LHC Moving Cantilever I H Beam Trolley SAW Welding Machine

A. Usage and Application of LHC I H Beam Cantilever SAW Welding Machine:

1. Function: As one of the three types of I H Beam SAW Welding Machine, LHC model produces submerged arc welded H Beam, following its assembly, and before flange straightening:

Wuxi JACK LHC model machine has SAW welding on 1200mm height H Beam, which is laid on 60° turnover equipment: (Fig.1)

2. Working Site: Unlike LHA series and LHT model machines on H Beam SAW welding, which are usually applied as individual equipment, here LHC model machine is basically applied in automatic I H Beam Welding Production Line, in the form of four sets deployed together, working on the 4 welding seams of H Beam respectively:

4 sets of Wuxi JACK LHC model machines, arranged at SAW area of automatic H Beam line: (Fig.2)

B. Operation on LHC Trolley Moving I H Beam Welding Machine:

a) Design sketch on structure and layout of 2 sets LHC: (Fig.3)

b) On site layout of LHC model machine in automatic H Beam line: (Fig.4)

1. Welding Torch Position Management in LHC I H Beam Trolley Welding Machine:

1) Preparation: By means of conveyors, the assembled and tack welded H beams from the previous station are put onto 60° hydraulic overturning equipment, and turned into 45° fillet welding position;

2) Degree of Freedom: During SAW welding stage, and controlled with automatic welding arc seam tracker, the welding torch moves in the three axes of:

a) X axis, horizontal direction, for modulating welding torch transverse movement along overhead beam of LHC machine frame. This movement can be controlled with handwheel: 

Installed on welding torch mechanism for adjusting its position: (Fig.5)

Note: Some customer request motor control along this direction movement in I H Beam SAW Welding Machine. Under such condition, we install a motor on the transverse beam, and have toggle switch on the operating pendant to manipulate it;

b) Y axis, up and down vertical way, motor drive. It is accomplished with toggle switch on machine operating panel;

c) Z axis, forward and backward along the rail. This movement is realized with trolley movement;

In this way, welding torch can be controlled precise alignment on welding seam all the time: (Fig.6)

2. Consumables of LHC Trolley Moving I H Beam SAW Welding Machine:

1) During its daily operation on SAW welding, there are two kinds of consumables with high volume consumption:

a) SAW Welding flux, the recommended grade is SJ101;

b) SAW welding wire, φ3.2～ φ5mm solid wire:

SAW welding torch mechanism, on 45° H Beam in LHC model machine: (Fig.7)

3. Daily Service on LHC I H Beam Trolley Welding Machine:

1) For SAW welding wire spool replacement and welding flux replenish, operator should drive welding arm transversely to the location close to machine upright column, and perform the replace work on the platform;

2) This is for the purpose of keep balance of LHC machine to the best degree. This is very important for precise management on submerged arc welding with stable performance.

C. Process Technology in LHC Trolley Moving I H Beam SAW Welding Machine:

1. 2 Welding Zones: In layout of H Beam Automatic Production Line, the four sets of LHC model machine are divided into two groups:

1) The first two sets work in the first welding area, and the second two sets in the second welding area;

2) Automatic, Fluent, Labor Saving Movement of H Beam in 2 Welding Zones:

a) The flipping and transport of H Beam among the four sets of LHC machine (Or, to be more precisely, between the first and second welding areas) is accomplished with 90° and 180° Overturning Rack as well as steel conveyor, without human intervention;

b) In this way, the four pieces of welding seams on a piece of H Beam can be welded in a stream line with its going through the four sets of LHC;

2. Main Trolley Movement of LHC I H Beam Trolley Welding Machine:

1) Mechanical Structure: LHC model machine adopts with motor drive moving trolley as its main frame for operation. All the remaining units of machine:

a) Welding torch mechanism;

b) SAW power supply;

c) Cantilever structure, of upright column and overhang arm;

d) Electric control board and operating panel;

Are all installed on this motorized moving trolley: (Fig.8)

2) SAW Welding Operation:

During work, after making adjustment on correct position of welding torch, the trolley can be started on moving along rail, which is also moving along H Beam being laid on overturning racks of 60° turnover machine, fulfilling SAW welding operation at the same time;

3. SAW Welding Speed in LHC Trolley Moving I H Beam Welding Machine:

1) Moving speed of trolley, which is also welding speed on H Beam, is controlled with A.C. inverter, and displayed instantaneously with digital display;

2) Based on H Beam flange and web thickness to be welded, as well as welding current and voltage of SAW power supply needed, the applicable SAW welding speed is within the range of 240~ 2,400mm/min., continuous adjusting. This speed is set with turning knob on the operating panel;

3) Standing on trolley, operator can observe this real time welding velocity, and make adjustment if necessary:

4) Operation panel of Wuxi JACK LHC model machine: (Fig.9)

4. Double drive in Trolley Movement of LHC I H Beam Cantilever SAW Welding Machine:

1) What is Double Drive: At both sides of trolley at its bottom, there are two sets of motors, driving gears into revolve by means of two motor reducers, which in turn drive the two pieces of shafts;

2) Benefit of Double Drive: In this way, the double drive style of double shafts and four wheels, (The wheels are fit at the bottom of the trolley and move along the rail) can avoid crawling issue caused from skidding, making sure trolley running in stable and reliable manner, during the entire SAW welding process;

3) Idle High Speed: When not in SAW welding operation, the trolley moves in idle high speed of 3,200mm/min., to retreat to its starting point, for carrying out next round of welding.

D. Composition and Supply Range of LHC I H Beam Trolley Welding Machine:

3 sets of LHC model machine at Wuxi JACK workshop: (Fig.10)

One set of this LHC machine is composed of:

1. Mechanical Main Frame:

1) Motor drive moving trolley, with moving wheels at its bottom;

2) Cantilever structure on the motorized moving trolley, which is composed of:

a) Upright column;

b) Overhang beam being assembled onto the column;

2.  SAW Welding Mechanism of LHC I H Beam Trolley Welding Machine:

1) Motor drive transverse moving carriage along the overhand boom;

2) Welding torch on the front surface of carriage;

3) Welding supporting units: Welding arc tracer and welding wire feeder;

4) The SAW welding units on overhand boom of LHC model machine: (Fig.11)

3. Drive and Transmission: Motor and travel reducers, for driving trolley movement and welding carriage movement respectively;  

4. Outsourced Parts: SAW Welding power supply, SAW welding flux recovery and recycling unit;

5. Pneumatic system, for driving welding arc tracer on welding torch;

6. Electric control system, including: Control board, operating panel, cable drag chain, cable hanging rack.

E. Technical Parameters of LHC I H Beam Cantilever SAW Welding Machine: