1. Output and Advantage of BOX Beam Production Line 2. Design Sketch of Welding BOX Beam 3. Process Technology of BOX Beam Production Line 4. Layout of BOX Beam Production Line 5. Main Equipment in BOX Beam Production Line 5.1 GZ12/ GZ15 Internal Baffle Assembly and Welding Machine: 5.2 UBZ12 BOX Beam Assembly Machine: 5.3 YF1220 180° Hydraulic Flipping Rack: 5.4 BOX Beam Back Welding Machine: 5.5 BOX Beam Electroslag Welding Machine: 5.6 BOX Beam SAW Welding Machine: 6. Application Range and Related Equipment of BOX Beam Production Line
The assistant work stations, including baffle manual welding, back welding, cutting of arc strike and riser in electroslag welding, IPV (Internal process validation) can all be completed in the BOX Beam Production Line. There is no need on traveling crane, except U Beam assembly, and finished BOX Beam loading offline;
A. Internal Baffle welding at BOX Beam Assembly Machine;
B. Twin Arc gas shielded CO2 Back Welding at BOX Beam Back Welding Machine;
C. Consumable nozzle electroslag welding at BOX Beam Electroslag Welding Machine;
D. Wire electrode electroslag welding at BOX Beam Electroslag Welding Machine;
E. Twin Arc and Triple Arc submerged arc welding at BOX Beam SAW Welding Machine.
By means of 180° and 90° Traveling Hydraulic Overturning Rack, all the automatic and manual welding operations in BOX Beam Production Line are implemented in optimum position (Vertical downward welding), guaranteeing the best degree of welding quality, high productivity, and operator friendly ergonomics operation.
4) For quick understanding, please check thematic page of “Brief Review on Wuxi JACK BOX Beam Production Line”.
5.1 GZ12/ GZ15 Internal Baffle Assembly and Welding Machine: 5.2 UBZ12 BOX Beam Assembly Machine: 5.3 YF1220 180° Hydraulic Flipping Rack: 5.4 BOX Beam Back Welding Machine: 5.5 BOX Beam Electroslag Welding Machine: 5.6 BOX Beam SAW Welding Machine:
| Model of Internal Baffle Assembly and Welding Machine | GZ12/ GZ15 |
| BOX Beam Cross Section H×W | 300×300∽1200×1200 mm / 300×300∽1500×1500 mm |
| BOX Beam Length | 3000∽12000 mm |
| Max. Workpiece weight | 20 Ton. |
| Baffle Thickness | ≤80 mm |
| Flip Motor Power | 2 kW |
| Flip Speed | 1.8 rpm |
| Work Table Loading Capacity | 1200 kg |
| Height of Flip Center | 1200 mm |
| Flip Range of Work Table | ±180° |
UBZ12 BOX Beam Assembly Machine assembles 4 pieces of beam board (Web) and 4 pieces of internal baffles into a piece of assembled and tack welded BOX Beam.
| Model of BOX Beam Assembly Machine | UBZ12 |
| Workpiece Cross Section Size | 300ｘ300～1200ｘ1200 mm |
| Max. Loading Capacity | 20 Ton |
| Gantry Travel Speed | 4000 mm/ min. |
| Hydraulic Pressure | 14 MPa |
| Max. Pressure of Sideward Stroke Cylinders | 15 Ton |
| Max. Pressure of Downward Stroke Cylinder | 30 Ton |
| Max. Stroke of Sideward Cylinders | 800 mm |
| Max. Stroke of Downward Cylinders | 900 mm |
| Oil Pump Motor | 11 kW |
1) YF1220 180° Hydraulic Flipping Rack is logistics equipment in BOX Beam Production Line. Its purpose is to have 90°/ 180° flipping of BOX Beam, as well as transferring among work stations in the line;
2) Working Way: The 180° Hydraulic Flipping Rack works in the form of 2 sets per group, to overturning and supporting the whole length of BOX beam;
3) Flipping of BOX Beam is driven with hydraulic oil cylinder; Traveling of BOX Beam is driven with A.C. motor reducer;
4) Quantity: There are 4 sets (Or, 2 groups) of 180° Hydraulic Flipping Rack deployed in a BOX Beam Production Line.
| Model of 180° Hydraulic Flipping Rack | YF1220 |
| Loading Capacity | 20 Ton |
| Power of Travel Motor Reducer | 1.5 kW |
| Travel Speed | 5000 mm/min. |
| Diameter of Flipping Drive Cylinder | φ150mm |
| Max. Hydraulic Pressure | 16 MPa |
| Rail Center Distance | 700 mm |
| Overturning Range | ±180° |
| Model of BOX Beam Back Welding Machine | XQ12 |
| BOX Beam Cross Section Size | 300ｘ300～1200ｘ1200 mm |
| BOX Beam Length | 4000～15000mm |
| CO2 Backing Welding Speed | 240 ~ 2400 mm/min. |
| Idle Running Speed | 3000 mm/min. |
| Model of BOX Beam Electroslag Welding Machine | XD12 / XD15 / XSD12 |
| Cross Size Size of BOX Beam | 300ｘ300～(1200ｘ1200mm/ 1500ｘ1500mm/ 1200ｘ1200mm) |
| BOX Beam Length | 4,000 ~ 15,000 mm |
| Trolley Rail Span | 1,000 mm |
| Trolley Travel Speed | 6,000 mm / min. |
| Trolley Travel Motor Power | 0.55 / 0.75/ 0.55 kW |
1) Function: BOX Beam SAW Welding Machine performs Twin Arc or even Triple Arc submerged arc welding on the assembled, tack welded, back welded, and electroslag welded BOX Beam flowing in the BOX Beam Production Line;
2) Classification: Based on structure of mechanical main frame, there are 2 types of BOX Beam SAW Welding Machine: LHE12 Gantry type and LHC12 Cantilever type;
3) Both types work in the same working mode: BOX Beam is put stationary on conveyor of the BOX Beam SAW Welding Machine, and the gantry frame or cantilever trolley moves in adjustable welding speed, performing Twin Arc or Triple Arc submerged arc welding at the same time;
4) Quality Control: During working of the BOX Beam SAW Welding Machine, welding torch is controlled with air cylinder drive mechanical style welding seam tracing unit, guaranteeing welding quality and productivity of the BOX Beam Production Line;
5) Working Nature: We can see that gantry type BOX Beam SAW Welding Machine has very similar machine structure and working principle as H Beam Gantry Welding Machine; And cantilever type BOX Beam SAW Welding Machine can be replaced as column structure H Beam Welding Machine which are deployed 4 sets in a group in automatic H Beam Production Line;
6) Quantity: In BOX Beam Production Line, there are 2 sets of either LHE gantry style or LHC cantilever structure BOX Beam SAW Welding Machine.
| Model of BOX Beam SAW Welding Machine | LHE12/ LHC12 |
| Mechanical Main Frame Structure | Traveling Gantry/ Traveling Trolley and Boom |
| BOX Beam Cross Section Size | 300ｘ300～1200ｘ1200 mm |
| BOX Beam Length | 4,000～15,000 mm |
| Gantry Rail Length | 18,000 mm |
| Gantry Rail Span | 1400 mm |
| Gantry Travel Stroke | 15,500 mm |
| Submerged Arc Welding Welding Speed | 150 ~ 1500 mm/min. |
| Idle Traveling Speed | 2400 mm/min. |
| Gas Pressure | 0.4 ~ 0.8 MPa |
| Flux Recovery Unit Power | 2 x 3 kW |
| BOX Beam SAW Welding Machine Power | 3 kW |