Background of This Blog on SAW Welding Flux Heating Machine for 3 in 1 H Beam Fabrication Machine:
1. Business Case: In Oct. 2023, Wuxi JACK finished producing a set of tailor made ZHJ-12 model 3 in 1 H Beam Fabrication Machine for a South American customer. The supplied equipment includes a set of SAW Welding Flux Heating Oven, which is not common seen equipment equipped in the field of H Beam fabrication;
2. Topics on Welding Flux Heating Oven being Applied with 3 in 1 H Beam Fabrication Line:
a) Main Equipment of ZHJ-12 model 3 in 1 H Beam line;
b) Usage and Technical Strong Points of Welding Flux Heating Machine;
c) Structure and Main Units of heating oven;
d) Main Technical Specifications of heating machine;
e) Operation on heating oven;
f) Matters for Attention on Daily Use of heating machine
A. Main Equipment in ZHJ-12 Model 3 in 1 H Beam Fabrication Line:
1. This includes:
1) Ready for shipment Wuxi JACK ZHJ-12 model 3 in 1 H Beam Assembly Welding Straightening Machine for South American customer: (Fig.1)
2) 1 group of hydraulic drive 90° Overturning Equipment for flipping H Beam during production: 3 sets of turnover racks in a group: (Fig.2)
3) 1 set of ZYDH-100 SAW Welding Flux Heating Machine to be serviced for H Beam 3 in 1 machine: (Fig.3)
2. The expected layout of ZHJ-12 model 3 in 1 H Beam Fabrication Line at customer facility, with 90° turning over machine at output conveyor roller table: (Fig.4)
B. Usage and Technical Strong Points of Welding Flux Heating Machine for 3 in 1 H Beam Assembly Welding Straightening Machine:
1. Why Need SAW Welding Flux Heating Oven for 3 in 1 H Beam Fabrication Machine:
1) SAW (Submerged arc welding) flux and electrode absorbs moisture during transportation and storage, which should will lead to inferior welding quality, and should be heated before welding;
2) Without heating, residual hydrogen will be left in the base metal with decomposition of water during welding, leading to cracks in welding seam;
2. Technical Strong Points of SAW Welding Flux Heating Machine in 3 in 1 H Beam Fabrication Line:
1) Operation on this heating machine is by pouring flux into the oven, convenient and reliable;
2) The stainless steel heating elements are distributed evenly inside heating oven, making sure uniform heating on welding flux. Its installation and dismantle is easy to perform;
3) The heating temperature inside the heating oven is controlled automatically with high precision. The water content in heated welding flux can be maintained less than 0.1%.
C. Structure and Main Units of SAW Welding Flux Heating Oven in 3 in 1 H Beam Fabrication Line:
1. Structure and Composition: This heating machine is composed of:
1) Heating oven;
2) External box;
3) Heating temperature control system;
1) The external box of heating machine is fabricated from high quality thin steel plates;
2) The heating oven is fabricated from heat resistant stainless steel plates, and stuffed with superior quality rock wool as insulation material;
3) Stainless steel heating elements are distributed evenly inside the heating oven;
4) Heated welding flux outlet is located at bottom of the heating oven, which consists of valve/ rotation shaft/ handle/ spring;
5) When it is necessary to discharge heating finished welding flux, just turn on the handle, the valve will be switched on accordingly, and heated welding flux will be discharged from the Welding Flux Heating Oven automatically;
6) When not in use, the valve is shut off under the action of spring;
7) Temperature control system of the SAW Welding Flux Heating Machine is composed of temperature controller/ control buttons and A.C. contactors.
D. Main Technical Specifications of Welding Flux Heating Machine:
1. Electricity: AC440V/ 60Hz 3 Phase 4 Line (Tailor made for customer country)
2. Rated Power: 4 kW;
3. Rated Temperature: 450 °C;
4. Rated Capacity: 100 kg;
5. Overall Dimension (Width x Depth x Height): 920mm x 600mm x 1350mm
E. Operation on SAW Welding Flux Heating Oven for 3 in 1 H Beam Assembly Welding Straightening Machine:
1. Operation Preparation Work on 3 in 1 H Beam Fabrication Line:
1) Location and Fixation: This Welding Flux Heating Machine should be located at indoor dry zone, and laid onto level plane, without additional fixation;
a) There should be a piece of dedicated use A.C breaker installed in electric power supply line;
b) And cables with same diameter of power line should be used as grounding wire;
3) Before Power On: Inspect electric performance of the control board, making sure there is no failure phenomenon happened, including open circuit/ electricity leakage, etc.;
4) Adding in Welding Flux: When everything is ready for work, open the top cover of the heating oven, and pour in welding flux, then close on the top cover;
2. Operation After Power On in 3 in 1 H Beam Fabrication Machine:
1) Select “High Temperature”: Turn on the electricity, switch the “Temperature Low High” switch to “High”;
2) Set on Parameters of SAW Welding Flux Heating:
a) Target high temperature for heating;
b) Heating temperature holding time;
c) Heating holding temperature;
Note: The detailed way of parameters setting up please check on manual book of Temperature Controller;
3) Start On: Upon completion of parameters setting, and confirm on correct setting, press on “Heating On” button. The SAW welding flux heating process initiates on work;
4) Operating panel of SAW Welding Flux Heating Oven: (Fig.5)
5) Finish Heating: At the completion of welding flux heating, shut off electricity of the heating oven, turn on its handle to open its valve, the heated welding flux can be discharged out of the oven, and being poured into container.
F. Matters for Attention on Daily Use of 3 in 1 H Beam Fabrication Line:
1. Coating Protection in 3 in 1 H Beam Assembly Welding Straightening Machine:
1) Main body of this SAW Welding Flux Heating Machine is fabricated from steel plates, and painted with flat paint;
2) During daily use, do not scratch or spoil coating film of the main body, which will lead to corrosion of heating oven main body;
2. Heating Capacity Management of 3 in 1 H Beam Fabrication Machine:
1) The SAW welding flux inside the heating oven for heating, its level height should be above top surface of electric heating tubes. Which means, the added welding flux should fully cover electric heating tubes;
2) Besides, when pouring welding flux into the heating oven, be sure not to spoil the heating tubes;
3. SAW Welding Flux Heating Machine Put into Use in 3 in 1 H Beam Fabrication Line:
For the newly purchased heating machine, or the machine being resumed on for use after long term storage, it should be:
1) The empty heating oven should be heated at the set temperature 40°C to 80°C for 2 hours, for the purpose of moisture dissipation, and enhance insulation performance of the heating machine;
2) Only after this can put the heating machine into normal use.
