1- 悬臂式埋弧焊机Boom type SAW machine

Wuxi JACK BOX Beam Production Line, the Most Reliable Machine Group for Customer!

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The Output and Advantage of Wuxi JACK BOX Beam Production Line

 

1. The Finished Product Produced from BOX Beam Production Line:

1) Welding BOX beam has the best degree of intensity and strength, which is the most important raw material in Steel Structure Industry for constructing high rise buildings;
2) BOX Beam Production Line is the professional machine group for producing welding BOX Beam. The cross section of BOX Beam is in the range of 300x300 mm to 1200x 1200 mm, and length from 3000 mm to 12000 mm. The max. weight of single piece of BOX Beam delivered from the BOX Beam Production Line can be up to 20Ton;

3) Welding BOX Beam of various sizes manufactured from Wuxi JACK BOX Beam Production Line:

Fig1 BOX Beam Production Line 12

 
Fig2 BOX Beam Production Line 44
 
Fig3 BOX Beam Production Line 61
 
 

2. Strong Points of Wuxi JACK BOX Beam Production Line:

 

1) Pragmatic and Fluent Process Technology Flow in BOX Beam Production Line:

The assistant work stations, including baffle manual welding, back welding, cutting of arc strike and riser in electroslag welding, IPV (Internal process validation) can all be completed in the BOX Beam Production Line. There is no need on traveling crane, except U Beam assembly, and finished BOX Beam loading offline;


2) Advanced Welding Technique Applied at Work Stations of BOX Beam Production Line:

Due to the enclosed structure of BOX Beam, in the sequence of process technology, the welding techniques adopted in work stations of BOX Beam Production Line all take the lead in Welding Equipment Industry:

A. Internal Baffle welding at BOX Beam Assembly Machine;
B. Twin Arc gas shielded CO2 Back Welding at BOX Beam Back Welding Machine;
C. Consumable nozzle electroslag welding at BOX Beam Electroslag Welding Machine;
D. Wire electrode electroslag welding at BOX Beam Electroslag Welding Machine;
E. Twin Arc and Triple Arc submerged arc welding at BOX Beam SAW Welding Machine.

 

The above listed welding technique applied in BOX Beam Production Line all have its unique advantage, which we will explain later in corresponding equipment.


3) Optimum Welding Position in Work Stations of BOX Beam Production Line:

By means of 180° and 90° Traveling Hydraulic Overturning Rack, all the automatic and manual welding operations in BOX Beam Production Line are implemented in optimum position (Vertical downward welding), guaranteeing the best degree of welding quality, high productivity, and operator friendly ergonomics operation.

Design Sketch of Welding BOX Beam to be Produced in Wuxi JACK BOX Beam Production Line

Process Technology of BOX Beam Production Line

Below is detailed illustration on process technology applied in welding BOX Beam Production Line. There are 35 automatic and manual working stations in total in a complete configured BOX Beam Production Line.

 

 

Put it briefly, the 35 stations in BOX Beam Production Line can be divided into 14 major steps of:


1. 1st Operation Plate Cutting: CNC Strip Plate Cutting Machine at Cut Off Area of BOX Beam Production Line;
2. Mark Line: Confirm position of internal Baffles and electroslag welding holes cutting;
3. Make Welding Groove on Beam Board: Edge Milling Machine;
4. Internal Baffle Assembly and Tack Welding: Internal Baffle Assembly Machine at Assembly Area of BOX Beam Production Line;
5. Tack Weld Internal Baffles onto Web: Conveyor of Box Beam Assembly Machine;
6. U Beam Assembly:Box Beam Assembly Machine at Assembly Area of BOX Beam Production Line;
7. 90o Flipping of Assembled U Beam:180o Traveling type Flipping Rack at Assembly Area of BOX Beam Production Line;
8. Assembly of Top Cover onto BOX Beam: Box Beam Assembly Machine at Assembly Area of BOX Beam Production Line;
9. 90o Flipping of Assembled U Beam:180o Traveling type Flipping Rack at Assembly Area of BOX Beam Production Line;
10. BOX Beam Welding Seam Back Welding: BOX Beam Back Welding Machine;
11. Internal Baffle Electroslag Welding: Cantilever type BOX Beam Electroslag Welding Machine: Consumable type or Wire Electrode type;
12. Assembled and Back Welded BOX Beam Sent to Submerged Arc Welding Station:180o Traveling type Flipping Rack at SAW welding Area of BOX Beam Production Line;
13. BOX Beam Submerged Arc Welding:LHC Column type or LHE Gantry frame BOX Beam SAW Welding Machine at SAW welding Area of BOX Beam Production Line;
14. BOX Beam End Face MillingBeam End Face Milling Machine

Layout of BOX Beam Production Line

Correspondingly, below is layout of a typical complex of BOX Beam Production Line:

Main Equipment in BOX Beam Production Line

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1. GZ12/ GZ15 Internal Baffle Assembly and Welding Machine of BOX Beam Production Line:

1. Usage, Models and Working Principle of Internal Baffle Assembly and Welding Machine:
 

1) Usage: This machine is for assembling and welding single piece of internal baffle, that will be assembled and welded inside BOX Beam at subsequent stations of BOX Beam Production Line;
2) Appearance: The design sketch and photo of finished internal baffles produced from the machine please check the 3rd and 4th photos;
3) Models: There are two models of Internal Baffle Assembly and Welding Machine deployed at BOX Beam Production Line: GZ12 and GZ15;
4) Quantity: There is 1 set of the machine deployed in BOX Beam Production Line;
5) Working Principle: The machine has rotating range of ±180°, which is driven with braking type A.C. motor. Upon arriving at target angular position, the workpiece is secured firmly by means of air cylinders. Welding of baffle is carried out in manual mode.

 

2. Technical Parameters of GZ12/GZ15 Internal Baffle Assembly and Welding Machine:

 Model of Internal Baffle Assembly and Welding Machine  GZ12/ GZ15
 BOX Beam Cross Section H×W   300×300∽1200×1200 mm /  300×300∽1500×1500 mm
 BOX Beam Length   3000∽12000 mm
 Max. Workpiece weight  20 Ton.
 Baffle Thickness   ≤80 mm
 Flip Motor Power  2 kW
 Flip Speed  1.8 rpm
 Work Table Loading Capacity  1200 kg
 Height of Flip Center  1200 mm
 Flip Range of Work Table  ±180°

2. UBZ12 BOX Beam Assembly Machine:

1. Usage of BOX Beam Assembly Machine:

UBZ12 BOX Beam Assembly Machine assembles 4 pieces of beam board (Web) and 4 pieces of internal baffles into a piece of assembled and tack welded BOX Beam.


2. Process Technology of BOX Beam Assembly Machine:

Below 4 sketches give how does webs and internal baffles first assembled and tack welded into U Beam, then into BOX Beam:

3. Technical Features of BOX Beam Assembly Machine:

1) The workpieces (U Beam/ BOX Beam) are assembled and tack welded during its traveling through the BOX Beam Assembly Machine. It is secured in 2 points of top downward and lateral pressing, driven with hydraulic oil cylinders;
2) Traveling rails are heavy duty 38kg/m type;
3) There is high strength pulling rod system equipped in the BOX Beam Assembly Machine, guaranteeing precise assembling of U Beam and BOX Beam;
4) There is 1 set of the BOX Beam Assembly Machine deployed in BOX Beam Production Line.

 

4. Technical Parameters of UBZ12 BOX Beam Assembly Machine:

 Model of BOX Beam Assembly Machine  UBZ12
 Workpiece Cross Section Size  300x300~1200x1200 mm
 Max. Loading Capacity  20 Ton
 Gantry Travel Speed   4000 mm/ min.
 Hydraulic Pressure  14 MPa
 Max. Pressure of Sideward Stroke Cylinders  15 Ton
 Max. Pressure of Downward Stroke Cylinder  30 Ton
 Max. Stroke of Sideward Cylinders  800 mm
 Max. Stroke of Downward Cylinders  900 mm
 Oil Pump Motor  11 kW

3. YF1220 180° Hydraulic Flipping Rack of BOX Beam Production Line:

1. Role of 180° Hydraulic Flipping Rack in BOX Beam Production Line, and Its Working Way:

1) YF1220 180° Hydraulic Flipping Rack is logistics equipment in BOX Beam Production Line. Its purpose is to have 90°/ 180° flipping of BOX Beam, as well as transferring among work stations in the line;
2) Working Way: The 180° Hydraulic Flipping Rack works in the form of 2 sets per group, to overturning and supporting the whole length of BOX beam;
3) Flipping of BOX Beam is driven with hydraulic oil cylinder; Traveling of BOX Beam is driven with A.C. motor reducer;
4) Quantity: There are 4 sets (Or, 2 groups) of 180° Hydraulic Flipping Rack deployed in a BOX Beam Production Line.

 

2. Technical Parameters of YF1220 180° Hydraulic Flipping Rack:

 Model of 180° Hydraulic Flipping Rack  YF1220
 Loading Capacity  20 Ton
 Power of Travel Motor Reducer  1.5 kW
 Travel Speed  5000 mm/min.
 Diameter of Flipping Drive Cylinder  φ150mm
 Max. Hydraulic Pressure  16 MPa
 Rail Center Distance  700 mm
 Overturning Range  ±180°

4. BOX Beam Back Welding Machine:

1. Usage and Working Principle of BOX Beam Back Welding Machine:
 

1) Usage: XQ12 BOX Beam Back Welding Machine performs Twin Arc CO2 back welding on assembled BOX Beam;

2) Working Principle of BOX Beam Back Welding Machine:

a) During working, the BOX Beam is laid stationary on conveyor, and moving trolley of the BOX Beam Back Welding Machine travels in welding speed, which is controlled with A.C. inverter, implementing Twin Arc CO2 back welding at the same time;
b) Welding torch carriage can be adjusted for its position along vertical, transverse direction on boom of the traveling trolley, based on size of BOX Beam produced in the BOX Beam Production Line;
c) During running of the BOX Beam Back Welding Machine, position of welding torch is traced and adjusted by means of the mechanical type arc guiding seam tracing unit;
3) Quantity: One set of BOX Beam Back Welding Machine is equipped with 2 sets of twin arc CO2 welding power supply; In BOX Beam Production Line, there are 2 sets of BOX Beam Back Welding Machine.

 

2. Technical Parameters of XQ12 BOX Beam Back Welding Machine:

 Model of BOX Beam Back Welding Machine  XQ12
 BOX Beam Cross Section Size  300x300~1200x1200 mm
 BOX Beam Length  4000~15000mm
 CO2 Backing Welding Speed  240 ~ 2400 mm/min.
 Idle Running Speed  3000 mm/min.

5. BOX Beam Electroslag Welding Machine of BOX Beam Production Line:

1. Usage, Classification and Specialty of BOX Beam Electroslag Welding Machine:

1) Usage: In BOX Beam Production Line, BOX Beam Electroslag Welding Machine is for final welding of internal baffles into the BOX Beam, following its tack welding completed in the previous station of BOX Beam Assembly Machine;
2) Classification: There are two types of BOX Beam Electroslag Welding Machine: Consumable Nozzle type, and non-consumable Wire Electrode type:
 

Consumable Nozzle type BOX Beam Electroslag Welding Machine:

 

Non-Consumable Wire Electrode type BOX Beam Electroslag Welding Machine:

 
3) Specialties: Consumable Nozzle type BOX Beam Electroslag Welding Machine works in the way of consuming welding nozzle. It has lower machine price and relative higher running cost; Comparatively, non-consumable Wire Electrode type BOX Beam Electroslag Welding Machine has relative higher machine price and lower running cost;
4) Advantages: For the BOX Beam Electroslag Welding Machine deployed in Wuxi JACK BOX Beam Production Line, cutting holes are cut out ahead of time at preceding stations. So that the quality issue of cutting fluid staying in the hole which bring negative effect can be eliminated;
5) Model: Consumable Nozzle type BOX Beam Electroslag Welding Machine has 2 models of XD12 and XD15; non-consumable Wire Electrode type BOX Beam Electroslag Welding Machine has one common used model of XSD12;
6) Quantity: In BOX Beam Production Line, there are 2 sets of BOX Beam Electroslag Welding Machine.

 

2. Technical Parameters of BOX Beam Electroslag Welding Machine:

 Model of BOX Beam Electroslag Welding Machine   XD12 / XD15 / XSD12
 Cross Size Size of BOX Beam    300x300~(1200x1200mm/ 1500x1500mm/ 1200x1200mm)
 BOX Beam Length  4,000 ~ 15,000 mm
 Trolley Rail Span   1,000 mm
 Trolley Travel Speed   6,000 mm / min.
 Trolley Travel Motor Power   0.55 / 0.75/ 0.55 kW

6. BOX Beam SAW Welding Machine of BOX Beam Production Line:

1. Function and Classification of BOX Beam SAW Welding Machine:

1) Function: BOX Beam SAW Welding Machine performs Twin Arc or even Triple Arc submerged arc welding on the assembled, tack welded, back welded, and electroslag welded BOX Beam flowing in the BOX Beam Production Line;
2) Classification: Based on structure of mechanical main frame, there are 2 types of BOX Beam SAW Welding Machine: LHE12 Gantry type and LHC12 Cantilever type;
3) Both types work in the same working mode: BOX Beam is put stationary on conveyor of the BOX Beam SAW Welding Machine, and the gantry frame or cantilever trolley moves in adjustable welding speed, performing Twin Arc or Triple Arc submerged arc welding at the same time;
4) Quality Control: During working of the BOX Beam SAW Welding Machine, welding torch is controlled with air cylinder drive mechanical style welding seam tracing unit, guaranteeing welding quality and productivity of the BOX Beam Production Line;
5) Working Nature: We can see that gantry type BOX Beam SAW Welding Machine has very similar machine structure and working principle as H Beam Gantry Welding Machine; And cantilever type BOX Beam SAW Welding Machine can be replaced as column structure H Beam Welding Machine which are deployed 4 sets in a group in automatic H Beam Production Line;
6) Quantity: In BOX Beam Production Line, there are 2 sets of either LHE gantry style or LHC cantilever structure BOX Beam SAW Welding Machine.


2. Technical Parameters of BOX Beam SAW Welding Machine:

 Model of BOX Beam SAW Welding Machine  LHE12/ LHC12
 Mechanical Main Frame Structure  Traveling Gantry/ Traveling Trolley and Boom
 BOX Beam Cross Section Size  300x300~1200x1200 mm
 BOX Beam Length  4,000~15,000 mm
 Gantry Rail Length  18,000 mm
 Gantry Rail Span  1400 mm
 Gantry Travel Stroke  15,500 mm
 Submerged Arc Welding Welding Speed  150 ~ 1500 mm/min.
 Idle Traveling Speed  2400 mm/min.
 Gas Pressure  0.4 ~ 0.8 MPa
 Flux Recovery Unit Power  2 x 3 kW
 BOX Beam SAW Welding Machine Power  3 kW

Application Range and Related Equipment of BOX Beam Production Line

1. BOX Beam Production Line is applied in Steel Structure Industry, producing welding BOX Beams for building up High Rises;
2. The other 2 common seen lines in Steel Structure Industry are H Beam Production Line, and T Beam Production Line;
3. Besides the equipment introduced in this page, the other necessary equipment to be installed in BOX Beam Production Line are, as mentioned at beginning, in the sequence of process technology: CNC Flame Cutting Machine, and Edge Milling Machine, and 90° Hydraulic Overturning Rack, and Steel Conveyor, and Beam End Face Milling Machine.
Steel Conveyor
01

Beam End Face Milling Machine
02

Flipping Rack
03

Other Series of Products We Own besides BOX Beam Production Line

BOX Beam Production Line Blogs

  • Technical Analysis on Steel Structure Overturning Equipment

    1. Brief: This article is on the topic of demand, classification, features, design, and put into use of Steel Structure Flipping Equipment. 2. Demand on Steel Structure Flipping Equipment:1) In manufacturing process of steel structure members, logistic job is critical in connecting work Read More

  • Technical Specialty of T Beam Production Line

    T beam production equipment is a kind of special profile whose properties are between Angle steel and I-shaped steel. Its unique properties make it widely used in the shipbuilding industry. In recent years, with the rapid development of China's shipbuilding industry, the demand for T-shaped steel is Read More

  • Process Technology of BOX Beam Production Line

    1. Overview:This article will have an explore on process technology of BOX Beam production, its challenge and solution, as well as our strength;2. Definition:BOX Beam: BOX Beam refers to large size and heavy duty steel structure members that used as raw materials of constructing on high rise Read More

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