1. Usage and Technical Characteristics of Longitudinal Seam Pipe Welding Machine:

1) Function: This machine is for carrying out back welding in medium to large diameters pipes, in the form of longitudinal seam, following Large Pipe Tack Welding Machine;
2) Application: This machine is necessary welding equipment on pipe fabrication, in industries and construction sites of Oil Pipeline/ Electric Light Pole / Municipal Construction/ Pipeline Deployment, etc.;
3) Welding mode: CO₂ gas shielded GMAW, serving as back welding, with 350- 500A welding current. The welding torch has circulating cooling water system, so as to prevent it from overheating during long longitudinal seam welding, protecting welding torch and maintain its long service life;
4) Welding Torch Swing Device: To manage on and acquire sufficient broad width of longitudinal back welding seam, which is to be formed on external surface of the pipe body, this Pipe Longitudinal Welding Machine is equipped with welding torch swing device, as shown in the above 2^nd photo;
5) Welding Torch Position Control: To precisely control on welding torch position during the entire longitudinal seam back welding operation, this machine has precise cross slides equipped on its welding torch mechanism, as shown in the above 1^st photo;
6) The longitudinal back welding operation and finished pipe with Wuxi JACK machine please check the above 3^rd and 4^th photos;
 

2. Welding Torch Water Cooling Unit in LHD Series Pipe Longitudinal Welding Machine:

1) Background: This machine performs longitudinal back welding by means of continuous CO₂ gas shielded welding, which generates large amount of heat during welding operation, and hence bring along negative effect of:

a) Affects on back welding performance;
b) Easily deteriorates welding torch itself, and shortens service life;
2) To guarantee long term stable running, welding torch is equipped with water cooling circulation and tank, as shown in the above 2^nd photo (Red color at lateral lower section of the Pipe Welding Machine main frame);
7) Eye Protection on Operators: CO₂ gas shielded welding emits out strong arc light, which is harmful on people eyesight. For this reason, welding torch mechanism has red color curtain surrounding it, isolating strong light, as shown in the above 2^nd photo;
8) Function of Welding Groove Cut: As shown in the above 3^rd photo, before being back welded in this Pipe Longitudinal Welding Machine, steel plates for being fabricated into pipe need to be beveled first with related machine tools, such as XBJ series Edge Milling Machine/ Hobbing Cutter Beveling Machine, cut out welding groove in place for the purpose of satisfactory welding performance.

1. Internal and External Pipe Flange Cylinder Circumferential Welding Machine:

1) Usage: This medium sized welding equipment can be used for implementing on both internal and external circumferential welding on pipes and flanges at the same time;
2) Execution Cells: As shown in righthand photo, there are 2 pieces of welding torch in one set of the machine, for carrying out internal and external circumferential welding simultaneously;
3) Length of machine horizontal bed is determined on the Max. length of pipe flange or cylinder, together with dimension of welding torches mechanism;

4) Workpiece Hold and Rotation in Pipe Flange Cylinder Circumferential Welding Machine:

a) There are 2 sets of Welding Rotators being installed along the machine mechanical horizontal base bed;
b) The Welding Rotators serve as workpiece (Pipe flange) support and rotating unit, which means, revolve of welding rotators lead workpiece into revolve, and the stationary welding torch completes circumferential welding accordingly;
c) To accommodate on different length of pipe flange cylinder, position of Welding Rotators can be adjusted manually along its guide rail, according to workpiece length;

5) Internal and External Circumferential Welding in Cylinder Flange Pipe Welding Machine:

a) External: The welding torch responsible for external circumferential welding can descends down within certain stroke, based on diameter of pipe flange. Its position will be adjusted right above the welding point, at 12 O’clock position. During welding, the welding torch keep still, and pipe flange rotates under adjustable velocity;
b) Internal: The related welding torch is smaller and installed at lower level, so as to be able to extend into the pipe flange for welding;
c) Selection and Switch: The 2 pieces of welding torches share the same set of welding power supply. So, at any moment, there is only one circumferential welding in operation in the Cylinder Pipe Flange Circumferential Welding Machine, either external or internal. The switch between internal and external circumferential welding is fulfilled with operating panel of the machine;

6) Work Velocity in Cylinder Pipe Flange Circumferential Welding Machine:

a) Rotating linear speed of turning rollers in Welding Rotators, equals to internal and external welding velocity;
b) This speed is controlled with A.C. inverter, conveniently adjusted continuously and displayed in real time manner during work;

7) Torch Position in Circumferential Seam Cylinder Flange Pipe Welding Machine:

a) The external circumferential welding is in the form of 45° TIG/ MIG fillet welding, welding torch tilts 45° inwardly toward joint seam of pipe flange, so as to get sufficient welding fusion and broad cover surface;
b) The internal circumferential welding is in the form of flat butt TIG/ MIG welding between pipe flange rim. Welding torch faces downward 90°, serving as assistant on pipe flange fabrication;
 

8) Technical Parameters of Internal and External Cylinder Pipe Flange Circumferential Welding Machine:

2. Compact Cylinder Body Circumferential Welding Machine for Strap Cladding:

1) Function: This welding equipment is used for small cylinder external CO₂ GMAW welding;

2) Structure Feature of Small Cylinder Circumferential Welding Machine:

As shown in the lefthand photo,
a) This welding equipment comes in between machinery and welding fixture. It has compact dimension and complicated structure;
b) There are 2 pieces of extending boom and related welding torch carriage in one set of the machine. So, workpieces can be welded at its both ends at the same time;
c) Workpiece Fixture: One end of the small cylinder is clamped into a small chuck, which rotates during external circumferential welding, in adjustable linear speed. The other end is a manual managed moving bracket;
d) The entire Cylinder Pipe Welding Machine is installed onto a stationary platform, with welding power supply put alongside on workshop floor;

3) Welding Operation in Small Cylinder Circumferential Welding Machine:

a) The 2 pieces of extending boom are for the purpose of feeding in and retreating welding torch, serving as welding arm, before and after welding in the cylinder application;
b) This is for the purpose of avoiding collision between welding torch and workpiece;
c) Strong arc light emitted during CO₂ welding will do harm to operator eyesight. So, need to put on goggles and helmet for protection;

4) Accommodating on Varied Length of Small Cylinder in Circumferential Welding Machine:

a) As shown in the lefthand photo, the upright workpiece support rack can be adjusted along the bottom rail, on machine platform, catering on varied length of cylinder body;
b) Movement of the support rack is protected with bellows cover, which is made from black color fire proof anti-worn cloth, protecting the unit against welding sparks;
c) Movement of the support rack is guided with double levels precise linear guiderails, which are installed on horizontal beam of rear side gantry;
5) Welding Mode: In the lefthand photo, the small cylinder body was being carried out strap cladding, or built-up welding.
 

3. Small Pipe Flange Circumferential Welding Machine:

1) Usage: This welding equipment is specifically designed, for fulfilling external circumferential welding on small flanges, or short length pipes;

2) Structure Specialty of Pipe Flange Circumferential Welding Machine:

a) Flange Fixture: As shown in the righthand photos, there is a set of small Welding Positioner being assembled at left end of the welding equipment body, serving as workpiece roller bed. A 3 claw chuck is installed right above the Welding Positioner, and flange is clamped into the 3 claw chuck;
b) Tilting Angle: In this way, adjusting on angular position of workpiece flange, so as to acquire on optimum position welding: Flange can be adjusted within the range of 0°- 45°;
3) Welding Position: Correspondingly, welding torch here is kept at 90° upright downward all the while, in stationary, a “comfortable” position for performing circumferential welding. The rotation of chuck and flange completes external circumferential welding accordingly;
4) For Short Length Small Diameter Pipe Welding: In addition, in this circumferential seam Flange Pipe Welding Machine, there is an upright small bracket at opposing end, facing on the Welding Positioner, of which its position can be adjusted with handwheel. This is for the purpose of welding small tubes as well;

5) Technical Parameters of Compact Size Small Pipe Flange Circumferential Welding Machine:

1. Specifications of Girder Production Line Longitudinal Welding Machine:

1) Typical Workpieces: Large size cross section girder/ Steel structure beam with super long length is a kind of important raw materials, in the process of manufacturing on and building up various large size Machinery / Port Machinery;
2) Typical Specifications: The typical cross section size of these girder/ large beam: 2,400mm width by 2,400mm width, with length up to 49m;
3) Suitable Industries: These large section long length girders are indispensable workpieces in industries of: Port Machinery/ Hoist Crane/ Bridge Construction/ Road Deployment.
 

2. Technical Features of Large Beam/ Pipe/ Girder Production Longitudinal Welding Machine:

1) Welding Carts in Symmetry: Considering the huge size of large beam girder and hence the Longitudinal Welding Machine itself, it is very difficult by direct access with people walk, the automatic welding here is performed by means of 2 sets of motor drive welding trolley, which are deployed at both sides of the large beam girder in parallel;

2) 45° Flat Welding in Large Beam Girder Longitudinal Welding Machine:

Considering factors of:
a) The large size girder beam production entails deep fusion of welding seam produced, to guarantee on strength of welding seam, and hence integrity of the entire large beam girder;
b) The large size girder beam is nearly impossible to be tilted, only laid flat during welding,
Accordingly, the longitudinal welding of long stroke should be carried out in the position of 45° flat welding, with 2 pieces of welding torch in 45° orientation facing each other:
Design sketch on welding cart and 2 pieces of symmetrical arranged welding torch in Wuxi JACK large Beam / Pipe / Girder Longitudinal Welding Machine: (Fig.1)

3) Welding Mode: To meet the requirement on high strength welding seam, continuous CO₂ GMAW is adopted here on large beam girder longitudinal welding, which has the best degree of welding impact resistant value (IK);
4) Security Assurance with Electric Interlock Control: In view of electric control, there is interlock between the 2 sets of welding trolley and its installed welding units. Which means, either set of moving welding cart can not be started independently. The only possible operation is simultaneous operation of the 2 welding carts, during the entire operation duration of Large Beam Girder Longitudinal Welding Machine.
 

3. Precondition on Large Beam Girder Longitudinal Welding Machine Operation:

1) Girder Longitudinal Camber: The super long length of large beam girder will inevitably have certain degree of camber. The default allowable camber for this machine is 80mm. Larger camber than this needs special design;
2) Base Plate Extension: The 45° flat welding needs certain extension of girder base plate, to help formation of longitudinal welding seam. Here the minimum extension is 20mm. Which means, should be ≥20mm;
3) Horizontal Stroke: To fully cover operating scope, each piece of welding torch has horizontal extension stroke of 700mm;
4) Welding Torch Tracker: This is indispensable assistant unit in any set of welding equipment. Here in this large Beam girder Longitudinal Welding Machine, considering large dimension of workpiece, the welding torch tracker is mechanical type, with horizontal and vertical direction stroke 100mm and 160mm respectively, and guided with high precision linear guiderail. The entire tracing operation is controlled digital system, detected with magnetic switch, a mature technology of Wuxi JACK welding machinery and equipment;
5) Water Cooling Welding Torch: The super long welding stroke of 49m needs water cooling unit to protect its CO₂ welding torch.

1. Usage and Application of Large Pipe Tack Welding Machine:

1) Function: This machine initiates on pipe fabrication in the form of pipe forming and tack welding, ahead of final step of pipe finished longitudinal welding;
2) Application Site: This machine is a kind of large scale/ heavy duty and special design Pipe Welding Machine. It is one of major machineries in Large Diameter Longitudinal Seam SAW Pipe Production Line, in the Chinese national East to West Nature Gas Transportation Pipeline, or production line on Lamp Post/ Power Post;
Sketch on layout of Wuxi JACK Large Pipe Tack Welding Machine: (Fig.2)

3) Similar Function Welding Machinery: This machine is similar to H Beam Assembly Machine, which, after steel plate is bent into round shape of large diameter pipe, applying final step of squeeze under the heavy force drive of hydraulic oil cylinders, and implement on longitudinal tack welding along the entire length of the large pipe body at the same time;
4) Workpieces being processed in this Large Pipe Tack Welding Machine is fairly large: Diameter is up to Φ1200mm, length up to 30m.

2. Technical Parameters of Wuxi JACK Large Pipe Tack Welding Machine: