Z30 Heavy Duty Large I H Beam Assembly Machine

A. Specialty of Z30 Heavy duty I H Beam Assembly Machine:

1. Purpose: This is a special made model of Z serious I H Beam Assembly and Tack Welding Machine, for fulfilling assembly and stitch welding on super large workpieces of T Beam/ H Beam/ I Beam;

2. Max. Workpiece Size: The max. height of assembled H Beam can be up to 3000mm, and flange thickness can be up to 80mm:

Wuxi JACK Z30 model machine produces assembled large vertical T Beam: (Fig.1)

3. Features of Z30 Large I H Beam Assembly Machine:

1) Threshold: Z30 is largest model that is applicable in automatic I H Beam production Line. H Beam web higher than 3,000mm is not applicable automatic welding. Under such cases, manual assembly and welding is more practical;

2) Semi-Automatic H Beam Assembly: On the other hand, for carrying out assembly and on such big H Beam, manual operation is not only low efficiency, but more importantly, dangerous for operators. So, the entire H Beam assembling and spot welding operation should be semi-automatic. Operator need to watch on working process, and make adjustment if necessary;

3) Automatic CO₂ tack welding with Manual Touch Up: Sometimes, automatic welding may not generate full penetration spot welding seam. So, operator need to check on every piece of finished assembled H Beam, and make repair welding if necessary;

4) Running site of Wuxi JACK Z30 model machine: 2 operators sit at both sides of machine output conveyor roller table: (Fig.2)

B. Application and Major Specifications of Z30 Heavy duty Large I H Beam Assembly and Tack Welding Machine:

1. Task of Z30 Heavy duty I H Beam Assembly Machine:

1) This is the first set of core equipment, being deployed in HB3000 automatic Heavy duty H Beam Production Line. It is for assembling flanges and web into the formed WIP (Working In Process) of assembled and tack welded H Beam;

2) Working Sites: Considering huge height of 3,000mm H Beam, Z30 model machine is not only applied in automatic line, but more frequently, as individual equipment on production:

Wuxi JACK Z30 model machine, at beginning station of HB3000 heavy duty automatic H Beam production Line: (Fig.3)

3) The related equipment with Z30 are also heavy duty models, such as YTJ80 hydraulic H Beam Flange Straightening Machine:

4) The H Beam with flange thickness of 80mm for straightening: (Fig.4)

2. Technical Specifications of Z30 Large Steel Structure Beam Assembly Machine:

1)  Web Height Range：                 300 ~ 3000mm

2)  Web Thickness Range：             6 ~ 60mm

3)  Flange Width Range：               200 ~ 1200mm

4)  Flange Thickness Range：         6 ~ 80mm

5)  Workpiece Length Range：       4000 ~ 12000mm

6)  Assembling Speed：                  4500mm/min, controlled with A.C. inverter, and displayed in operating panel

7) Spot Welding Mode:                  Automatic with manual touchup welding (machine without CO₂ welder)

8) Input Conveyor：     2600mm× 3 (Two roller tables are drive section, installed with individual motor reducer)

9) Output Conveyor:    2600mm× 3 (Two roller tables are drive section, installed with individual motor reducer)

10) Flange and Web Assembly Press: By means of hydraulic cylinder to assembly

11) Machine Total Power：              21 KW

C. Working Style and Configuration of Z30 Large I H Beam Assembly Machine with Tack Welding:

1.  2 Main Functions in Z30 Large I H Beam Assembly Machine:

1) H Beam Fitting Up: Positioning and clamping 2 pieces of flange, with 1 piece of web, into formed H Beam. For such large size H Beam, a pair of assistant rollers need to be used;

2) Stitch Welding: Perform CO₂ intermittent welding on the assembled T I H Beam at the same time, to strengthen the workpiece. The entire welding operation:

a) Tack welding speed;

b) Length of each segment welding seam on assemble Beam;

c) Interval between 2 segments of adjacent welding seams;

Are managed precisely with PLC and A.C. inverter;

2. Assembly Form on 3,000mm Height Large T I H Beam:

1) Semi-Automatic: One side of H Beam is driven with heavy force hydraulic oil cylinders, and the opposing side is managed with precise mechanical leadscrew, Shown in below:

2) The integrated hydraulic and mechanical assembling design, in Wuxi JACK Z30 model machine: (Fig.5)

3. Welding Mode and Style on 3,000mm Height Large T I H Beam:

1) Automatic together with Manual: This is automatic CO₂ GMAW gas shielded welding, with cored flux welding wire, implemented by operator manual touchup welding:

2) CO₂ stitch welding in Wuxi JACK Z30 model machine: (Fig.6)

4.  Operation on Z30 Large I H Beam Assembly and Tack Welding Machine:

Correspondingly, there should be 2 operators for working on this large size machine, fulfilling the 2 main duties of:

1) Managing on logic action for H Beam flange and web fitting up, by means of buttons and switches on operating pendant;

2) Performing semi-automatic CO₂ welding on the assembled T H Beam, following its sending forward in continuous VFD adjustable assembly working speed.

D. Technical Features of Z30 Large Size Steel Structure Beam Assembly Machine:

1.  Workpiece Assembly Principle in Steel Structure Beam Assembly Machine:

To catering for high efficiency and accurate assembly on such super large H Beam, we adopt the assembling style of:

1) One side of H Beam positioning is managed with mechanical leadscrew;

2) The other side positioning is driven with hydraulic cylinders pushing;

3) Such working style is especially applicable for precise fitting up on large H Beam, with height equals to and above 2,000mm;

2. Composition of Assembly Unit in Z30 Large I H Beam Assembly Machine:

1)  There are 2 sets of assembly rollers, for both flange and web clamping;

2)  Each set of the assembly roller is equipped with positioning leadscrew and hydraulic drive cylinders;

3) Even for assembling on high thickness plate of H Beam flange and web, the Z30 large machine can deliver satisfactory performance, on clamp and assembly with great ease; It is very suitable for assembly on heavy duty T I H Beam;

4) Special Gadget: Considering the big height of vertical H Beam, there is workpiece supporting mechanism, being installed on Z30 model machine mechanical gantry, to prevent the high upright H Beam from tipping down:

The upright large H Beam supporting mechanism in Wuxi JACK Z30 large machine: (Fig.7)

3. Tack Welding: This set of Z30 model machine for assembling large size H Beam is equipped with 2 sets of CO₂ spot welding power supply. Welding consumables are prepared by customers.

E. Three Working Modes in Heavy duty I H Beam Assembly Machine:

1. Manual Mode of I H Beam Assembly and Tack Welding Machine:

a) Importance: This is the default working mode on H Beam assembly. Which means, the machine works under Manual mode after power on;

b) Meaning: This manual mode is for trial run, commissioning, and trouble shooting on H Beam assembly operation:

c) Specific Steps: With start of oil pump, the machine will have operations of:

1) Forward and Backward of drive, input and output conveyor roller tables;

2) Clamp and release on oil cylinder of hydraulic pulling rod system;

3) Press and release on gantry alignment rollers;

4) Start on oil cylinder of flange and web alignment unit;

5) Extension and retreat of positioning unit;

6) Upward and downward of welding torch;

7) Start and stop of CO₂ gas shielded welding power source;  

2. Single Cycle in Automatic I H Beam Assembly Machine:

1) Definition on Single Cycle: This automatic machine accomplishes GMAW stitch welding, with a segment of welding seam during period T, and advances the assembled H Beam a distance at the same time. This is called Single Cycle. Which means, single cycle is the cycle time, which a segment of welding seam is completed on H Beam;  

2) 2 Working Speeds: For carrying out Single Cycle operation, we have definition on:

a) VL (Velocity low) for conveyor welding and sending forward workpiece speed during welding;

b) VH (Velocity high) for conveyor speed during idle movement of transporting H Beam forward without welding;

c) Period t1 means CO₂ spot welding cycle;

3) Within period t1 of machine operation, conveyor roller tables send H Beam forward in A.C. inverter control adjustable speed VL; Meanwhile, welding power source finishes a segment of welding seam on the workpiece assembled H Beam;

4) During period T-t1, welding power source stops operation, and conveyor sends the H Beam a distance in high speed VH;

5) Thus finishes one time of Single Cycle in the machine;

3. Auto Cycle in Automatic I H Beam Assembly and Tack Welding Machine:

1) What is Auto Cycle: The automatic and continuous running of Single cycle is Auto cycle;

2)How to: With machine power on and oil pump start, no matter the machine is in Manual or Single Cycle mode, just press the Auto Cycle button on the operating pendant, the machine will be switched to Auto Cycle;  

3) Fluent Operation: If operation on automatic H Beam assembly is correct and conforms to requirement of welding process technology, the entire piece of H Beam can be assembled and tack welded in Auto Cycle mode in the machine:

Well managed and highly efficient working site of Wuxi JACK Z30 model machine: (Fig.8)