A. Necessity and Usage of XD12/ XD15 BOX Beam Consumable Electroslag Welding Machine:
1. Which Step in BOX Beam Production Line: The second step of welding following CO2 back welding is electroslag welding on internal baffle plates, which is implemented with the Electroslag Welder Machine. It is for finished welding on baffles as stiffeners inside the assembled BOX Beam:
Effect of internal baffles plates (Stiffener) inside BOX Beam: (Fig.1)
2. Why Need Electroslag Welding Equipment for BOX Beam Production:
1) As shown in below 2 sketches, with the final assembling step of cover plate being welded onto the BOX Beam, with conventional welding operation, it is difficult, or impossible to perform welding on internal baffles with the cover plate:
2) Put the cover plate onto assembled U Beam, with internal baffles assembled inside: (Fig.2)
3) Effect of cover plate fully put onto and welded, making U Beam into BOX Beam, with internal baffles inside: (Fig.3)
4) Summing up, to realize fully welding and fusion of these baffle plates with the cover plate, and hence get a perfect assembling effect, it is necessary to have electroslag welding on the assembled and backing welded BOX Beam;
3. Two Major Types of BOX Beam Electroslag Welder Machine:
Depending on type of welding material adopted in the process of electroslag welding, the machine can be classified into 2 types of:
1) Consumable Electroslag Welding Equipment: The nozzles are used as part of welding media, which “vanish” and melt into base metal;
2) Electrode type Equipment: The welding nozzles will not be consumed, and can be reused after this time welding.
B. Structure and Performance of XD12/ XD15 BOX Beam Consumable Electroslag Welder Machine:
1. Mechanical Structure: The XD series BOX Beam Electroslag Welding Machine serves as mechanical supporting mechanism of electroslag welding power supply. It has machine body of cantilever structure, or also called as overhanging structure:
Overall appearance of Wuxi JACK XD12 model machine: (Fig.4)
2. Major Units in BOX Beam Electroslag Welding Equipment:
This machine is mainly composed of:
1) Motor drive moving trolley;
2) Upright column on moving trolley;
3) The overhanging beam on the upright column;
4) Electroslag welding power supply;
5) Electric control and operating panel;
Of which the upright column and overhanging beam form the basic skeleton of the machine, for the purpose of holding and securing the electroslag welding power supply, making sure welding tip precisely aiming at welding seam all along;
3. Operation in Consumable Electroslag Welding Machine:
1) The moving trolley plays the role of “legs and feet” of the machine, which leads the entire machine and welding system moving along rail in welding speed during operation, or in high speed during idle period;
2) Management: This trolley movement is driven with A.C. motor reducer and controlled with A.C. inverter:
3) At Wuxi JACK workshop: Operating panel, trolley, and electroslag welding being in trial run: (Fig.5)
4) At customer facility: The trolley carries out electroslag welding on BOX Beam: (Fig.6)
4. The electroslag welding power supply is the main outsourced part, as well as “brain and hand” of the Electroslag Welder Machine. As to its brand and model, there are multiple options available in the market, both from Chinese supplier or overseas;
5. Arrangement of Consumable Electroslag Welding Machine at Running Site:
1) As can be observed from attached and below photo, electroslag welding power supply and its console, together with electric control board are all put onto trolley;
2) Such arrangement has two merits:
a) One is convenient operation;
b) The other is simple and concise cable routing:
3) Welding head mechanism of Wuxi JACK XD12/ XD15 model machine: (Fig.7)
C. Working Manner XD12/ XD15 BOX Beam Consumable Electroslag Welding Equipment:
1. Precondition on Electroslag Welding: In the process of BOX Beam assembly, the clearance for later on vertical perpendicular electroslag welding is reserved ahead of time;
2. To Station: After assembling and back welding, the BOX Beam is sent to work station of electroslag welding;
3. Electroslag Welding Operation: With the upright perpendicular electroslag welding power supply installed on the overhanging beam of the machine, the vertical downward perpendicular electroslag welding operation is performed into the reserved hole of BOX Beam. Please check attached photo and below:
Working site of Wuxi JACK XD15 model machine at BOX Beam Production Line: (Fig.8)
4. Electroslag Welding on Entire BOX Beam: The cantilever type, or overhanging beam moves along its rail, fulfilling the electroslag welding along the entire length of BOX Beam:
1) Moment of consumable electroslag welding: (Fig.9)
2) Finished consumable electroslag welding on BOX Beam: (Fig.10)
D. Supply Range of XD12/ XD15 BOX Beam Consumable Electroslag Welding Machine:
1. Hardware of Consumable Electroslag Welding Machine:
The entire set of function units delivered to customer for XD series machine can be listed as:
1) Mechanical system: Including moving trolley, column, overhanging beam, welding torch carriage mechanism, welding torch vertical moving adjusting unit, welding inching adjustment unit;
2) Drive and Transmission System: A.C. motor, reducer and transmission;
3) Welding System: Electroslag welding power supply, welding wire feeder, control console;
4) Electric Control System: Control board and operating panel, A.C. inverter, control elements, cables;
2. Technical Documents of Consumable Electroslag Welder Machine:
There are also complete set of materials to be handed over to customers together with this equipment:
1) Operating manual of XD12/ XD15 machine;
2) Operating manual of Electroslag welding power supply;
3) Foundation drawing and electric diagram;
4) Consumable list and drawing;
5) Quality certificate and Packing list
E. Technical Parameters of XD12/ XD15 BOX Beam Consumable Electroslag Welder Machine:
BOX Beam Cross Section Size | XD12: 300ｘ300 ～ 1200ｘ1200mm XD15: 300ｘ300 ～ 1500ｘ1500mm |
BOX Beam Length | 4000 ～ 15000mm |
Trolley Rail Span | 1000 mm |
Trolley Electroslag Welding Moving Speed | 100 ~ 1,000 mm/min. Variable Frequency Drive and real time display |
Trolley Idle Moving Speed | 6,000 mm/ min. |
Trolley Movement Drive Motor Power | 0.75 kW |
