Z15/Z18/Z20 Conventional Size Automatic H Beam Assembly Machine with Tack Welding

A. Application of Z15~ Z18 Automatic I H Beam Assembly and Tack Weld Machine:

1. Function: As is the first typical group of H Beam Production Machine in the process technology of I H Beam Production Line, Z15/ Z18/ Z20 models Automatic I H Beam Assembling Machine produces half finished workpiece of assembled I H Beam, with cross section web height of 1500mm/ 1800mm/ 2000mm respectively:

1) Cross section view on assembled I H Beam: (Fig.1)

2) Integral piece view on assembled I H Beam: (Fig.2)

2. Operating Mode: These Z15~ Z20 models machines have 2 major steps for fabricating on assembled I H Beam:

1) Automatic assembly on flanges and web into H Beam shape:

Assembly moment of Wuxi JACK Z20 model machine, assembling a piece of T Beam: (Fig.3)

2) At the same time, carryout automatic CO₂ tack welding on the assembled H Beam:

CO₂ welding in Wuxi JACK Z15 model machine on assembled T Beam: (Fig.4)

3. Advantages of Automatic I H Beam Assembly Machine:

1) Labor Cost Saving: Operation involves only one operator, instead of two operators in manual machine;

2) Quality Assurance: Stable and consistent assembly and welding quality delivered;

3) Less requirement on skill and experience of operator than manual work mode;

B. Technical View on Z15~ Z18 Automatic I H Beam Assembly Machine:

1. Machine Major Units:

The fit up of I H Beam is realized in the fashion of:

1) Two sets of CO₂ gas shielded welding power source perform on automatic stitch welding: (Fig.5)

2) The operating logic, especially length and interval of tack welding seam is controlled with PLC: (Fig.6)

3) Working velocity is controlled with A.C. inverter, and displayed instantaneously in digital display: (Fig.7)

4) Assembly Drive Mode: Flange and web fitting up and alignment force are from hydraulic cylinders, which entails heavy and stable: (Fig.8)

2. Importance of High Precision for Automatic I H Beam Assembling and Tack Welding Machine:

1) Foremost Factors: During H I Beam assembly process, “high precision” is the foremost request on machine performance. The control parameters include:

a) Size and contour of assembled workpiece cross section;

b) Length and interval of stitch welding seams on assembled I H Beam;

2) The reason is, the essential task of this automatic machine is to assemble the flanges and web into H structure and strengthen it with tack welding;

3) Significance: So, accurate fitting up and CO₂ welding is precondition for next step of H Beam submerged arc welding and H Beam straightening, for the purpose of delivering qualified finish workpiece of welded I H Beam.

3. Work Principle of Automatic I H Beam Assembly and Tack Weld Machine:

During its work, the machine clamps and aligns both sides of flange and web together in phase, ensuring accurate and straight assembly. The entire process can be divided into 2 primary steps of:

1) T Beam Assembly: Assembles one piece of flange and one piece of web into “ ┷” Beam, or inversed T Beam;

2) H Beam Assembly: Flip the assembled T Beam 180°, and assembles the second piece of flange, making the workpiece into a piece of H Beam;

3) General view on principle and major steps of Z15/ Z18/ Z20 models machines on H Beam assembly and tack welding: (Fig.9)

4. Alignment of Flanges and Web in Automatic I H Beam Assembly Machine:

1) Drive: Due to the heavy force necessary for positioning and alignment, the operation is driven with hydraulic transmission, with both sides clamped and aligned synchronously, ensuring precise control on web and flange of H Beam with various specifications:

Way of H Beam fit up in Wuxi JACK Z15 model machine: (Fig.10)

2) High Precision Alignment Rollers: Automatic alignment is accurate, for the batch of T Beam/ I H Beam with same specification, no need to make adjustment every time. Eccentric roller is used for inching adjustment:

Pairs of alignment rollers, at different height level, for fitting on flanges and web respectively, in Wuxi JACK Z models machines: (Fig.11)

3) Flange and Web End Alignment: During operation, the stopping racks driven with hydraulic system at the edge of H Beam, play the role of ensuring perfect alignment on edge of web and flanges. This is exclusive unit of Wuxi JACK machine:

Delicate design alignment end of flanges with web, in Wuxi JACK Z models machines: (Fig.12)

C. Electric Control System of Z15/Z18/Z20 Automatic I H Beam Assembling Machine:

Importance: As the commanding center on operation, electric system controls machine work, achieving stable and high standard automatic working mode:

1. PLC--- Programmable Logic Controller:

1) Role: PLC is the core element of electric control system. Its function is implement on T I H Beam assembly and CO₂ tack welding, based on pre-determined working steps, which is compiled into the PLC by machine producer;

2) Work Mode: During work, PLC sends out command in the form of digital signal, controlling function elements acts accordingly, fulfilling tasks of positioning H Beam web and flange, FOR/RVR of input and output drive conveyor, welding start, etc.;

3) PLC Advantages: Change on machine control logic involves only compiling PLC program, instead of reworking or replacing hard wired relay circuit. This is the most conspicuous merit with PLC;

2. A.C. Inverter in Electric Control System of Automatic I H Beam Assembling and Tack Welding Machine:

1) Function: Main drive motor, input and output drive conveyor of the machine are all controlled with A.C. inverter, in unified adjustable speed;

2) Parameters Set Up: Eight sets of frequency are set in the A.C. inverter ahead of time (preset), corresponding with eight segments of required motor revolve velocity for H Beam assembly and tack welding;

3) Double Work Modes: When this automatic machine works under Single Cycle or Auto Cycle, output frequency of A.C. inverter is controlled with PLC;

4) Single Cycle: When machine works under Manual mode, output frequency of A.C. inverter is controlled with a DIP switch on the machine operating panel;

5) Major Specifications: A.C. inverter used in these Z15/ Z18/ Z20 Automatic I H Beam Assembly Machine has 0~ 400Hz output frequency range, 0.01Hz resolution, and consummate protection function;

6) Benefit: This makes sure that speed control of main drive and conveyor features in extensive range, smooth running and reliable work.

D. Technical Parameters of Z15~ Z20 Automatic I H Beam Assembling and Tack Welding Machine: