FAQ FRO ANGLE STRAIGHTENING MACHINE

A This mainly involves 4 aspects of: Electricity/ Gas/ Hydraulic Oil/ Water

1. 1. Flame triple cutting: There are three ways of cutting gas pipeline:

1. 1) Pre-heating Oxygen;
2. 2) Cutting Oxygen;
3. 3) Cutting gas: Acetylene / Propane;

With gas array and manifold;

1. 2. Hydraulic Drive: For driving on pressing blocks, which secure metal plates against bottom copper pads. The corresponding pump station has motor power of 4kW; The hydraulic pressure is 8MPa;
2. 3. Cooling Water Circulation: In Wuxi JACK Steel Plate Flat Butt Welder Machine, there are several pieces of water tube (Blue color) connected between butt welding work table and cooling water tank. The volume of water tank is 400L; The water pressure is 0.2~ 0.4 MPa;
3. 4. Electricity: One set of Wuxi JACK MP30 (One of the often selected model) steel Plate Flat Joint Butt Welding Machine has total power of around 12.5kW+ 75KVA;

A In sequence of operation:

1. 1. Steel Plate Loading In: By means of alignment mechanism along input and output conveyors: Alignment rollers/ Leadscrew/ Pushing oil cylinders, make sure fully linearity and straightness of the 2 pieces of butt welding long plate. This is very critical for subsequent steps operation. As to steel plate sending in speed, switch between copper pads elevation, also selects on Fast/ Slow speed of plate transportation;
2. 2. Flame Triple Cutting on edges of steel plate: This is optional configuration of steel plate Flat Butt Welder Machine, for cutting out grooves before butt welding. Operator need to adjust on:

1. a) Tilting angle of triple cutting torches;
2. b) Pressure and flames of Preheating Oxygen/ Cutting Oxygen/ Cutting Gas;

1. 3. SAW Butt Welding: This is the core operation in steel Plate Butt Welding Joint Machine. Operator need to adjust on:

1. 1) Butt welding velocity, based on thickness and material of joint plates, by means of HMI touch screen;
2. 2) Butt welding current/ voltage, by means of HMI touch screen, or welding power supply control console.

A

1. 1) Although with large dimension, which occupies land area of 5mx 24m for model of MP20, Steel Plate Flat Butt Welder Machine does not need have foundation. We give customers layout drawing ahead of time, customer can make plan on machine arrangement accordingly;
2. 2) The critical control point of this machine is to make sure straightness and linearity of input and output conveyors roller tables, which has total length of over 20m. This is precondition on correct alignment and butt welding of joint plates. One of the good method is to pull rope along conveyors of steel Plate Butt Welding Joining Machine;
3. 3) The main machine/ conveyor roller tables frames will be fixed firmly into workshop floor, by means of anchor bolts.

A Safety is always the first priority for Wuxi JACK, when developing and manufacturing machine and tool for customer. For this plate Flat Butt Welder Machine, below are critical points for attention on safe operation:

1. 1) Operator Squeeze: There is narrow passage between main machine (Butt welding table and triple flame cutting) and input/ output conveyor roller tables. During operation, be careful not to enter into this narrow isle, to avoid being bumped or squeezed by sudden feeding in of steel plates;
2. 2) Hand Scald: The newly finished butt welded joint plate has high temperature. Be careful, do not touch it directly. Put on gloves, and carry joint plate after cooling down;
3. 3) Rotation Units: All the moving/ rotating units of steel Plate Butt Welding Joining Machine, such as chains/ sprockets, are covered with eye catching orange or bright yellow colors, this can give alarm on people safety;
4. 4) Eye Protection: SAW has little effect on eyesight. However, when carry out CO₂ butt welding, or, during spot welding on corners of narrow plates, be careful to avoid direct eye contact with strong light generated from CO₂ spot welding.

 

A Quality and safety are two primary focuses throughout the entire Order to Delivery process of every set of our machine:

1. 1) Design is based on past experience/ technical know-how accumulation/ close communication with customer on their demand. The initial design is validated by means of virtual design technology, and practical butt welding test;
2. 2) Sizes of plate Flat Butt Welder Machine and components are obvious larger than other producers, with sufficient margin;
3. 3) Material of components/ units/ assemblies are high quality metals, including carbon steel/ casting/ Stainless steel/ Section steel...;
4. 4) Production process technology has mature management system, with IPV and quality gate at each production station of steel Plate Butt Welding Joining Machine;
5. 5) Brand of Major Outsourced Parts in Wuxi JACK Steel Plate Butt Welding Joint Machine:

1. a) Butt welding power supply: From renowned profession suppliers, such as Chinese AOTAI/ HUAYUAN/ American Lincoln...;
2. b) Butt welding torch and flame triple cutting torch movement guidance: Heavy duty precise linear guiderail of HIWIN;
3. c) HMI (Human machine interface): Mitsubishi;
4. d) A.C. inverter and other electric control elements: Mitsubishi or Scheider;
5. e) Hydraulic pump station: Chinese YOSHENG.

A No. The operation capability can be commanded quickly after study. Our Flat Butt Welder Machine has fully considered these requirement during development. Meanwhile, need to pay attention on below control points of:

1. 1) Two layers of dedicated SAW welding flux need to be deposited on the copper pads, and on the joint plates respectively;
2. 2) Two layers welding flux are of different grade, which we give recommendation based on accumulated empirical data and years of experience on steel Plate Butt Welding Joining Machine, which varies on material and thickness of metal plates;
3. 3) Also, we will give a rule of thumb on suggested key process parameters, including Butt Joint plate clearance/ Butt welding current/ Welding Voltage/ Welding wire feeding speed in manual book of the machine.

A

1. 1) Logic Interlock: To fully make sure safety operation in the steel Plate Butt Welding Joint Machine, and the best quality butt welding effect delivered, in control system of machine, there are interlock logic between input and output conveyors and function units (Flame triple cutting unit and Butt welding unit);
2. 2) For example, when the working mode selection switch is at “Cutting” or “Welding”, managing on input and output conveyors is invalid;
3. 3) Operator should understand and follow these logics for proper handling and position control on steel plates.

A In a nutshell, for delivering satisfactory joint plate effect, you need to complete the basic steps of:

1. 1) Material Handling in Steel Plate Joint Welding Machine:

This includes:

1. a) Loading on two pieces of metal plates onto input / output conveyor roller table;
2. b) Loading finished joint plate off output conveyor;

1. 2) Alignment on Metal Plates in Flat Butt Welding Machine:

1. a) This is critical for guaranteeing eligible melt thru butt welding quality;
2. b) It includes aligning two pieces of metal plates along its length direction, so that lateral side of the two metal plates are collinear;
3. c) And aligning width side of metal plates, for joint against centerline of copper pads;

1. 3) Flame Triple Cutting: Properly setting pressure/ flame of Oxygen and cutting gas, and angle of triple cutting torches;
2. 4) Melt thru Butt Welding: This is “Core of the core” in operating the Flat Butt Welding Machine: Welding current/ welding voltage/ wire feeding speed.

A

1. 1) Operator should be familiar with all the buttons/ selection switches of machine;
2. 2) Make sure all components/ Subassemblies are in normal state for running;
3. 3) Modulate process parameters of triple cutting/ butt welding;
4. 4) Switch on supply of preheating oxygen/ cutting oxygen/ acetylene or propane and adjust its pressure based on thickness and chamfer type of the workpieces:
5. 5) Start on water cooling system for copper pads, and adjust water pressure (0.2~ 0.4 MPa)

A

1. 1) Operation on Wuxi JACK steel Plate Joint Welding Machine is easy, convenient, intuitive. With advanced technique of HMI (Human machine interface), operator just need to input process parameters on butt welding, by means of touch screen;
2. 2) Butt welding operation is managed with welding power supply control console;
3. 3) Meanwhile, operator should command on skill: Adjusting flame triple cutting,  experience/ knowledge to judge on butt welding operation.

A

1. 1) Do not stuck steel plates for joint completely together: Leave a gap of 2mm to 3mm, which will leave space for welding wire and flux filling in, and hence butt welding seam formation;
2. 2) If butt welding seam is too wide or narrow from perspective of customer, just modulate on welding process parameters: Welding current and voltage;
3. 3) Butt welding velocity is adjustable by means of A.C. inverter in steel plate Flat Butt Welder machine, which should not be too high: Too fast welding will cause insufficient fusion and hence welding seam integrity.

A

1. 1) The default, or recommended way of operation is to butt weld on 2 pieces of steel plate;
2. 2) Sometimes, customer expects on more narrow pieces to be placed in a row, and being butt welded together. This is considered out of raising efficiency. This can be accomplished in Wuxi JACK steel Plate Butt Joint Welding Machine, only with precondition that, before official butt welding, the small plates should be spot welded into an integral piece, and then performed with final butt welding. Such way of operation can avoid defect of uneven butt welding seam.

A

1. 1, Welding Wire:

1. 1) Φ2.5mm- Φ4.0mm for SAW welding;
2. 2) Φ1.2mm- Φ1.6mm for GMAW welding;

1. 2, Welding Flux in the case of SAW Welding:

There are double layers of SAW welding flux for butt welding:

1. 1) Major part: The layer being laid on top surface of steel plate. It can be any common seen grades: SJ101, 501, 301, etc.;
2. 2) Important: The layer being laid right beneath steel plate. Although only with small consumption, around 10% of the top layer flux consumption, it plays key role in guaranteeing successful operation of steel Plate Butt Joint Welding Machine. If not select properly, the copper pads will be damaged soon. The recommended grades on bottom layer flux are:

1. Swedish ESAB OK FLUX 10.69;
2. Chinese TIANGAO TGF-B;

1. 3, Circulating Cooling Water:

This cost the least among all welding consumables of steel plate Flat Butt Welder machine. Running water is ok. Depending on operation efficiency of machine, it should be replaced regularly. For example: With single shift 7/2 arrangement, every half year replacement is acceptable.

A

1. 1) As a niche (Small using volume) and featured 1^st operation equipment, steel plate Flat Butt Welder machine helps customer acquire whatever size of raw material they need, no matter small or large, which is necessary for production, but difficult to get with other means. The process is highly efficient and user friendly;
2. 2) The steel plate scrap that grows useless because of small size can become profitable again, by means of butt welded with other small plates. This greatly improves financial reward for customer;
3. 3) Accordingly, although selling in large number, steel Plate Butt Welding Machine is indispensable, and stable requirement in market.

A Yes. Compared with other automatic equipment, the BOX H Beam Steel Structure Overturn Machine has relatively simple structure and operation, maintenance is also easy. Besides, it has integral structure, which means, it is not necessary to dismantle the equipment for transportation. Also no need on making foundation ahead of time. In this way, after the overturning cart being delivered to customer site, just locate it into place, fix it and connect on electricity and hydraulic hose, then the BOX H Beam Steel Structure Turnover Machine can be put into use.

A

1. Depending on working site production technology requirement, sometimes the workpiece not only need to be rotated, but should be moved certain distance, to another work station. For such conditions, the stationary BOX H Beam Steel Structure Flipping Machine should be equipped with moving wheels, so as to turned into a set of motorized Turnover Cart;
2. Such flexible design can meet on customer requirement to the most degree.

A

1. This equipment relieves operator from traditional dangerous/ low value added/ tedious work of flipping and sending workpieces, which have large dimension and heavy weight, even hot after SAW welding, and hard for direct human contact;
2. Besides, as automatic equipment, BOX H Beam Steel Structure Turnover Machine has controllable and stable performance, which is precondition on pushing lean production and management;
3. In all, with introduction of these 60°/ 90°/ 180° flipping cart, the strenuous working site of steel structure production can be improved into modernized management, reducing necessary operators, providing maximum benefits for customers.

A First, the process technology station of H Beam line:

1. 90° turnover cart is used in H Beam assembly and tack welding;  
2. 60° turnover cart is used in H Beam fillet Submerged Arc Welding;  
3. 180° turnover cart is used in H Beam flange straightening after SAW;  

Second, the Min. and Max., especially the Max. size and weight of BOX Beam and H Beam. This is the design base on Steel Structure Turnover Machine.

A

1. From perspective of manipulator, of course the Steel Structure Overturn Machine is with hard L shape arm, and Chain Flipping Machine is with soft chains;
2. From perspective of applicable types of workpieces, hard rack Steel Structure Turnover Machine is major used on BOX H Beam production; While Chain Manipulator can accommodate on more wider range of workpieces, especially shape and length;
3. From perspective of using volume, hard rack Steel Structure Overturn Machine is more common seen, because H Beam and BOX Beam are the first 2 most widely used workpieces.

A

1. The trend is in fact reversed: At early station of BOX H Beam production, the turn over/ transportation job was accomplished with manual job, supported with other tools, especially travel crane;
2. Such arrangement can fulfil task of small production BOX H Beam volume. However, with production rate going up to meet market demand on expansion, such traditional way can not keep up with new request. Besides, manual operation has serious hidden risk of personnel danger, which should be completely removed, especially under the global trend of lesser and lesser labor available, operator grow more precious. The BOX H Beam Steel Structure Flipping Machine is a must for customers.