1 Flat Butt Welding Machine 5

Wuxi JACK Flat Butt Welding Machine, the Optimum Solution on Plate Joint

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The Improvement on Plate Butt Joint with Flat Butt Welding Machine

With the Introducing of Flat Butt Welding Machine, the Improvement on plate butt joining can be generalized into two aspects of Quality and Cost:

 

1. Quality Assurance on Plate Joint with Plate Butt Joining Machine:

1) Plate Butt Joint Welding Machine, the other name is Flat Butt Welding Machine, and Plate Butt Joint Machine, is for flat butt joining 2 pieces of steel plate by means of welding, so that longer length and larger size of steel plate can be got;
 

2) Close Up Joint Steel Plate and Welding Seam from Wuxi JACK Plate Butt Joining Welding Machine:

Fig1 Plate Joint Welding Machine 38
 

Observing Welding Seam on Melt-Thru of Wuxi JACK Plate Joint Welding Machine:

 
Fig2 Plate Butt Joining Welding Machine 21
 
 
 

2. Cost Reduction on Plate Joint from Use of Plate Butt Joining Machine:

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.

 

This page is the complement on “Plate Butt Joining Welding Machine”, focusing on technical aspect of the equipment.

Overview on Different Models and Stages of Wuxi JACK Flat Butt Welding Machine

Model Selection on Wuxi JACK Plate 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;

 

3. Below are Technical Specifications of Wuxi JACK MP20 ~ MP50 Plate Butt Joining Welding 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)

 

Working Video of Wuxi JACK Plate Flat Butt Welding Machine

Here we give 6 videos of Wuxi JACK MP series Flat Butt Welding Machine. For more videos of the Plate Butt Joining Machine, please visit specific page of “Working Video of Plate Butt Joining Welding Machine”.

Overall View on Melt-Thru Submerged Arc Welding in Wuxi JACK MP Models Plate Butt Joining Welding Machine: Wire Feeder, Welding Power Supply, and Flux Deposition

Rear Side of Welding Torch during Melt-Thru Welding in Wuxi JACK MP Series Flat Butt Welding Machine: The Formed Welding Seam, and Welding Flux

Welding Torch Complex and Control Console in Wuxi JACK MP Model Plate Butt Joining Machine

Close Observance on Melt-Thru Welding, and Laser Light Spot Control in Wuxi JACK MP Series Flat Butt Welding Machine

Factory Acceptance on Melt-Thru Welding in Wuxi JACK MP Plate Butt Joining Machine

Beveling on Edge of Steel Plate with Triple Flame Cutting in Wuxi JACK MP30 Plate Joint Welding Machine 

Design of Wuxi JACK MP Series Plate Butt Joining Welding Machine

1. General Arrangement of MP Model Plate Joint Welding Machine:

1) The righthand 1st design drawing gives general layout of any set of Wuxi JACK Flat Butt Welding Machine;
2) The material flow is indicated with red color arrow: From left to right. This can also be identified with length of conveyors at right side of Plate Joint Welding Machine main frame, compared with left side of the main frame;
3) Triple flame cutting is installed at left side, or incoming side of the Plate Butt Joining Machine;
4) Melt-thru welding system is installed at right side, or outcoming side of the Plate Joint Welding Machine;
5) For more information on general layout of the machine at customer site, please check product MP25 Flat Butt Welding Machine
 
 
 

2. Main Frame of MP Model Plate Butt Joining Welding Machine:

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: 

Fig1 Flat Butt Welding Machine 41- IMG_4763

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

 
 
 

3. Working Energy Source in MP Model Flat Butt Welding Machine:

MP series Plate Butt Joining Welding Machine is a sophisticated equipment, integrating electricity, hydraulic cylinder, Oxy-Acetylene cutting gas, and water:

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.

 

The typical general arrangement of a set of Wuxi JACK MP Plate Butt Joining Welding Machine please check the righthand photo.

Operating Tips of Wuxi JACK Plate Butt Joining Welding Machine

1. Triple Flame Cutting in MP Flat Butt Welding Machine:

1) The 1st and 2nd photos: For steel plate thickness less than 15mm, no need to have triple cutting before welding. Just leave 3mm clearance between the 2 pieces of steel plates, and perform butt welding in the Flat Butt Welding Machine directly;
2) For steel plate thickness in the range of 15mm to 28mm, straight edge and slant edge cutting can be made together in the Plate Butt Joining Machine at the same time. In other words, with one time flame cutting;
3) For steel plate thickness in the range of 28mm to 40mm, to have eligible welding groove effect on steel plates, it should be made like this in the Plate Butt Joining Welding Machine: First have straight edge cutting; Then recede the cutting torch and turn it 150°, then cut slant edge with triple flame;
4) For more information on triple flame cutting technology in the machine, please check product MP25 Plate Joint Welding Machine.
 

2. Melt-Thru Welding in MP Series Plate Joint Welding Machine:

1) Welding Flux Deposition in the Flat Butt Welding Machine:

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;

2) Process Control Parameters for Melt-thru Welding in the Flat Butt Welding Machine:

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.

Steel Plate Conveying and Positioning in Wuxi JACK MP Models Plate Flat Butt Welding Machine

The smooth transportation, accurate positioning, and reliable secure of steel plates are precondition on successful running of the Plate Butt Joining Welding Machine:

1. Conveying of Steel Plate forward along Conveyor of the Plate Joint Welding Machine:

 

1) The 1st Photo: There are alignment rollers along input and output conveyors of the Plate Butt Joining Machine, guaranteeing linearity of steel plates, especially joint long length steel plate all the while;
2) The 2nd Photo: The sending forward of steel plate at main frame of the Plate Joint Welding Machine is realized by means of 2 pieces of transmission rollers, which are driven with A.C. cycloidal motor;
3) The 3rd Sketch: Top surface of copper cushions should be flush with top surface of input/ output conveyors of the Plate Butt Joining Welding Machine. Besides, there is interlock between height of the copper cushion and conveyors: If top surface of the copper pads is higher, the conveyors of the Flat Butt Welding Machine will not work;
4) The 4th Photo: There is interlock between triple cutting torch/ welding complex and input/ output conveyors of the Plate Joint Welding Machine also: If triple cutting or welding is in operation, the workpiece can not be moved forward or backward on the conveyors.

2. Positioning of Steel Plate at Welding Station of the Plate Butt Joining Welding Machine:

 

1) The 1st Photo: During melt-thru welding, steel plates are pressed firming on the array of copper cushion. Here copper cushion has 2 functions for operation of the Plate Butt Joining Machine: One is to support the steel plates; The second is more important: It helps accomplishing Melt-thru welding in the Flat Butt Welding Machine, by means of welding flux, as well as heat dissipation with water tubes inside the copper cushion;
2) The 2nd Photo: When not in welding, the copper blocks are lowered at its bottom original position. And, before the official Melt-thru welding in the Plate Joint Welding Machine, the copper blocks ascend under the drive of worm gear motor. To accommodate varied thickness of steel plates in the Flat Butt Welding Machine, there are top and bottom limit switches along vertical stroke of the copper pads;
3) The 3rd Photo: The preparation on array of copper blocks before it being assembled into main body of the Plate Butt Joining Welding Machine. You can identify the blue color water tubes that were about to be inserted into and pulled through the entire length of copper cushions, by way of the lateral through holes;
4) The 4th Photo: During Melt-thru welding in the Plate Butt Joining Welding Machine, the steel plates will be located right above the copper blocks. The secure of the steel plates is realized by means of the black color blocks, which are distributed in regular interval along the length of copper pads in the Flat Butt Welding Machine: In other words, the whole length of steel plates. These black pressing blocks are driven with 2 arrays of oil cylinders, which are installed inside the V slot of welding table of the Flat Butt Welding Machine, as you can find from the 1st and 2nd photos.

Welding Torch Position Control in Wuxi JACK MP Series Plate Joint Welding Machine

Precise position of welding torch determines directly quality of Melt-thru welding in the Flat Butt Welding Machine:

 

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.

Plate Joint Welding Machine
01

Flat Butt Welding Machine
02

Plate Butt Joining Welding Machine
03

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