One Replacing Three ZHJ8018 Fit Up Full I Beam Fabrication Machine

Following the former section of ZHJ8015 Fit Up Full I Beam Fabrication Machine, we go on to discuss welding technique on the ZHJ series Automatic H Beam Fabrication Machine.

1.  Meaning of “One Replacing Three” for ZHJ8018 Integral H Beam welding Equipment:

1) Huge Benefit: Here this phrase refers to that for making welding H Beam/I Beam of height up to 1,800mm, one set of PHJ18 model 3 in 1 T H Beam Welding Machine takes the place of conventional three sets of Automatic H Beam Production Machine, in terms of process technology in sequence: Assembly/ Welding/ Straightening;

2) Business Background of the 2 sets of 3 in 1 H Beam Welding Machine: 

The attached 1^st photo was taken at a Chinese customer site, in their new workshop. There are 2 sets of ZHJ series Fit Up Full I Beam Fabrication Machine (Automatic H Beam Production Machine) installed here: 

a) The left one model is ZHJ8015, for fabricating on welding T/ I/ H Beam wit height up to 1,500mm;

b) The right one model is ZHJ8018, for fabricating on welding T/ I/ H Beam wit height up to 1,800mm;

With such kind of combination on 3 in 1 H Beam Welding Equipment, full range of workpiece size (200mm ~ 1,500mm ~ 1,800mm H Beam web height) can be made, giving consideration to both capacity and efficiency.

2. Welding Technique in Daily Operating the ZHJ Series H Beam Welding Machine:

SAW (Submerged arc welding) is the core step in operation of ZHJ Pull Through H Beam Welder. There are some techniques involved in it, which, determines directly welding quality of the workpiece to be made from 3 in 1 T H Beam Welding Equipment (T Beam Welding Equipment):

1) Welding Current of the 3 in 1 T H Beam Welding Machine:

a) Significance: This is the most important parameter in welding operation. It is determined by workpiece thickness (In directly proportion relationship);

b) Specification: The SAW power supply equipped with the ZHJ Automatic H Beam Production Machine has max. welding current of 1000A;

c) General Range: The most often seen welding current in this integral function H Beam Welding Equipment ranges 500A~600A~700A, for the workpiece thickness around 10~12mm;

d) Pre-machining Equipment: For thicker H Beam web of 20mm ~32mm thickness, welding grooves need to be made on the web ahead of time with XBJ series Edge Milling Machine;

2) Welding Wire Diameter in the 3 in 1 H Beam Welding Machine:

a) SAW Welding Wire Size: In SAW of the ZHJ Automatic H Beam Production Machine, there are 3 grades of 2.5mm/ 3mm/ 4mm solid wire for use, which is also determined by workpiece thickness;

b) As a rule of thumb, for H Beam web thickness of around 5~6mm, the welding wire should be 2.5mm diameter; For thickness above 10mm, the welding wire of 3mm/ 4mm diameter should be selected in the H Beam Welding Machine;

c) Welding Wire Size Selection: Please check the 2^nd photo. In the welding torches of ZHJ Pull Through H Beam Welder, at its front end of wire feeding mechanism, there is dip switch for selecting the corresponding grades of welding wire size;

3) Welding Wire Feeding Speed in the 3 in 1 H Beam Welding Machine:

This is automatically controlled with SAW control console, based on welding current to be adjusted, (And hence thickness of workpiece H Beam in the T H Beam Welding Equipment);

4) The choice of Welding Flux in the 3 in 1 H Beam Welding Machine:

a) In SAW, sintered flux is better than melting flux; In Chinese welding industry, there is a national grade of SJ101 sinter flux applicable for SAW welding in the 3 in 1 H Beam Welding Equipment;

b) Function of welding flux: Under large current of SAW, welding flux give protection on welding molten pool, keeping it from oxidization, thus getting welding seam of good appearance formation and high strength; Meanwhile, welding flux can transfer certain amount of trace active element into welding seam (Such as Manganese/ Silicon), so as to improve mechanical characteristic of welding seam produced from 3 in 1 H Beam Welding Equipment;

c) Welding Wire Choice: There is switch on the welding torches of the ZHJ H Beam Welding Machine. Please check the 3^rd photo for welding flux applied in the H Beam Welding Equipment;

5) For technical view on the ZHJ series 3 in 1 H Beam Fabrication Machine, please check product section of ZHJ8018 Automatic H Beam Production Machine and ZHJ8020 Integral H Beam Welding Equipment.

Design sketch on finished welding H Beam (I Beam) being produced from 3 in 1 H Beam Welding Machine: (Fig.1)

3. Technical Parameters of the ZHJ8018 T H Beam Fabrication Machine:

Below are primary technical index of ZHJ8018 model Automatic H Beam Production Machine (Pull Through H Beam Welder):