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1 BOX Beam Production Line 1

Wuxi JACK BOX Beam Welding Production Line

A. Subject of this Page on Wuxi JACK BOX Beam Welding Production Machines:

1. This page is for brief review on Wuxi JACK BOX Beam SAW Welding Machine and other types of welding: Electroslag welding, CO2 back welding, equipment on assembly, end face milling, Workpiece (From raw material to WIP U Beam, to finished workpieces of BOX Beam) send and flip, in the form of intuitive graphical slides, covering topics of:
1) Advantages of our machines;
2) Specifications of finished workpiece (Welding BOX Beam);
3) Major process technology route of BOX Beam Welding Production Line;
4) General layout of our machine line group on BOX Beam assembly, welding production;
5) Major machines and its usage in the process technology on BOX Beam welding and production;
6) FAQ (Frequently asked questions) on Wuxi JACK BOX Beam Welding Production Line;
2. Our Goal: By checking this web page, customers and anyone who have interest on Wuxi JACK BOX Beam Welding Production Line, can have a plain and quick review on this important type of Steel Structure production machine group, after 5- 10 minutes of reviewing on the slides;
3. Function of Production Line: This is a kind of very important Steel Structure production machine group, for producing common seen sized welding BOX Beam, in the height from 300mm to 1200mm, and 1500mm; BOX Beam is a kind of important steel structure component, for building up High Rises, and various large scale heavy duty Steel Structure Construction;
Wuxi JACK BOX Beam SAW Welding Machine has tandem arc submerged arc welding on BOX Beam: (Fig.1)

Fig1 BOX Beam Production Line 1

B. General Introduction and Technical View on Wuxi JACK BOX SAW Beam Welding Machine and Other Equipment:

Slides 1: The Turn Key Project of Wuxi JACK BOX Beam Welding Production Line Delivered to Customer

This page of Slides is on general review on advantages of Wuxi JACK line:
The photo in this page of slides was taken from the LHC model column boom structure machine on BOX Beam submerged arc welding. As can be seen from the photo:

1. Production Efficiency of Wuxi JACK BOX SAW Beam Welding Machine:

1) Layout of Wuxi JACK the production line delivers production of welding BOX Beam in high efficiency streamline style;
2) The cycle time and TAKT of the entire production line can be adjusted flexibly, based on customer demand on throughput;
3) Balance Rate: Under whatever output, balance rate of the welding production line can be maintained at least 90%;
4) Output of this production line is over 12000 ton per year under the arrangement of single shift;

 

2. Operation of Wuxi JACK BOX Beam Welding Production Machine:

1) The material flow of WIP (Work in process) through the entire welding production line is fluent, reducing WIP stock to the minimum level;
2) The flipping and transportation of workpieces among each work station, is completed with hydraulic drive automatic moving 180° Overturning Equipment and Steel Conveyor, with advantages of automatic, safe, consistent and controllable;
3) Multiple welding modes at different work station of BOX Beam production, deliver the optimum welding performance, with the most reasonable cost;

 

3. Delivery of Wuxi JACK BOX Beam Welding Production Line to Customers:

1) This is turnkey project for customers. Wuxi JACK engineering team will be responsible for the entire Order to Delivery value chain of machine order: From design and validation, to production and test, to customer acceptance and painting, to machines installation at customer facility, to final hand over to customer;
2) Besides machines delivery, Wuxi JACK engineers will also:
a) Propose layout of the BOX Beam Welding Production Line and confirm with customer;
b) Propose to customer process technology on manufacturing welding BOX Beam, and merge it with machines layout;
3) We not only produce all the major BOX Beam Welding Production Machines involved, but also many other support machines of the production line, such as:
a) CNC Flame Plasma Cutting Machine;
b) Steel Plate Edge Milling Machine;
c) H BOX Beam End Face Milling;
d) Hydraulic drive BOX Beam 180° Turnover Machine

1 BOX Beam Production Line

Slides 2: The Finished Workpiece Produced from Wuxi JACK BOX Beam Welding Production Line

1. What can Wuxi JACK BOX SAW Beam Welding Machine Produce?

This page of slides gives design sketch and main specifications of welding BOX Beam produced from our BOX SAW Beam Welding Machine:
1) Cross section of welding BOX Beam is from 300mm x 300mm to 1500mm x 1500mm;
2) Length of welding BOX Beam is from 3m to 12m;
3) Max. weight of single piece of welding BOX Beam can be up to 20 Ton/ piece;
4) Wall thickness of welding BOX Beam is from 16mm to 80mm;
2. So, this is a genuine sense of heavy duty steel structure Production Line. The welding operation involved is also heavy type: Tandem arc or even triple arc submerged arc welding;
3. Design sketch on the welding BOX Beam in this page of Slides also gives detailed information on distribution, types and dimensions of welding seams on it.

2 BOX Beam Production Line

Slides 3: Major Process Technology of Wuxi JACK BOX Beam Welding Production Line

This page of Slides illustrates on the main working stations in the production line, which can be generalized into 7 major steps of:
1. The 1st Operation: Steel Plate Cut into BOX Beam plates and baffles:
Just like H Beam Production Line, this station is installed with CNC Strip Plate Cutting Machine, for cutting out strip plates, being used as raw materials for making welding BOX Beam;
2. Baffle Assembly and Tack Welding with GZ12 Model BOX Beam Welding Production Machine:
This is the first step of assembly, from strip plates to half finished baffle plates assembling unit;
3. U Beam BOX Beam Assembly and Tack Welding with UBZ12 Model Machine:
This is the finished step of assembly in the line, from baffle plate unit, to U Beam, then to BOX Beam, together with stitched welding;

4. CO2 Back Welding on the Assembled BOX Beam:

1) This is the first step of welding carried out in BOX Beam Welding Production Line, for performing CO2 back welding on assembled BOX Beam;
2) Its function is similar to H Beam Assembly Machine, which builds up initial structure of BOX Beam, before subsequent finished welding;

5. Internal Electroslag Welding on Baffle Plates:

1) The specialty and challenge of electroslag welding here is, the baffle plates have already being placed and stacked inside the BOX Beam, so its welding can not be fulfilled with conventional welding mode. Instead, it is accomplished by means of special type welding consumables, either nozzle or wire, to be melted and integrated with BOX Beam during process;
2) Electroslag welding on baffle plates is the second step of welding in the BOX Beam Welding Production Line. It strengthens the entire piece of BOX Beam, by means of solidifying several pieces of baffle plates;

6. Finished SAW (Submerged Arc Welding) of BOX Beam SAW Welding Machine:

1) This is the final step in BOX Beam welding, which has high welding current and working velocity. The welding operation is rather heavy, of tandem arc or triple arc welding;
2) Workpieces output can be viewed as rough finished workpieces of BOX Beam, just need end face milling and painting;
7. BOX Beam End Face Milling at EOL (End of Production Line):
The machine of this work station is same as that of H Beam Production Line: The DX Series steel structure BOX H Beam End Face Milling Machine.

3 BOX Beam Production Line

Slides 4: The General Layout View of Wuxi JACK BOX Beam Welding Production Line

This page of Slides gives layout sketch and land occupation of our steel structure production line:


1. Area of BOX Beam Welding Production Line:

1) The workshop floor for installation and laying of all the primary BOX Beam Welding Production Machines is 3200m2: 133m length by 24m width;
2) The 24m width workshop is divided into two bays, with 3m width foot walk in the middle;
2. Material Handling:
1) The steel plate onto CNC Flame Cutting Machine and finished plates off the machine is by means of overhead travel crane;
2) For all the following working stations, the workpiece (Baffle plates, U Beam, BOX Beam) movement and transfer is by means of Steel Structure Conveyor and other automatic equipment;

3. Arrangement of BOX Beam Welding Production Machines:

1) The 1st set of machine: CNC-CG4000 CNC Strip Plate Cutting Machine is installed individually, followed with UZ12 Baffle Plate Assembly Machine;
2) The remaining 5 types of machine, from assembly to Overturning Equipment to BOX Beam SAW Welding Machine, are deployed in sequence at the other bay of the workshop;
4. The workpiece manufacture and flow through the entire production line is fulfilled automatically.

4 BOX Beam Production Line

Slides 5: Major BOX Beam Welding Production Machines in Sequence of Process Route

1. The 1st Set of Machine: CNC-CG4000 CNC Strip Plate Cutting Machine:

1) Same as H Beam Production Line, BOX Beam Welding Production Line also starts with steel plate cutting for raw material preparation;
2) The “standard” (Common seen) model is CNC-CG4000, which has cutting width of 3200mm.
 

2. The 2nd set of BOX Beam Welding Production Machine: GZ12 Baffle Plate Assembly Machine:

1) As shown in the photo of this slides, the GZ12 Baffle Assembly Machine is in essence a kind of semi-automatic operated fitting up and welding fixture;
2) Design sketch and photo of assembled baffles are also pasted in this Slides: A piece of square or rectangular plate will be strengthened with 2 pieces of stiffeners at the lateral, forming into a small plate unit.

5 BOX Beam Production Line

Slides 6: The U Beam and BOX Beam Assembly in Wuxi JACK BOX Beam Welding Production Line

Continued with the previous Slides,

3. The 3rd set of BOX Beam Welding Production Machine: UBZ12 U Beam BOX Beam Assembly Machine:

1) The raw material of this assembly machine is a piece of long plate unit: 4 pieces of erected and upright baffle plates are welded onto base plate of BOX Beam, in the right angle of 90°, in same interval with each other;
2) With this machine, the 4 pieces of baffle plates will be assembled and tack welded together with 4 pieces of side plates, to make the workpiece first turned into U Beam, then into BOX Beam;
3) The illustration on U Beam BOX Beam assembly steps implemented in BOX Beam Welding Production Line, and finished BOX Beam are pasted in right side of this page of slides.

6 BOX Beam Production Line

Slides 7: The CO2 Back Welding and 180° Overturning in Wuxi JACK BOX Beam Welding Production Line

This page of Slides is on the CO2 Back Welding and logistics unit:

4. The 4th set of BOX Beam Welding Production Machine: BOX Beam CO2 Back Welding Machine:

1) Task: According to BOX Beam production process technology, after its assembly, the BOX Beam needs to be back welded by means of CO2 gas shielded welding;
2) Working Mode: In this set of CO2 Back Welding Machine, BOX Beam is laid on its sending conveyor, and trolley moves in welding speed, performing CO2 Back welding at the same time;
3) Operator Protection: As shown in the lefthand photo, operator needs to put on welding helmet and goggle, to protect his eyes, against the harmful strong arc light generated from CO2 welding, strong fumes in the process;
 

5. The 5th Type of BOX Beam Welding Production Machine: Motor Drive Moving Hydraulic Drive BOX Beam 180° Turnover Machine:

1) Considering the large size and heavy weight of BOX Beam, its flipping and conveying is rather dangerous, suppose manipulated by operators. Instead, this job should be completed by means of automatic running hydraulic drive flipping equipment;
2) These logistics units not only relieve operators from dangerous and toilful job of workpiece turning, but also improves automation degree of the production line;
3) Wuxi JACK designs and produces various types and specifications of hydraulic drive 60°/ 90°/ 180° Overturning Equipment, Steel Conveyor, and Chain type Overturning Equipment, which are indispensable equipment being applied in all types of Steel Structure Production Line.

7 BOX Beam Production Line

Slides 8: The Electroslag Welding in Wuxi JACK BOX Beam Welding Production Line

6. The 6th Set of BOX Beam Welding Production Machine: BOX Beam Electroslag Welding:

1) Position in the Production Process Technology: Electroslag welding is the second type of welding operation performed in BOX Beam welding stations, following CO2 back welding, and preceding SAW finished welding;

2) Function: This step is for welding the internal baffle plates inside the assembled BOX Beam, which is difficult to access directly by means of conventional welding method;
3) Classification: For being applied in BOX Beam Welding Production Line, there are two types of BOX Beam electroslag welding technology: The consuming wire type and electrode type. Of which, currently, the consuming wire type electroslag welding has wider application and takes main stream, benefitting from its advantages of easy operation and lower cost;

4) Workpiece: This page of Slides indicates on Wuxi JACK BOX Beam Electroslag Welding Machine:

a) Operates at customer workshop;
b) 2 types of electroslag welding torch unit and its moving trolley, and operation on assembled BOX Beam;
c) Explode sketch on baffle plates electroslag welding inside the assembled BOX Beam;
d) Close distance on baffle plates electroslag welding in Wuxi JACK welding machine.

8 BOX Beam Production Line

Slides 9: Wuxi JACK BOX SAW Beam Welding Machine and End Face Milling

This page of slides is on the final 2 types of core BOX Beam Welding Production Machine:

7. The 7th Set: BOX SAW Beam Welding Machine:

1) Same as H Beam Production Line, SAW finished welding is 3rd step of welding, also the final one in process technology of welding BOX Beam production;

2) There are 2 types of structure BOX Beam SAW Welding Machine:

a) LHE model Closed frame Gantry moving structure, similar to LHA/ LHT in the case of H Beam production;
b) LHC model Open frame moving Trolley structure, same as LHC in automatic H Beam Production Line;
For which customers can make choice based on their condition and preference;
3) The photo in this page of Slides presents the LHE model closed frame Gantry moving structure BOX SAW Beam Welding Machine.
 

8. The 8th set of BOX Beam Welding Production Machine: BOX Beam End Face Milling Machine at EOL Station:

1) The right photo in this page of Slides is on a set of Wuxi JACK DX2040 model BOX Beam End Face Milling Machine, which is the last one important machine in BOX Beam Welding Production Line;
2) This machine is not confined to BOX Beam production use. Instead, it can be applied in all types of Steel Structure Production Line: H Beam Production Line, T Beam Production Line, etc.;
3) Equipped with CNC controller, the CNC control Beam End Face Milling Machine can also be used for polishing any kind of special shape structure members and pipes, etc.

9 BOX Beam Production Line

Slides 10: Wuxi JACK BOX SAW Beam Welding Machine

This page of Slides demonstrates on Wuxi JACK LHE15 model gantry frame structure BOX SAW Beam Welding Machine, which is being installed and commissioned by Wuxi JACK engineers, and close distance view on test on tandem arc SAW on BOX Beam:
10 BOX SAW Beam Welding Machine

FAQ on Wuxi JACK BOX Beam Welding Production Line

Below are some typical frequently asked questions on our BOX Beam Welding Production Line from customers, from year 2009 to today May 2026:

  • Q Besides the above listed BOX Beam Welding Production Machine, what are other machines, equipment and tools necessary prepare, for kicking off BOX Beam Welding Production Line?

    A There are totally 35 stations in complete set of BOX Beam Welding Production Line. Besides the machines listed above, below are other necessary BOX Beam Welding Production Machines:
    1. 1) Lineation table for confirming on positions of baffle plates, and hole cutting;
    2. 2) Edge Milling Machine: For cutting out 0° - ±45° welding grooves on main plates of BOX Beam;
    3. 3) Welding seam test: Ultrasonic testing machine;
    4. 4) Clearing on electroslag welding gate and riser: Carbon gouge;
    5. 5) BOX Beam Longitudinal Straightening: Horizontal Press Straightening Machine;
    6. 6) BOX Beam surface clean: Shot Blasting Machine

  • Q What are Total Power of Machines in BOX Beam Welding Production Line, especially large current heavy duty BOX SAW Beam Welding Machine?

    A
    1. 1. The set up of entire BOX Beam Welding Production Line definitely involves careful prepare on workshop utility, especially electricity capacity. In all, installing all the major BOX Beam Welding Production Machines being introduced in this page need total power of:
    1. 1) Either 2 sets of 800KVA transformer for tandem arc (9KW＋240KVA×2, 63A＋250A×4 air breaker) BOX SAW Beam Welding Machine;
    2. 2) Or 2 sets of 1000KVA transformer for triple arc (9KW＋385KVA×2, 63A＋250A×6 air breaker) BOX SAW Beam Welding Machine;
    1. 2. Wuxi JACK engineers will give customer detailed list of electricity capacity and necessary air breaker for each set of BOX Beam Welding Production Machine, before customer prepare on the workshop of our BOX Beam Welding Production Line;
    2. 3. For example, for installing one set of UBZ12/ UBZ15 model U Beam BOX Beam Assembly and Tack Welding Machine, it needs electricity capacity of 15.4KW+25.6KVA, and air breaker of 63A×3.

  • Q Which Brands Wuxi JACK select, on various welding power supplies being equipped with our BOX Beam Welding Production Line, especially the core equipment of BOX SAW Beam Welding Machine?

    A
    1. 1) 20 years ago, in the year before 2010, the various modes of welding power supplies were usually selected from overseas famous brand, to make sure quality and performance on BOX Beam welding at different stations. For example, American Lincoln (DC1000A plus AC1200A in the condition of tandem arc SAW) for our BOX SAW Beam Welding Machine, and Japan OTC SESNET-WT for BOX Beam electroslag welding;
    2. 2) Over the past 10- 15 years, with the rapid development of Chinese suppliers technique on welding, nowadays by year 2026, all the welding power supplies in our Wuxi JACK production line, especially the most important one BOX SAW Beam Welding Machine, can be sourced from Chinese top grade professional suppliers: HUAYUAN, AOTAI, under different customer requirement and practical condition. These Chinese welding power supplies have stable and top grade performance, and much reasonable price than overseas brands, which promise more benefits and profits for customers.

  • Q How Many Operators are Necessary for Building Up and Running on Wuxi JACK BOX Beam Welding Production Line?

    A
    1. 1) Compared with H Beam production, BOX Beam production is obviously more complicated, with more work stations and machine involved;
    2. 2) Depending on customer budget and MGPP (Multiple Generation Product Plan) and layout, there are 12 to 35 types and sets of BOX Beam Welding Production Machines, which need to be installed and operated. Correspondingly, each machine needs one to two veteran operators to work on;
    3. 3) Summing up, the single shift of welding BOX Beam production needs 20 to 60 operators working on, excluding logistic team for material replenish and convey;
    4. 4) Operators work on different station entails related skills. For example, for working on the most important BOX SAW Beam Welding Machine, operator should be familiar with managing on automatic machines; Welding experience on adjusting welding wires, welding torches, judging welding quality, etc.;
    5. 5) Besides, there should be also a team of profession service, to make sure fluent operation of the entire BOX Beam Welding Production Line. By means of TPM (Total Preventive Management), to make sure these machines have as short shutdown as possible. And in case of malfunction happens, to overhaul the machine, and resume operation with the quickest response.

Wuxi JACK Other Steel Structure Production Line and Machines besides BOX SAW Beam Welding Machine

1. Machines and Equipment of H Beam Production Line:
Z18 model I H Beam Assembly and Tack Welding Machine
LHA5Z model center operate I H Beam SAW Welding Machine
LHA5C model lateral operate I H Beam SAW Welding Machine
YTJ60 model Hydraulic Drive H Beam Straightening Machine
2. Other Important Steel Structure Machinery:
J20 model Stiffener Plate Unit Straightening Machine
ASM63 model Angle Steel Straightening Machine
HJ300 model I H BOX Beam Horizontal Press Straightening Machine
Steel Structure I H BOX Beam Convey and Lifting Machine
3. Welding and Milling Machines, Steel Structure BOX H Beam End Face Milling Machine:
LH50 model Pipe Flange Circumferential Welding Machine
LHD1500 model Gantry Frame Moving Pipe Longitudinal Welding Machine
CNC-DX2525 model CNC control BOX Beam End Face Milling Machine
RH1000 model Steel Plate and H Beam Edge Rounding Machine
BOX Beam Production Line
01

BOX SAW Beam Welding Machine
02

BOX SAW Beam Welding Machine
03

Other Series of Products We Own besides BOX Beam Welding Production Line

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4. Technical View on ASM63:
5. Technical Parameters of ASM63:
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Symmetric Beam ZHJ18 Model 3 in 1 Vertical H Beam Welder Machine
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E. Operation:
F. Range of Supply on Wuxi JACK RT20:
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D. Supply Range:
E. Technical Parameters:
 
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2. Operation of HGZ80:
3. Arrangement of HGZ80:
4. Benefit of HGZ80:
5. Technical Parameters of HGZ80:
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HGZ Roller Bed Adjusting High Quality Self Adjustable Welding Rotator
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1. What is Bed Adjusting type Self Adjusting Welding Rotator?
2. Usage
3. Technical Parameters of HGZ Series:
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HGK High Efficiency Universal Adjustable Welding Rotator by Leadscrew
HGK High Efficiency Universal Adjustable Welding Rotator by Leadscrew
1. Specialty and Characteristic of HGK Series Adjusting by Leadscrew:
2. Brief on HGK Series Adjustable by Leadscrew:
3. Difference between HGK Series Leadscrew Adjusting and HGZ Series Self Adjustable:
4. Classification on HGK Series Adjustable by Leadscrew:
5. Technical Parameters:
 
 
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Blogs on Wuxi JACK BOX Beam Welding Production Line

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