1) Based on customer request, this machine mainly utilizes HMI (Human machine interface) as its way of operating butt welding on steel plates, on the basis of conventional way of machine operating panel plus welding power supply control console:
a) The tailor made HMI with its colored touch screen, of Wuxi JACK MP23 model machine: (Fig.1)
b) Control console of SAW welding power supply, also manages on process control parameters on plate butt welding: (Fig.2)
2) Convenient and Flexible Operation:
a) The HMI is integrated with standing type electric control cabinet of Steel Plate Butt Joining Machine and its operating panel, in height of adult male operator, away from machine main frame;
b) Control console of SAW welding power supply is assembled onto motor drive moving carriage of welding torch, which moves together with welding torch during operation;
c) In this way, operator can get access on management easily with double choices available:
d) HMI touch screen integrated with operating switches of MP23 model Flat Butt Welding Machine: (Fig.3)
e) Please check the attached video of this machine, viewing on HMI management and corresponding melt-thru butt welding in the machine;
1) Task: MP23 Steel Plate Butt Joint Welding Machine is used for flat joint on any 2 pieces of metal steel plates, by means of melt thru butt welding;
2) Customer of this MP23 model machine is a famous Chinese producer company on crane and derrick, in Yangzhou city;
3) Plate Specifications: All the plates with width equal to or less than 2300mm, thickness not up to 30mm can be joint with this model machine. The length of completed joining plate can be up to 30m:
a) SAW submerged arc welding of melt-thru, in Wuxi JACK MP23 model Steel Plate Flat Butt Welding Machine: (Fig.4)
b) Finished test piece on butt welding from MP23: (Fig.5)
4) Strength of joint seam of completed joint plate, delivered from this MP23 model is stronger than base material, based on the adopted advanced technique of melt thru;
5) The linearity of completed long length joint plate is fully guaranteed, by means of the 5 sets of alignment rollers, installed on input and output conveyors roller tables of the Steel Plate Butt Joint Welding Machine;
6) In a nutshell, both the mechanical property, and physical appearance of completed joint plate, produced from this machine, are superior than that of an integral piece of steel plate from Steel Mill, but with longer length and or wider width.
a) Design illustration on main frame of MP23 model machine: (Fig.6)
b) The machine is composed of:
1) Stationary mechanical main frame: Gantry and butt welding worktable;
2) Oxygen fuel triple cutting system;
3) SAW melt-thru butt welding system: Welding power supply/ Welding flux recycling machine; Motorized welding torch and its moving carriage;
4) Hydraulic pump station, oil cylinders and control electromagnetic valves;
5) Input and output conveyor roller table, its plate alignment units;
6) Electric control system: Control board, HMI;
c) Arrangement on MP23 model Steel Plate Flat Butt Welding Machine at customer facility: (Fig.7)
1) The two major function cells in machine: The triple flame cutting system, and melt thru butt welding system are deployed at inlet and outlet side of the mechanical main frame respectively;
2) First, the 2 pieces of steel plates for joint, are sent to flame triple cutting side of machine gantry, in high speed of 2,000 mm/min.;
3) Cutting out bevel on joint edges of the 2 pieces of steel plate, in the form of flame triple cutting, especially thickness of steel plates are equal to or larger than 15mm: (Fig.8)
4) SAW Butt Welding: Sending the 2 pieces of beveled steel plate, to the opposite side of gantry: SAW melt-thru welding work table, and carry out butt welding accordingly:
Lateral view on MP23 model machine: From right to left, steel plates going in direction, the flame triple cutting unit at right side of gantry, the SAW melt-thru butt welding at left side: (Fig.9)
5) In this way, with the movement of steel plates going through the Steel Plate Flat Butt Welding Machine, first its edges got beveled at one side, then butt welded at the opposing side, and transported out for finished joint plate offloading.
1. The critical core technique in this powerful machine is its melt thru welding, which means “One side welding, and welding seam formed on both sides of steel plate”:
a) The SAW melt thru butt welding operation in MP23 model machine: (Fig.10)
b) The finished butt welding joint plate, and welding seam: (Fig.11)
2. Critical Units: Shown in the above photos, such leading edge technology is realized with array of copper blocks, which is circulated with cooling water for heat dissipation, during the large current SAW (Submerged arc welding) in the machine;
3. Double Layer Welding Flux: There are 2 layers of special welding flux, being deposited above and beneath steel plates respectively, this helps forceful and rapid formation of fully penetration high strength welding seam, on both sides of joint plate;
4. Workpiece Clamp: Steel plates are pressed firmly on the copper pads, driven under hydraulic system of the Steel Plate Flat Butt Welding Machine;
5. Operation of this MP23 model machine, as introduced in the previous segment, is by means of double assurance of:
a) Machine Motion: User friendly interface of HMI (Human machine interface) with operating switches;
b) SAW Process Parameters: SAW welding power supply control console;
c) All the parameters and specifications for operation can be keyed in by operator through this HMI, directly and conveniently.
This includes 2 separate sections, of which fixed position will be decided on site at customer workshop, based on workshop surroundings and plate size:
1) The higher double side operation box structure gantry;
2) The lower SAW butt welding worktable, with trapezoidal cross section V slot welding bench:
3) Cross section view on Wuxi JACK MP models steel plate Flat Butt Welding Machine gantry and welding worktable: (Fig.12)
2. Plates Clamp during Butt Welding: The 2 units of downward acting plate pressing blocks are distributed at outlet of the main body. It is adopted with individual acting style of pressing points, making sure reliable pressing of plate and little welding deformation:
Distribution of copper pads/ grounding cables/ pressing block, along the entire length of machine welding work table: (Fig.13)
3. The copper pads block can be lifted up and lowered down integrally, controlled with proximity switch;
1) Rollers of conveyors roller tables are made from Diameter Φ133mm seamless steel pipes, arranged in interval of 1200mm;
2) Driving section and idler section are installed in stagger;
3) There are 2 choices of high speed and lower speed available;
4) Plate Alignment: To fully make sure perfect alignment of plates against input and output conveyors, there are 2 units of aligning rollers in input and output conveyors respectively; The adjustment way is inching mode, realized with manual turning leadscrew.
No. | Parameters | Specification | Note |
1 | Applicable Plate Thickness | 8- 30 mm | Carbon steel, Stainless Steel, or Al Alloy; 6- 12mm direct joint，16- 30mm with beveling |
2 | Max. Valid Welding Seam Length | 300- 2300 mm | Or Max. plate width 2,300mm |
3 | Max. Length of Joint Plate | 30 m | |
4 | Melt Thru Welding Speed | 200- 1200 mm/min | A.C. Inverter Control |
5 | Idle Speed | 2000 mm/min. | |
6 | Transverse Transmission | Guided with precision linear guiderail, transmitted with gear and rack couple | |
7 | Plate Pressing Form | Hydraulic cylinder | |
8 | Welding Mode | Melt thru SAW | |
9 | Flame Triple Cutting | 1 set | For making welding groove |
10 | Conveyor Alignment Unit | 4 sets | 2 sets input, 2 sets output |
11 | Alignment Style | Manual CW/ CCW Leadscrew | |
12 | Input Conveyor | 10 m | 2 segments, 1 is driving |
13 | Output Conveyor | 35 m | 6 segments, 3 are driving |
14 | Plate Feeding Speed | 4000 mm/min | |