A. Usage of XSD12 BOX Beam Wire Electrode Electroslag Weld Machine:
1. Task: In BOX Beam Production Line following back welding, the XSD12 Wire Electrode Electroslag Welder Machine implements the other kind of electroslag welding on BOX Beam workpiece, different from nozzle consumable type;
2. Comparison with Consumable type Electroslag Weld Equipment:
In a nutshell, from wire electrode electroslag welding perspective,
1) Lower Variable Cost: such machine has lower running cost compared with nozzle consumable type, because its nozzle will not be consumed in the process of welding;
2) Higher Period Cost: But higher machine quotation, around 30~ 40% higher than consumable type machine;
3) Relative more complicated operation, which entails skill and experience of operator to deliver eligible welding performance.
B. Structure and Technical Characteristic of XSD12 BOX Beam Wire Electrode Electroslag Welder Machine:
1. Function: Same as XD series nozzle consumable type, the XSD12 Wire Electrode Electroslag Welder Machine is also for the purpose of welding internal baffles of BOX Beam with cover plate already onto it, to have the thorough confusion of BOX Beam plates and eligible assembly quality;
2. Preparation Work: For this target, two or four holes are prepared on BOX Beam, during its internal baffle plates assembly;
3. To Current Station: At the completion of assembly, tack welding and back welding, BOX Beam is sent to this station of Non Consumable Electroslag Weld Equipment. Here, Non Consumable has the same meaning as wire electrode;
4. Electrode Electroslag Welding Operation: Manipulated with inching adjustment unit on welding head, the water cooled fuse tube (Welding tip) descends in vertical perpendicular direction, all the way downward to the position of welding seam, and carries out electroslag welding;
5. Electroslag Welding Assistant Unit: On the moving carriage of machine, there is a horizontal swing unit, which controls the water cooled fuse tube, and can be set and swing based on size of molten pool, making sure high quality electroslag welding operation;
6. Continuous Electroslag Welding: Adjusted with A.C. inverter and drive with motor reducer, the entire of the Wire Electrode Electroslag Weld Machine moves on the rail along the whole length of BOX Beam, in adjusted welding speed, fulfilling electroslag welding on all internal baffle plates;
7. At the completion of electroslag welding, or when not in welding just for changing position of the carriage, the trolley moves in higher idle speed, to target position.
C. Configuration and Operation of XSD12 BOX Beam Wire Electrode Electroslag Weld Equipment:
1. Main Units: Same as XD series consumable type, this wire electrode type machine also consists of cantilever frame, trolley, wire electrode power supply and electric control unit;
2. Machine Main Frame: The cantilever constructure is the trunk of the Electroslag Welder Machine, placing the wire electrode electroslag power supply, wire barrel, water tank and welding head holding unit;
3. Movement Drive: The A.C. motor powered trolley put in motion the complete set of machine during work;
4. Function Unit: Please check attached picture and below. Holding unit (3 dimensional manipulating unit) of the welding head is installed on the overhanging beam, which can be adjusted leftward and rightward along the horizontal guardrail, promising the effect of welding tip directing at welding seam all the while:
Mechanism of wire electrode electroslag welding head: (Fig.1)
5. Important Assistant Unit in Wire Electrode Electroslag Weld Machine:
To make sure satisfactory delivery of this equipment, there are some important welding assistant gadgets on welding mechanism:
1) Swing unit of the water cooled welding wire feeder;
2) Reverse pumping unit of the welding wire feeder;
3) Electroslag welding power supply control console;
All of these units are fit onto the abovementioned holding unit of the welding head;
6. Welding Power Supply of Wire Electrode Electroslag Welder Machine:
As to the brand and model of non consumable electroslag welding power supply, there are several options in the market. Of which three choices are:
1) Japan SESNET;
2) Japan Panasonic KH-600 plus YX090 water tank;
3) American Lincoln DC600 plus Cool Arc 40 water tank.
D. Comparison between Consumable and Non Consumable Electroslag Weld Machine:
This can be analyzed in below main aspects of:
1. Daily Operation Cost of Two Types of Electroslag Weld Equipment:
1) As its name implies, the consumable nozzle type has its nozzle melted and consumed in the process of electroslag welding;
2) While in wire electrode type, the welding nozzle is not a kind of instant consumed part, but can be used multiple times as durable consumables, if operated properly;
3) For this reason, compared with consumable nozzle type, the wire electrode type electroslag welding has lower running cost;
2. Investment Budget and Operation Difficulty Level of Two Types of Electroslag Weld Machine:
1) Machine Price: On the other hand, quotation of the Consumable type machine is 30%~ 40% lower than that of the wire electrode type machine,
2) Operation: With the simpler operation and relative lower failure rate at the same time than that of wire electrode type equipment;
3) Operator Capability: Accordingly, operator of wire electrode type machine should command on higher skills, richer experience, and should be wholly focused during electroslag welding;
3. Conclusion on Current Status on Application Volume: These three major factors contribute to the wider application of Nozzle Consumable Electroslag Weld Equipment, than Wire Electrode type machine in the industry, especially in working sites of BOX Beam Production Line.
E. Technical Parameters of XSD12 BOX Beam Non Consumable Electroslag Welder Machine:
BOX Beam Cross Section Size | 300ｘ300 ～ 1200ｘ1200mm |
BOX Beam Length | 4000 ～ 15000mm |
Trolley Rail Span | 1000 mm |
Electrode Wire Electroslag Welding Speed | 100 ~ 1,000mm/min., controlled with A.C. inverter, and with digital display |
Trolley Idle Moving Speed | 6,000 mm/ min. |
Trolley Movement Drive Motor Power | 0.55 kW |
