In the 1st photo a set of Wuxi JACK ZHJ8015 model 3 in 1 H Beam Fabrication Machine was being installed in a new workshop.
1) Technical Features: ZHJ and PHJ series 3 in 1 H Beam Welding Line is an efficient and powerful equipment applied in Steel Structure industry, integrating the three core steps for making welding H / I / T Beam: Assembly, SAW or GMAW welding, and straightening;
a) Raising productivity;
b) Maintaining high standard quality level;
c) Reducing period cost (Workshop land area) and variable cost (Utility cost and manufacturing cost)
For customers;
The welding mode in this 3 in 1 H Beam Welding Line is SAW (Submerged arc welding). It has:
1) Large welding current: Working current of 380~ 750A, capacity of up to 1000A;
2) Big welding seam toe size, broad welding cover surface, and high intensity welding seam;
3) Relative high welding speed (100 ~ 1000 mm/min.);
So, ZHJ8015 model 3 in 1 H Beam Fabrication Machine is applicable for producing workpieces in large volume;
1) Wide Application: The welding H / I / T Beam manufactured from ZHJ and PHJ series 3 in 1 SAW H Beam Welding Machine is the most universal adopted raw materials in steel structure industry;
Most often have three grades based on H Beam web height size:
a) From the smallest size of 200mm;
b) Up to max. 1500mm/ 1800mm/ 2000mm height;
c) Correspondingly, model of the 3 in 1 SAW H Beam Welding Machine has 3 options of ZHJ/PHJ 8015/ 8010/ 8020 respectively;
These fabricated welding H Beams can be classified into two broad categories of:
a) H Beam flange thickness higher than 40mm;
b) Single piece weight heavier than 8ton;
a) Sub- Division: With respect to cross section shape, there are:
Majority of symmetric (Account for over 70%~ 80%);
Minority of asymmetric (Around 20% as the case be);
Here, ZHJ series 3 in 1 H Beam Fabrication Machine (Pull Through H Beam Welder) is dedicated for producing symmetric workpiece;
It is composed of three basic machines for fulfilling perations of:
a) H Beam Assembling and CO2 tack welding;
b) SAW (Submerged arc welding);
c) H Beam Flange Straightening;
Together with Transferring Carts and Overturning Racks;
2) For producing light and medium duty workpieces, the ZHJ series Integral Function H Beam Welding Machine (3 in 1 H Beam Assembly Welding Straightening Machine) is perfect solution.
As can be checked from the above layout print,
1) The working area of 3 in 1 H Beam Assembly Welding Straightening Machine has land occupation of 28m length by 7m width, which is only 30% that of H Beam Production Line;
2) Please check the production section of “PHJ ZHJ Compact 3 in 1 H Beam Assembly Welding Straightening Machine” on detailed analysis;
1) Material Flow Way: In the above layout drawing, the material flow is from right to left;
2) In the attached first photo, working parts flow is from inside screen from out of the screen. Or, in the 1st photo the conveyor we see is output conveyor of the 3 in 1 H Beam Welding Line;
3) Conveyor Style: As can be seen from the layout, there are 2~3 sets of manipulators deployed along the input conveyor of the 3 in 1 SAW H Beam Welding Machine, depending on length of workpiece;
1) Appearance: The attached 4th photo was taken on this oil cylinder drive manipulator (Pulling rod) and its installed conveyor;
a) When the flange and web are hoisted onto the input conveyor of the 3 in 1 SAW H Beam Welding Machine, these strip plates need to be maintained to its expected orientation:
b) Flange in horizontal orientation, and web vertical orientation;
c) Both flanges and web should be aligned with centerline of the 3 in 1 H Beam Assembly Welding Straightening Machine mechanical main body. The hydraulic drive manipulator here plays this role;
1) Composition: The base bed (Shown in the attached 3rd photo) and inverted U gantry beam (Shown in the attached 5th photo) construct main body of the 3 in 1 SAW H Beam Welding Machine;
2) Importance: These 2 assemblies are the core parts of the 3 in 1 H Beam Welder, integrating the three working cells of assembling (Fine alignment for flange and web)/ SAW Welding / Flange straightening;
In the 3rd photo the closet to us is straightening section of the Vertical H Beam Welder:
1) Back to the 2nd picture of 3 in 1 SAW H Beam Welding Machine layout;
2) It is suggested to locate the three function units of the vertical H Beam Welder: Control board/ Hydraulic pump station/ SAW power cell in a row, right next to the main body;
3) These working units need to be managed/ monitor during the entire working process of the Integral Function H Beam Welding Machine;
4) The welding supporting units in this 3 in 1 SAW H Beam Welding Machine, including wire feeding mechanism/ Welding flux sending and recovery/ Welding flux hopper, as can be seen in the 1st photo, are all installed and distributed on columns and overhead platform of 3 in 1 H Beam Welding Line main body;
Finally, with the on position of all the units of the ZHJ series Integral Function H Beam Welding Machine, it will be put into use at customer site. As is shown in the attached 6th photo;
Below are technical specifications of ZHJ8015 model SAW Integral Function H Beam Welding Machine (Vertical H Beam Welder):
Technical parameter | ZHJ8015 Automatic 3 in 1 H Beam Fabrication Machine |
Web | Height: 200 ∼ 1500 mm; Thickness: 6 ∼ 32 mm |
Flange | Width: 150 ∼ 750 mm; Thickness: 6 ∼ 40 mm |
Workpiece (Welding H Beam) Length | 3,000 ∼ 15,000 mm (Can be special made) |
Three-in-one Working Speed of Assembly/ Welding Straightening | Scope: 200∼1200 mm/min.(Stepless, Inverter Control, VFD Working Speed: 500~ 700 mm/min. |
Height of Single Pass Welding Seam | Max. 8~12 mm, flat fillet welding of SAW |
Workpiece | Welding H Beam/T Beam of Symmetric Section shape Only |
Overall Dimension(L×W×H) of ZHJ8015 3 in 1 H Beam Welding Line | 28m × 4m × 4.2m |
Input / Output Conveyor | 10~11m length each, 3 segments each; One segment with motor, two segments follower; Input conveyor has three pairs of fitting manipulators |
Driving Mode | Assembly/ Straightening: Hydraulic Cylinder Workpiece Traveling: A.C. motor |
Flange and Web Assembling | Hydraulic motor and cylinder automatically in-phase |
Welding Mode | SAW (Submerged Arc Welding), Single Arc or Twin Arc |
Welding Current | Working current : 380~ 750A; Up Limit: 1000 A |