Z10 Automatic T Beam Assembly And Tack Welding Machine

A. Usage of Z10 Automatic T Beam Assembly Machine:

1. Purpose of Automatic T Beam Assembling and Tack Welding Machine:

In the 3^rd station of welding T Beam Production Line, following:

1) Plate cut;

2) Horizontal end plate edge trimming and rounding;

The horizontal end plate and vertical stiffener should be assembled and spot welded into semi-finished workpieces of assembled T Beam, with this Z10 model machine:

T Beam assembling and tack welding in Wuxi JACK Z10 model machine: (Fig.1)

2.  Working Principle and Finished Workpiece:

1) The Z10 model machine on T Beam assembly has similar working principle and structure as H Beam Assembly Machine;

2) The difference lies in smaller size of assembled T Beam than H Beam:

a) Max. height of vertical plate (Stiffener) is 1000mm, compared with Max. 1500mm height of H Beam web;

b) Max. width of horizontal plate (Stiffener) is 500mm, compared with Max. 800mm width of H Beam flange.

B. Technical Brief on Z10 Automatic T Beam Assembly and Tack Welding Machine:

1. Function: This machine is for assembling two pieces of steel plate into inversed T Beam, and strengthen it with CO₂ tack welding, delivering a piece of assembled T Beam;

2. Operation in Z10 Automatic T Beam Assembly Machine:

1)  Fully Automatic: The entire operation in Z10 is automatic, except loading end plate and stiffener onto machine conveyor, unloading assembled T Beam off the machine;

2) Especially the complicated jobs of:

a) Controlling on interval and length stitch welding seam: This is managed with PLC;

b) T Beam both sides in phase CO₂ welding on vertical stiffener with horizontal end plate: This is automatically accomplished with 2 sets of CO₂ welding power supply and its control console;

3) Operating panel of Z10 T Beam Assembly and Tack Welding Machine is installed on the right lower section of gantry column, for the purpose of operator easy access and observance on operating process, on T Beam fit up and tack welding:

Operating panel of Wuxi JACK Z10 model machine: (Fig.2)

4) Management on CO₂ welding system is integrated into Z10 model machine operating panel;

3. Structure of Z10 Automatic T Beam Assembling Machine:

1) Please check attached photos. The Z10 model machine has mechanical main body of gantry frame assembled onto machine base bed:

Front view on Wuxi JACK Z10 model Automatic T Beam Assembling and Tack Welding Machine: (Fig.3)

2) Input conveyor and output conveyors: With 10m ~12m length respectively, composed of 2 ~ 3 sets of roller tables. This conveyors are for conveying end plate and stiffener into the Z10 model machine, and assembled T Beam out of this machine:

Conveyors roller tables of Wuxi JACK Z10 model machine: (Fig.4)

3) Hydraulic pump station: Providing assembling force on T Beam assembly, the pump station is put alongside Z10 machine body, for the purpose of easy connection and maintenance;

4) 2 sets of CO₂ tack welding power supply are put on the overhead platform at the top of Z10 model machine U shape gantry, with a staircase assembled at the lateral side, for operators climbing up the platform.

C. Working Principle of Z10 Automatic T Beam Assembling Machine:

The assembly and tack welding of T Beam with this Z10 automatic machine can be divided into below three major steps of:

1. The First Step in T Beam Assembly Machine:

This step completes T Beam first stage rough assembling:

1) By means of 2 ~ 3 sets of hydraulic manipulators (Pulling rod system, please check the 2^nd attached picture) installed on the input conveyor:

2) Hydraulic manipulators alongside Z10 machine input conveyor: (Fig.5)

3) These manipulators (Pulling rod system) are hydraulic oil cylinder driven. It fit up and clamp 2 pieces of steel plates as horizontal end plate and vertical stiffener of inversed T Beam, and clamp the T Beam for maintaining T shape;

2. The 2^nd and 3^rd Steps of T Beam Assembly and Tack Welding Machine:

a) These 2 steps complete T Beam Precise Assembly and at the same time CO₂ Tack Welding:

b) Get hint from equipment name of “T Beam Assembly and Tack Welding Machine”, the 2^nd and 3^rd steps are carried out simultaneously, at central zone of the machine:

c) Automatic assembly and CO₂ spot welding units of Wuxi JACK Z10 model machine: (Fig.6)

The entire 2^nd and 3^rd steps are finished as below:

1) Workpiece Send In: The rough fit up T Beam goes forward to Z10 model machine base bed, which is the central working area of the machine;

2) Finished Assembly: There are final assembly unit, in the form of set of alignment rollers (Please check the 3^rd attached photo), which adjusts and tightens the fit up T Beam, finishing the second step of T Beam final assembly;

3) CO₂ Stitch Welding: The 3^rd step operation is to implement on CO₂ tack welding, in constant speed of adjustable speed of 200mm ~ 2000mm/min., along both sides of the assembled T Beam. making it finished workpiece of Z10: Assembled T Beam;

4) Following that, the assembled T Beam will be sent to next station of T Beam Production Line: T Beam continuous welding.

D. Main Units of Z10 Automatic T Beam Assembling and Tack Welding Machine:

This Automatic machine is mainly composed of:

1. Mechanical Main Body:

Including:

1) U shape gantry frame in the top section;

2) Mechanical base bed at the lower section;

The 2 assemblies are assembled together into an integral part;

2. Input and output conveyor roller table: Its sending workpiece speed is constant, different from that of T Beam assembly and tack welding;

3. Hydraulic drive pulling rod system (Manipulator): For fulfilling the first step of T Beam assembly (Rough assembling), installed on along input conveyor roller tables, oil cylinder driven;

4. T Beam precise assembly unit: For completing final step of T Beam assembly (Precise assembly), in the form of set of alignment rollers, hydraulic driven;

5. CO₂ Tack Welding System in Automatic T Beam Assembly Machine:

Including:

1) 2 sets of CO₂ welding power supply;

2) Welding control console;

3) Welding torch position adjustment mechanism;

4) Welding wire feeder;

6. Hydraulic system: Provide drive force on T Beam assembly operation;

7. Electric control system:

Its core elements include:

1) PLC (Programmable logic controller);

2) A.C. inverter;

3)  Conventional electric elements: Contactor, relay, breaker, digital display.

E. Technical Parameters of Z10 Automatic T Beam Assembly and Tack Welding Machine:

Model	Z10 Automatic T Beam Assembly Machine with Tack   Welding
Max. Height of T Beam Stiffener (Vertical Plate)	1000 mm
Thickness of T Beam Stiffener (Vertical Plate)	8∽ 20 mm
Width of T Beam End Plate (Horizontal Plate)	100∽ 500 mm
Thickness of T Beam End Plate (Horizontal Plate)	10∽ 40 mm
T Beam Length	4000∽ 12000 mm
T Beam Assembly and Tack Welding Velocity	200 ~   2000 mm/min., continuously controlled with A.C. inverter
Max. T Beam Weight	15 Ton
T Beam Assembly Style	Automatic Positioning and Alignment
Tack Welding Technology	Automatic CO2 tack welding
Operator	1 operator
Conveyor speed	2000 mm/min.,   constant