Manual Assembling And Automatic Welding Z18 I Beam Assembly Machine

A. Purpose of Z18 I H Beam Assembly Machine with Automatic Stitch Welding:

1. Finished Workpiece: As one of the basic/ indispensable/ and the most widely used H Beam production machine, the model Z18 H I Beam Assembly and Tack Welding Machine refers to the max. web height of welded T I H Beam, of the Max. 1,800mm web height:

1) Design print on H Beam: (Fig.1)

2) Vertical small H Beam, assembled from Wuxi JACK Z18 model machine: (Fig.2)

3) Work In Process: The Z18 (And other models of Z series) machine does not produce finished H Beam for customer, instead, a piece of WIP assembled and tack welded H Beam;

2. Process Step: In the work stations of HB1800 automatic I H Beam Production Line, this Z18 model machine needs to work together with LHC H Beam Submerged Arc Welding Machine, for fabricating on the rough finished welding H Beam:

Comprehensive view on H Beam automatic production site: Assembled H Beams from Z18 model H Beam Assembling Machine, were laid down on conveyors, and sent to 4 sets of LHC model H Beam SAW Welding Machine: (Fig.3)

3. In Manual H Beam Production: When applied as individual equipment, this Z18 model machine needs to work with LHA5Z or LHT model H Beam gantry welding machine, for fabricating on finished welding H Beam.

B. Structure and Main Units of I H Beam Assembling and Tack Welding Machine:

1) Layout print of Z models machines: (Fig.4)

2) At customer workshop, installation site of Wuxi JACK Z18 model on H Beam assembly: (Fig.5)

1. Composition of H I Beam Assembly Machine:

1) Mechanical main body:

a) The top half stationary gantry with four pieces of rectangular rails fit;

b) The lower half fixed base bed, with function units assembled;

2) Hydraulic drive pulling rod system, two sets, for rough positioning of flange with web;

3) Input and output conveyor roller tables;

4) Hydraulic system: For driving the H Beam assembly step;

5) Electric control system;

2. Mechanical Main Body:

The installed and assembled integral frame of Wuxi JACK Z18 model machine: (Fig.6)

The main body is the basic frame of the machine, which is composed of top gantry, bed, platform, motor reducer, hydraulic system and control system;

3. Machine Base Bed:

Close view: (Fig.7)

1) Machine bed is composed of two pieces of wall boards and bottom beam, fit with welding arc guiding unit, web and flange clamping unit, main transmission system;

2) Its main function is to localize and clamp H Beam of various specifications, and carry out spot welding at the same time, together with H Beam transportation;

4. Motor Reducer:

Installed along machine base bed: (Fig.8)

This unit drives main transmission roller by way of coupler. The reducer is individually from machine main body, easy for package and installation;

5. Mechanical Transmission System in H Beam Assembling and Tack Welding Machine:

The guide and transmission unit of Wuxi JACK Z18 model machine: (Fig.9)

1) Main transmission system is driven with motor reducer, which is joint with main transmission roller directly through coupler and transmission shaft;

2) The two pieces of flange supporting rollers at the front and rear side of main transmission roller are driven with sprocket, on the transmission shaft through chain, and rotate in phase with the main transmission roller.

C. Mechanical Frame of H I Beam Assembly Machine:

1. Top Gantry of I H Beam Assembly Machine:

A piece of assembled painted gantry for Wuxi JACK Z18 model machine: (Fig.10)

1) Assembly: Top gantry is composed of top horizontal beam, upright columns, elevating beam, downward pressing roller, downward pressing cylinder;

2) Its main function is to firmly press H Beam web against flange, during assembly and CO₂ tack welding. This is accomplished with a piece of overhead assembled downward press beam, which is driven with solid oil cylinder;

3) Structure: As can be seen from above photo, top gantry is an inversed U shape frame, installed on machine base bed;

4) Way of Production: The entire top gantry assembly is of welding structure, and assembled into shape in such error proof way: In its top beam there is a square hole made to receive a tenon and so to form a joint;

5) Precise Assembly: To fully guarantee precise alignment of flange with web operation, there are four pieces of precise guideways, which are fit on the left and right sides of internal surface of the two columns, making sure smooth, stable and precise movement of downward pressing unit;

6) Performance: Such design of top gantry is same for both automatic operation, CO₂ tack welding, together with web flange being fit together, and manual working mode in the machine;

2. Downward Pressing Unit in I Beam Assembly and Tack Welding Machine:

Front view on Wuxi JACK Z18: (Fig.11)

1) Function: In operation, this unit serves as positioning and holding function for assembly process. It is fit at internal of the top gantry, and travels along the above mentioned four pieces of precise guideways;

2) Main components include elevating beam, downward pressing roller, and downward pressing oil cylinder;

3) There is a circle of slot at middle of the downward pressing roller, for clipping with edge of H Beam web perfectly, during operation;

4) Local zoom up on connecting section of the downward pressing unit, onto guideways: (Fig.12)

a)  There is copper slice fit between the downward pressing unit and guideway, serving as cushion for vertical movement of the downward pressing unit. Copper has good anti-abrasion performance;

b) The pieces of four bolts are used for adjusting clearance between the downward pressing unit and guideway, for best fitting effect;

3. As summary, with years of application practice and continuous improvement, structure and make up of these Z15/ Z18/ Z20 models I H Beam Assembly Machine grows more and more rational.

D. CO₂ Welding Power Supply in I H Beam Assembling Machine:

1.  Significance: With PLC controlled CO₂ tack welding process, welding power source is a very important outsourced unit for Z15, Z18, and Z20 models machine;

2. Two Options of CO₂ Welding Power Supply for H Beam Assembling and Tack Welding Machine:

1) Chinese HUAYUAN NB-350 Model: (Fig.13)

2) PANASONIC KR-350 Model: (Fig.14)

Both types of the CO₂ welding power source have superior high standard and stable performance on H Beam tack welding;

3. HUAYUAN CO₂ Power Supply in H I Beam Assembly and Tack Welding Machine:

1) Characteristic of heavy duty cycle applicable for heavy industry application;

2) State-of-art technique with digital control and soft function button, makes sure reliable working;

3) With the latest technique of adaptive control system, arc characteristic of CO₂ welding matches with type and diameter of welding wire without any problem;

4) Welding parameters can be set up ahead of time (preset) in precise manner, before formal working, and manage welding performance accordingly;

5) Protection against exterior infiltration such as dust, humid, noise, and salt, etc. Makes the CO₂ Welding power supply a rigid and durable working unit;

6) Welding supplementary units of welding wire feeding unit, of double drive with four rollers makes wire feeding process smooth and stable;

7) Operating friendly function of welding parameter (Welding current, voltage, velocity) storage in library, and available for selection. This function is very useful, because it is necessary to have eight stages of welding speed to be chosen during CO₂ tack welding;

8) Terminal interface reserved for remote control access, to have communication with other equipment. By this the welding power supply can be controlled with a CNC or industrial computer at certain distance away. And for this Z models machine, we can have the welding power source started on machine operating pendant:

Operation on H Beam assembly with Wuxi JACK Z18 I H Beam Assembly Machine: (Fig.15)

9) Self-started protection mechanism against problems of over voltage, lack voltage, over heat or phase failure, so that the CO₂ welding power supply work reliably.

E. Technical Parameters of Z18 H I Beam Assembly and Tack Welding Machine: