic tilting rack;

16) Finished BOX Beam Sent to checking area：Conveyor;

17) Test on welding seam of BOX Beam: Ultrasonic testing instrument, Movable 180° hydraulic tilting rack;

18) Manual repair weld;

19) Welding of end join plate：Manual welding machine;

7. EOL Stations of Welding BOX Beam Production Line:

1) Manual flame straightening

2) Facing on both ends of finished BOX Beam：BOX Beam End Face Milling Machine. The BOX Beam will be flipped with traveling crane;

3) Surface de-rusting：BOX Beam shotblasting machine;

4) Surface painting：Painting equipment or manual painting unit;

As summary, these BOX Beam Production Machine can work as individual equipment, or as station of line. The movement of BOX Beam along the entire line is assisted with conveyor /Auxiliary equipment, like steel conveyor or flipping equipment; The above process flow is the detailed version for fully automatic Welding BOX Beam Production Line. At customer site, a simplified line can also be set up, with installation of crucial equipment of BOX Beam Assembly Machine and BOX Beam Welding Machine.