1) Variable Labor Cost Reduction: From 2 operators to 1 operator;
2) Variable Operating Cost Reduction: From 2 times welding to 1 time welding in the Plate Joint Welding Machine; Removing carbon gouging and workpiece flipping;
3) Period Utility Cost Reduction: Remove equipment for welding groove making, and hoist for workpiece flipping.
4. For quick reviewing, please check report slides of “The Powerful Wuxi JACK Flat Butt Welding Machine”.
1. From customer perspective, the critical specifications for selection applicable models of the Flat Butt Welding Machine are width and thickness of steel plates for joint;
2. Machine models are distinguished based on plate width. In other words, length of joint welding seam delivered: MP20, and MP25, and MP30, and MP35, and MP40, and MP45, and MP50 Plate Butt Joining Machine;
Models of Flat Butt Welding Machine | MP20/ 25/ 30/ 35/ 40/ 45/ 50 |
Max. Width of Metal Plates for Joint (Max. Length of Butt Joint Welding Seam) | 2/ 2.5/ 3/ 3.5/ 4/ 4.5/ 5 m |
Thickness and Material of Metal Plates for Joint | Thickness: 6 ~ 40mm for SAW, 2~ 6mm for CO2 welding Material: Low carbon steel, Stainless steel or Al alloy |
Butt Welding of Straight Edge Thickness without Groove | 6 ~ 15 mm |
Optional Flame Triple Cutting Velocity | 100 ~ 800mm/min. Stepless Adjusting, A.C. Inverter control |
Fully Penetration Welding Melt- thru Velocity | 200 ~ 1000mm/min. Stepless Adjusting, A.C. Inverter control |
Metal Plate Feeding Speed | 2500 mm/min. |
Welding style | Submerged Arc Welding / CO2 Gas Shielded Fully Penetration Welding Melt thru |
Length of Single Piece Metal Plate before Joint | 6000 ~ 15000 mm (Can be special made) |
1) The righthand 2nd design drawing gives detailed information on main frame of the Plate Butt Joining Machine. As can be seen from it, main frame of the machine is in the form of box structure gantry beam, both sides equipped with working groups;
2) Triple cutting torch and welding torch complex are assembled onto horizontal beam of the main frame at both sides, guided with precise linear guiderail, and transmitted with rack, guaranteeing smooth and precise running of the working units carriages, during working of the Flat Butt Welding Machine:
3) The welding worktable of the Plate Joint Welding Machine is separate from the main frame. Meanwhile, its position should be accurately managed, so as to make sure that for melt-thru welding in the Flat Butt Welding Machine, centerline of copper cushion should be right beneath tip of welding torch. Please check the righthand 2nd design drawing: Side view on main frame of the Flat Butt Welding Machine;
4) For more information on main frame design and manufacture, please check product MP40 Plate Butt Joining Machine.
1) Workpiece feeding and transport on conveyors of the Plate Joint Welding Machine, as well as welding power supply management: Electric control cycloidal A.C. motor;
2) Workpiece welding groove making: Oxy-Acetylene cutting gas of triple cutting;
3) Workpiece locating and pressing during melt-thru welding in the Plate Butt Joining Machine: Hydraulic oil cylinder drive, in constant pressure of 8MPa;
4) Heat dissipation for welding seam formation in Melt-thru welding: Circulating water running through copper pads of the Plate Joint Welding Machine central zone.
See the 3rd photo: For the purpose of successful implementation of Melt-thru in the Plate Butt Joining Welding Machine, 2 layers of welding flux need to be deposited:
a) One layer is on the surface of copper pads, which means against bottom surface of steel plates; And the other layer is on top surface of steel plates directly, before welding in the Flat Butt Welding Machine;
b) For Chinese customers, recommended grades of the welding flux to be applied are FCB-1R and FCB-1 respectively;
Take steel plates of thickness in the range of 8mm to 20mm as example, the critical process control parameters for Melt-thru welding in the MP series Plate Butt Joining Welding Machine include:
a) Welding current (680~ 760A); Welding voltage (35~ 37V); Welding speed (420 ~ 585 mm/min.); Butt clearance (1 ~ 2.5mm); Welding torch angle: 0°~ 20°; Blunt side: 0~ 4mm;
b) Please check the 4th photo, on test sample piece delivered from Wuxi JACK MP Flat Butt Welding Machine. You can check validated parameters on the sample piece.
1. The 1st Photo: The up and down movement of welding torch catering for thickness of steel plates to be joint in the Plate Butt Joining Machine is realized in 2 stages: First descend the welding torch quickly with motor drive; Then make adjustment in inching mode by means of the cross slide;
2. The 2nd Photo: During the Melt-thru welding in the Plate Butt Joining Welding Machine, there is a laser light spot moving ahead of welding torch tip: This is for denoting correct position of welding seam, and help operator checking the proper trace of welding torch in the process of Melt-thru welding in the Flat Butt Welding Machine;
3. The 3rd Photo: The Melt-thru welding control system applied in the Plate Joint Welding Machine: The laser generator and its white color pushbutton; The wire feeder and its managing knacks, for selecting diameter of welding wire; The straining condition modulating unit...;
4. The 4th Photo: The working phenomenon of welding torch complex, during Melt-thru welding carried out in the Flat Butt Welding Machine.
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