4- HB2000 Automatic H Beam Production Line

A. The Subject of this Page on Wuxi JACK H Beam Production Line:

1. This page is converted from introduction slides on H Beam Production Line, for quick review on Usage/ Workpiece Specification/ Strong Points/ Process Technology/ Layout and Main H Beam Production Equipment, of Wuxi JACK produced H Beam Production Line;

 

2. We expect this short slides can be helpful to anyone who have interest on H Beam Production Line and H Beam Production Machine, and want to spend the least time to get a general picture on it, either for the purpose of purchase, or just plan to have an general idea.

 

B. Usage of H Beam Production Line:
 

1. Function of H Beam Production Line:

H Beam Production Line produces welding H Beam and T Beam of light/ medium/ heavy duty, from the minimum 200mm web height, to the largest 2000mm web height;

A piece of welding H Beam produced from Wuxi JACK H Beam Production Line: (Fig.1)

Fig1 H Beam Production Machine 29-5 PHJ

2. Uniqueness of H Beam Production Line and its H Beam Production Machine:

1) Recent years, there is a kind of new generation H Beam Production Equipment: 3 in 1 H Beam Assembly Welding Straightening Integral Machine, which has many advantages in replacing traditional H Beam Production Line, for producing light duty and medium duty H Beam/ T Beam;
2) Meanwhile, in the field of producing heavy duty welding H Beam, which means welding seam needs to be completed with more than one time pass, the traditional H Beam Production Line still has its irreplaceable position.

 

C. Classification of H Beam Production Line:
 

Based on internal material transferring way among H Beam Production Machine, the H Beam Production Line can be classified into automatic and semi-automatic:

1. Automatic H Beam Production Line:

1) Automatic H Beam Production Line has the least degree of human intervention, as shown in banner of this page: Utilizing 60° / 90°/ 180° Overturning Equipment and Steel Conveyor, materials flow inside the entire H Beam Production Line is fully automatic and safe;
2) Automatic H Beam Production Line involves relative large workshop land occupation and more investment;

2. Semi-Automatic H Beam Production Line:

1) With 3 types of basic H Beam Production Equipment:

a) H Beam Assembly and Tack Welding Machine;
b) H Beam Submerged Arc Welding Machine;
c) H Beam Straightening Machine;
2) And human transfer of WIP (Work in process) among these H Beam Production Machine by operators with the use of traveling crane, a set of Semi-Automatic H Beam Production Line is set up;
3) Semi-Automatic H Beam Production Line has smaller land occupation, flexible layout, and less investment, compared with automatic H Beam Production Line.

 

 

 

D. For deep down exploration on technical details of Wuxi JACK H Beam Production Line and corresponding H Beam Production Equipment, please visit thematic product pages of:

1) H Beam Production Line;
2) Automatic and Manual H Beam Production Line;
3) H Beam Production Equipment

E. General Picture of Wuxi JACK H Beam Production Line:

Slides 1: Finished Workpiece Specifications and Advantages of H Beam Production Line:

1. Specifications of Finished Workpiece from H Beam Production Line:

1) H Beam Production Line produces 3 grades of Max. welding H Beam based on its model, which is distinguished according to Max. web height: 1500mm/ 1800mm/ 2000mm;
2) Of which, the 1500mm grade (HB1500) has the widest application;
2. This slides also lists main strong points of H Beam Production Line. In general, this turnkey project builds up a modern workshop for Steel Structure manufacture at customer site;
3. The photo in this slides presents a set of HB1500 heavy duty automatic H Beam Production Line exported by Wuxi JACK to a Russian client in the year 2014.

Slides 2: The Fluent Process Flow of Wuxi JACK H Beam Production Line:

This slides gives a graphic view on process technology route in producing welding H Beam, in both automatic and semi-automatic H Beam Production Line;
General speaking, it goes through 5 steps, and involves operation of 5 sets of H Beam Production Machine:

1. The 1st Step: 1st Operation with CNC Strip Plate Cutting Machine:

1) This step is for preparing raw materials when making H Beam/ T Beam;
2) The strip boards cut from carbon steel will be applied as flange and web of H Beam;
 

2. The 2nd Step: Assemble Flange and Web into T Beam/ H Beam, and have stitch Welding, with H Beam Assembly Machine:

The corresponding H Beam Production Equipment in this step is H Beam Assembly and Tack Welding Machine:

1) In this step, first one piece of flange and one piece of web will be fit up and stitch welded into T Beam;
2) Then, the WIP (Work in process) is flipped 180°, and sent into the H Beam Assembly and Tack Welding Machine again;
3) Add on the 2nd piece of flange, to make T Beam into H Beam;
 

3. The 3rd Step: Implement Large Current SAW (Submerged Arc Welding) with H Beam Submerged Arc Welding Machine:

The corresponding H Beam Production Equipment in this step is H Beam Submerged Arc Welding Machine:

1) In automatic H Beam Production Line, there are 4 sets of LHC Trolley Moving H Beam Submerged Arc Welding Machine, deployed in a consecutive straight line;
2) Each set of the LHC Trolley Moving H Beam Submerged Arc Welding Machine is responsible for welding 1 piece of H Beam seam;
3) Every time 1 piece of seam is completed welding, the H Beam is flipped 90°, and sent to next set of LHC H Beam SAW Machine, until 4 pieces of seams all finished fabrication;
4) In Semi-Automatic H Beam Production Line, the LHA H Beam Gantry Welding Machine, or LHT T Frame Open Structure H Beam Submerged Arc Welding Machine is applied for this task;
 

4. The 4th Step: Flange Straightening with H Beam Straightening Machine:

The corresponding H Beam Production Equipment in this step is H Beam Flange Straightening Machine:

1) After the large current submerged arc welding, flanges of H Beam will be distorted upward somewhat, which should be flattened out in H Beam Flange Straightening Machine;
2) Sometimes, the distortion along H Beam lengthways is also obvious, which should be straightened with H Beam Lengthways Straightening Machine;
 

5. The 5th Step: H Beam End Face Polishing with Beam End Face Milling Machine:

1) The corresponding H Beam Production Equipment in this step is Beam End Face Milling Machine;
2) This step is for machining end face of fabricated H Beam, so that these finished parts can be jointed together for carrying out Steel Structure construction;
 

6. Material Flow among H Beam Production Machine:

1) In automatic H Beam Production Line, workpiece 60°/ 90°/ 180° rotating and transportation is fulfilled by means of moving or stationary 60°/ 90°/ 180° Hydraulic Overturning Equipment and Steel Conveyor;
2) In semi- automatic H Beam Production Line, the material flow is basically completed by operators with the help of traveling cranes.

Slides 3: The Recommended Layout of Wuxi JACK H Beam Production Line:

1. This slides gives suggested layout of H Beam Production Line, which takes workshop land area in the range of 2000 m2 to 5000 m2:
 

The four sets of core H Beam Production Machine are:

1) H Beam Assembly and Tack Welding Machine;
2) H Beam Submerged Arc Welding Machine;
3) H Beam Flange Straightening Machine;
4) Beam End Face Milling Machine;
Are installed in sequence in a straight row, so that workpieces can flow these H Beam Production Machine along the shortest path;
2. CNC Strip Plate Cutting Machine, which is a kind of more general purpose equipment and not confined to H Beam Production Line use, is arranged in another span along side the 4 sets of H Beam Production Machine, together with storage area;

3. For such layout of H Beam Production Line,

1) The required least area is: 95m length x 24m width (2 arrays of 11m span, together with 2m walking passage) = 2280m2;
2) The ideal occupied area is: 200m length x 24m width = 4800m2.

Slides 4: The Main H Beam Production Machine of H Beam Production Line: CNC Strip Plate Cutting Machine, together with H Beam Assembly and Tack Welding Machine:

From this slides, photos of main H Beam Production Machine are pasted in sequence:
 

1. CNC Strip Plate Cutting Machine:

1) As mentioned previously, it is kind of universal equipment, which can serve not only H Beam Production Line, but also other process technology;
2) CNC Strip Plate Cutting Machine is deployed at start of line station;
3) There are numerous configurations of CNC Strip Plate Cutting Machine, in terms of Cutting width (Gantry span)/ Cutting way (Flame or Plasma)/ Cutting torch quantity, etc.;
4) For being applied in H Beam Production Line, the CNC Strip Plate Cutting Machine is usually as configuration of: CG4000 (4m span), Oxygen flame cutting, 9 sets of strip cutting torches, and 2 pieces of CNC cutting torches;
 

2. H Beam Assembly and Tack Welding Machine:

1) This is the first set of genuine sense H Beam Production Equipment;
2) Its core technical requirement is high precision: Accuracy and reliability of H Beam assembling process;
3) This H Beam Production Machine is a sophisticated equipment: Hydraulic drive, PLC control for logic working, and inverter for working speed control.

Slides 5: The Main H Beam Production Machine of H Beam Production Line: H Beam Assembly and Tack Welding Machine, together with H Beam Submerged Arc Welding Machine:

1) We paste H Beam Assembly and Tack Welding Machine again in this slides, because as a tightly arranged working zone, all the H Beam Production Machine inside H Beam Production Line are deployed in “seamless” style, as can be seen from the slides;
2) As can be observed from the slides, the 4 sets of LHC trolley moving H Beam Submerged Arc Welding Machine is positioned right behind Z15 H Beam Assembly and Tack Welding Machine: The assembled H Beam will be sent to welding area by way of conveyors;
3) The 2 photos in this slides reflect working condition at automatic H Beam Production Line: Seldom operators are necessary.

Slides 6: The Main H Beam Production Equipment of H Beam Production Line: H Beam Submerged Arc Welding Machine and H Beam Flange Straightening Machine:

1) In this slides, the LHC trolley moving H Beam Submerged Arc Welding Machine can be observed in close distance and more clearly: The H Beam is laid onto 180° Overturning Rack in 60° position, for performing 45° fillet welding;
2) H Beam Flange Straightening Machine is the 3rd set of core H Beam Production Equipment. There are 2 types of the machine: Mechanical motor drive and hydraulic cylinder drive. In this slides, it is a set of HYJ-800 mechanical motor drive H Beam Straightening Machine.

Slides 7: The Main H Beam Production Equipment of H Beam Production Line: Beam End Face Milling Machine and 60°/ 90°/ 180° Overturning Equipment:

1. DX series Beam End Face Milling Machine is deployed at EOL position (End of Line) in H Beam Production Line:

 

1) Besides working as a set of H Beam Production Machine, this machine can also be used for end face machining on all the other steel structure members: BOX Beam/ Cross Beam/ Pipe... etc.;
2) For being applied in H Beam Production Line, the often selected models are usually DX1215, or DX1520;
3) The slides shows a group of Milling and Facing Center, which is composed of 2 sets of DX1540 CNC Beam End Face Milling Machine, and turning tables/ Hydraulic clamp systems. It was exported to Belarus from Wuxi JACK in the year of 2014;
2. This slides also reflects the working moment of Moving style hydraulic 180° Overturning Equipment, in a group of automatic H Beam Production Line.
Beam End Face Milling Machine
01

Edge Milling Machine
02

H Beam Straightening Machine
03

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