FAQ FRO ANGLE STRAIGHTENING MACHINE

A This is very practical question, every customer will ask this when they decided to introduce new equipment on H Beam production:

1. 1) This is wholly determined with specifications of H Beam. Besides the common seen criterion, that large H Beam, which means SAW welding need to have multiple passes of seams, with sizes over 12mm;
2. 2) There are also many small H Beams, although looks small in size, but, because of its large thickness, for example, on Oct.1^st 2025, we had a Singapore customer inquiry, who has H Beam flange 400mm width with 40mm thickness. This can only be straightening with YTJ80 model hydraulic H Beam Straightening Machine;
3. 3) Wuxi JACK engineers work with customer to find which is more applicable, H Beam Welding 3 in 1 Machine or individual H Beam production machine.

A Although a complicated machine integrating 3 functions of H Beam assembly/ welding / straightening, H Beam Welding 3 in 1 Machine is very user friendly. This is characteristic of all automatic machines:

1. 1) Operator task is to load on and off workpiece onto and from the machine, before/ during/ after T H Beam production, and watch on automatic operation in the process. At completion of SAW welding, knock off welding flux from H Beam;
2. 2) As to skill, operator need to command on capability of managing on machine operating panel, and judging on H Beam welding performance.

A

1. 1) Take Lead on Machine Development: Wuxi JACK is the first company to deliver mature product of H Beam Welding 3 in 1 Machine into market. From the year 2000~ 2008, this machine was only in laboratory stage. Due to some technical difficulties, this machine could not be pushed to market in genuine sense;
2. 2) In 2009, Wuxi JACK took the lead in launching the first set of ready to use 3 in 1 H Beam Fabrication Welding Machine to customers, upgrading it from years of concept design to practical application;
3. 3) Advanced Design and Superior Quality: Wuxi JACK H Beam 3 in 1 machine has comprehensive advantages compared with other suppliers, as introduced at this page. Customer using our machine can get the ideal rewarding on H Beam quality and financial reward.

A Wuxi JACK steel Plate Flat Butt Welder machine adopts with the first class suppliers, to fully guarantee quality and performance:

1. 1) SAW/ CO₂ Butt Welding Power Supply: Chinese HUAYUAN or AOTAI. Customer can also designate brand, for example, we had a customer once asked for American Lincoln;
2. 2) HMI (Human machine interface) and inverter: Japan Mitsubishi or Germany Schneider;
3. 3) Electric Control Elements: Germany Siemens;
4. 4) Hydraulic pump station and electromagnetic valves: Chinese YOSHENG

A

1. 1) The conventional specification of the minimum width in Wuxi JACK steel Plate Flat Butt Welder machine is 300mm, and, it can be special designed according to customer demand, for example, 145mm for a Cambodia customer in Aug. 2025;
2. 2) The reason is, the mechanism for holding on small plate is hydraulic drive pressing blocks, which are distributed in regular interval along butt welding table of machine. To secure firmly these small plates, there is limitation on the minimum width of plates;
3. 3) Usually, the steel Plate Flat Joint Butt Welding Machine is designed for butt welding on single pair of sheet metal, especially on medium and large width plates, 500mm and above; When customer want to have several pairs, for example, 3 pairs to be butt welded with one time stroke, these small plate need to be pieced and tack welded into an integral piece first, then sent to machine for butt welding.

A Operator should command skill on managing the Oxygen fuel flame triple cutting operation, and overseeing butt welding step:

1. 1) The flame triple cutting entails ability and experience on adjusting gas pressure of Oxygen/ Acetylene, and adjusting angle of flame triple cutting torches, based on beveling requirement for plate butt welding;
2. 2) Wuxi JACK MP series steel Plate Flat Butt Welder Machine adopts fully penetration welding, which means single face welding double face completion. Although it is automatic process, operator should have knowledge on what are proper process control parameter range for implementing on butt welding process, including welding current/ voltage/ wire feeding speed.

A

1. 1) Cooling water --- This costs the minimum, just ordinary running water can be used. It should be replaced around every half a year, under operation arrangement of single shift;
2. 2) SAW Welding wire --- This is one of major consumables of plate butt welding. It should be Φ2.5mm – Φ4.0mm SAW welding wire. Under the working speed of 500- 800 mm/min., consumption is around 1- 2kg SAW welding wire every hour;
3. 3) SAW Welding Flux --- There are 2 different types of SAW welding flux for operating on steel Plate Flat Butt Welder machine: The top layer SJ101 or 301 ordinary type, which is the main consumed flux in butt welding, and special TGF-B or OK Flux 10.69 at bottom layer, which, although only 1/10^th consumption volume of top layer, plays key role in guaranteeing quality and performance of butt welding;
4. 4) Oxygen and Cutting Gas (Acetylene or Propane) --- Depending on production output of steel Plate Joining Butt Welding Machine. Some customers not very often use triple cutting;
5. 5) Copper Pads, Cutting Torch, Welding Torch --- These units have longer service life, in the middle between long service parts and consumables, which greatly depend on maintenance and production output of machine. Operating properly, its replace frequency can be obviously reduced.

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.