Wuxi JACK BOX Beam Production Line,

Provide Turnkey Project of BOX Beam Production Machine for Customer!

4 Consumable Electroslag BOX Beam Welding Machine

8 Consumable Electroslag BOX Beam Welding Machine

Output, Application and Advantages of Wuxi JACK BOX Beam Production Machine

A. Finished Workpieces Produced from BOX Beam Production Line:

1. Welding BOX Beam has cross section of square shape, with the best degree of overall intensity and mechanical strength. It is one of the most important working parts being applied in Steel Structure field;
2. Usage and Applied Industry: BOX Beam are widely used for constructing high rise buildings/ Bridge construction etc. of large project. Correspondingly, BOX Beam Production Line is indispensable equipment group in Steel Structure/ Bridge/ Infrastructure;

3. Welding BOX Beam manufactured from Wuxi JACK BOX Beam Production Line: (Fig.1)

4. Specifications of BOX Beam Fabricated from BOX Beam Production Line:

BOX Beam Production Machine is the professional machine group for producing welding BOX Beam:
1) Cross section size of BOX Beam: 300x300 mm to 1200x 1200 mm;
2) Length of BOX Beam: 3000 mm to 12000 mm;
3) The max. weight of single piece BOX Beam delivered from BOX Beam Welding Machine can be up to 20 Ton;

4) Welding BOX Beam being polished at EOL (End of line) of BOX Beam Production Line: (Fig.2)

Fig2 BOX Beam End Face Milling Machine 5

B. Major BOX Beam Production Machine of Wuxi JACK BOX Beam Production Line:

1. CNC Flame Cutting Machine: For cut off steel plates into narrow strips, serving as raw materials of next station BOX Beam Assembly Machine;

2. BOX Beam Assembly Machine:

Including 2 type of assembly equipment:
1) Baffle Plate and U Beam Assembly Machine – First step;
2) BOX Beam Assembly Machine with CO₂ tack welding – Finished assembly;

3. BOX Beam Welding Machine:

Including 3 types of welding equipment:
1) BOX Beam Welding Machine with electroslag welding, for welding internal baffles;
2) BOX Beam Welding Machine with CO2 back welding, for completing on primer welding;
3) BOX Beam Welding Machine with finished SAW (Submerged arc welding), for fabricating finished BOX Beam;

4) Welding head of Wuxi JACK electroslag BOX Beam Welding Machine: (Fig.3)

Fig3 Electroslag BOX Beam Welding Machine 1B

4. BOX Beam Overturning Equipment Turntable: Being deployed at every work station of BOX Beam Production Line, and among these work stations, serving as manipulators for flipping and conveying BOX Beams, to get expected operating positions;
5. BOX Beam End Face Milling Machine: Being installed at EOL station of BOX Beam Production Line, for performing face machining on fabricated BOX Beam from BOX Beam Welding Machine.

C. Strong Points of Wuxi JACK BOX Beam Production Line:

1. Highly Efficient Fluent Process Flow among BOX Beam Production Machine:

1) Turnkey Project for Customer: The assistant work stations of BOX Beam Production Line, including baffle manual welding/ back welding/ cutting arc strike and riser in electroslag welding, IPV (Internal process validation) can all be prepared by Wuxi JACK for customer;
2) Fully Automation: Manual operation is reduced to the minimum level. Operators can be relieved from painstaking job of working parts movement, and hard to manage job of manual welding. Traveling crane is only used at U Beam assembly station, and finished BOX Beam being loaded offline from BOX Beam Production Line;
3) High Efficiency and Quality Promise: The entire BOX Beam Production Line has controllable TAKT time and performance, eliminating all factors causing fluctuations on quality and productivity;
4) Saving Variable Cost: Correspondingly, number of operators at BOX Beam Production Line can be far less than original manual production on BOX Beam;

2. Advanced Welding Technique Adopted at 3 Major BOX Beam Welding Machine:

a) Technical Difficulty: Due to the enclosed structure of BOX Beam, internal baffle plates are difficult to access for carrying on welding. Let alone guarantee efficiency and quality;
b) Our Solution: Wuxi JACK engineering team adopts series of advanced technique to solve the problem. Welding techniques of BOX Beam Welding Machine all take the lead in Welding Equipment Industry:
1) Internal Baffle welding at BOX Beam Assembly Machine;
2) Twin arc CO2 gas shielded welding at back welding BOX Beam Welding Machine;
3) Consumable nozzle electroslag welding at electroslag BOX Beam Welding Machine;

Electroslag welding on BOX Beam from electroslag BOX Beam Welding Machine: (Fig.4)

4) Wire electrode electroslag welding at electroslag BOX Beam Welding Machine;
5) Twin Arc and triple arc SAW (submerged arc welding) at finished BOX Beam Welding Machine;

3. Welding Quality Assurance from Wuxi JACK BOX Beam Welding Machine:

1) Optimum Welding Orientation: By means of 90° and 180° motorized moving hydraulic drive overturning rack turntable, all the automatic and manual welding operations in BOX Beam Welding Machine are implemented in optimum position (Upright Downward Welding), guaranteeing the best degree of welding quality, high productivity, and operator friendly ergonomics operation;

2) Welding torch orientation in BOX Beam Welding Machine: (Fig.5)

4. Quick Understanding: Presentation slides page of “Brief Review on Wuxi JACK BOX Beam Production Line”.

Major Equipment in BOX Beam Production Line: BOX Beam Assembly Machine and BOX Beam Welding Machine

Design Sketch of Sample Welding BOX Beam from Wuxi JACK BOX Beam Production Line

Process Technology and Involved BOX Beam Production Machine of BOX Beam Production Line

Illustration on Working Parts Flow and Major Operation at Every Station of BOX Beam Production Line:

a) Work Stations: There are totally 35 automatic and manual working stations in complete configured BOX Beam Production Line.

b) Process Step: The 35 working stations in BOX Beam Production Line can be divided into 14 major steps of:

1. 1^st Operation Plate Cutting: By means of CNC Strip Plate Cutting Machine, at steel plates cut off zone of BOX Beam Production Line;
2. Mark Line on Workpiece: Confirm position of internal Baffles and electroslag welding holes cutting;
3. Machining Welding Groove on Steel Plate: By means of Edge Milling Machine, for machining U/ V/ X slant bevels on edges of steel plate, before BOX Beam Welding Machine;
4. Internal Baffle Assembly and Tack Welding: With Internal Baffle Assembly Machine at assembly zone of BOX Beam Production Line;
5. Tack Welding on Internal Baffles onto Web: This is completed at conveyor of Box Beam Assembly Machine;
6. U Beam Assembly：This is fulfiled with Box Beam Assembly Machine, at assembly area of BOX Beam Production Line;
7. 90^o Turning of Assembled U Beam：This is acquired with motor drive moving 180o Overturning Equipment turntable, at assembly zone of BOX Beam Production Line;
8. Assembling Top Cover onto BOX Beam: This is performed with Box Beam Assembly Machine at assembly zone of BOX Beam Production Line, producing finished assembled BOX Beam;
9. 90^o Turning of Assembled BOX Beam：This is made with motor drive moving 180o Overturning Rack turntable, at assembly area of BOX Beam Production Line;
10. BOX Beam Back Welding: This is implemented with Back Welding BOX Beam Welding Machine;
11. Internal Baffle Electroslag Welding: This is made with cantilever type electroslag welding BOX Beam Welding Machine: Either Consumable type or Wire Electrode type;
12. Assembled and Back Welded BOX Beam Sent to Submerged Arc Welding Station：This is carried out with motor drive moving 180^o Flipping Equipment turntable, at SAW welding Area of BOX Beam Production Line;
13. BOX Beam Finished Submerged Arc Welding：By means of LHC model Column type or LHE model gantry frame SAW BOX Beam Welding Machine, at SAW welding Area of BOX Beam Production Line;
14. BOX Beam End Face Milling：This is carried out with BOX Beam End Face Milling Machine.

Layout of BOX Beam Production Line

Layout design of typical BOX Beam Production Line on the basis of the above process technology:

Main BOX Beam Production Machine in BOX Beam Production Line

1. GZ12/ GZ15 Internal Baffle BOX Beam Assembly Machine:

1. Function and Use of Internal Baffle BOX Beam Assembly Machine:

1) Task and Structure: This machine is for assembling and welding internal baffles, which will be assembled and welded to internal of BOX Beam at subsequent stations of BOX Beam Production Line. As shown in the above photos, this machine looks like Welding Fixture;
2) Internal Baffle: The design sketch and photo of finished internal baffles produced from the internal baffle BOX Beam Assembly Machine, is shown in the above 3^rd and 4^th photos;
3) Models: There are two models of Internal Baffle BOX Beam Assembly Machine applicable: GZ12 and GZ15, which are used for 1200mm and 1500mm side size BOX Beam production respectively;
4) Quantity of the Machine: There is 1 set of the GZ12/ 15 internal baffle BOX Beam Assembly Machine necessary in BOX Beam Production Line;

5) Working Principle of internal baffle BOX Beam Assembly Machine:

a) Working Mode: The machine works in semi-automatic way;
b) Flipping: This machine has rotating range of ±180°, which is driven with braking type A.C. motor;
c) Workpiece Secure: Upon arriving at target angular position, the internal baffle is secured firmly by means of air cylinders onto the flipping rack of the machine;
d) Fit Up and Welding: Next, internal baffle is welded manually in the BOX Beam Assembly Machine.

2. Technical Parameters of GZ12/GZ15 Internal Baffle BOX Beam Assembly Machine:

Model of Internal Baffle BOX Beam Assembly Machine	GZ12/ GZ15
BOX Beam Cross Section H×W	300×300∽1200×1200 mm / 300×300∽1500×1500 mm
BOX Beam Length	3000∽12000 mm
BOX Beam Max. Weight	20 Ton.
Baffle Plate Thickness	≤80 mm
Flip Motor Power	2 kW
Flip Speed	1.8 rpm
Work Table Loading Capacity	1200 kg
Height of Flip Center	1200 mm
Flip Range of Work Table	±180°

2. UBZ12 BOX Beam Assembly Machine:

1. Usage of UBZ12 BOX Beam Assembly Machine:

1) Function: UBZ12 BOX Beam Assembly Machine assembles 4 pieces of BOX beam board (Web) and 4 pieces of internal baffles into a piece of integral assembled and tack welded BOX Beam: First U Beam, then BOX Beam;

2) Process route of BOX Beam assembly: 4 webs and 4 internal baffles be assembled and tack welded into U Beam, then into BOX Beam: (Fig.6)

2. Technical Features of BOX Beam Assembly Machine:

1) Workpieces Variation: 4 Webs and4 internal baffles each → 1 U Beam → 1 BOX Beam;
2) Work Principle: The workpiece is assembled and tack welded during its moving through the UBZ12 BOX Beam Assembly Machine. It is secured in 2 points of top downward and lateral pressing, driven with hydraulic oil cylinders;
3) Moving rails of workpieces are heavy duty 38kg/m type, to promise stable movement of heavy BOX Beam;
4) Assembly Precision Guarantee: There is high strength pulling rod system equipped in the UBZ12 BOX Beam Assembly Machine, of downward orientation, guaranteeing precise assembling of U Beam and BOX Beam;
5) Quantity of the Machine: There is 1 set of the UBZ12 BOX Beam Assembly Machine deployed in BOX Beam Production Line.

3. Technical Parameters of UBZ12 BOX Beam Assembly Machine:

Model of BOX Beam Assembly Machine	UBZ12
Workpiece Cross Section Size	300ｘ300～1200ｘ1200 mm
Max. Loading Capacity	20 Ton
Gantry Travel Speed	4000 mm/ min.
Hydraulic Pressure	14 MPa
Max. Pressure of Sideward Stroke Cylinders	15 Ton
Max. Pressure of Downward Stroke Cylinder	30 Ton
Max. Stroke of Sideward Cylinders	800 mm
Max. Stroke of Downward Cylinders	900 mm
Oil Pump Motor	11 kW

2. YF1220 Hydraulic Drive 180° Overturning Rack Turntable:

1. Use of 180° Overturning Rack Turntable in BOX Beam Production Line:

1) Function: YF1220 motor drive moving Hydraulic 180° Overturning Rack is logistics equipment in BOX Beam Production Line. It has 2 purposes: Accomplish 90°/ 180° flipping of BOX Beam, and transferring BOX Beam among work stations in the line;

2) Working Way: The 180° Flipping Rack turntable works in the form of 2 sets per group, to overturn and support the entire piece of BOX beam;
3) Drive Way: Flipping of BOX Beam is driven with hydraulic oil cylinder; Movement of BOX Beam is driven with A.C. motor reducer;
4) Quantity of the Equipment: There are 4 sets (Or, 2 groups) of 180° Flipping Rack turntable deployed in a BOX Beam Production Line.

2. Technical Parameters of YF1220 Motorized Moving Hydraulic Drive 180° Flipping Rack Turntable:

Model of Hydraulic 180° Flipping Rack	YF1220
Loading Capacity	20 Ton
Power of Travel Motor Reducer	1.5 kW
Travel Speed	5000 mm/min.
Diameter of Flipping Drive Cylinder	φ150mm
Max. Hydraulic Pressure	16 MPa
Rail Center Distance	700 mm
Overturning Range	±180°

4. XQ12 Back BOX Beam Welding Machine:

1. Usage and Operating Way of Back BOX Beam Welding Machine:

1) Function: XQ12 Back BOX Beam Welding Machine performs Twin Arc CO₂ back welding on assembled BOX Beam, which is fabricated from BOX Beam Assembly Machine;

2) Working Manner of XQ12 Back BOX Beam Welding Machine:

a) Welding Mode and Form: The BOX Beam is laid onto conveyor of the machine; Conveyor of the Back BOX Beam Welding Machine moves in adjustable welding speed, which is controlled with A.C. inverter, implementing Twin Arc CO₂ back welding at the same time;
b) Welding Position Management: Welding torch carriage can be adjusted on its position along vertical/ transverse direction along boom of the moving trolley, based on size of BOX Beam Production Line workpiece. This is for guaranteeing always accurate position of welding tip;
c) Welding Seam Tracing Unit: During welding period of the Back BOX Beam Welding Machine, position of welding torch is always traced and adjusted by means of the mechanical style arc guiding seam tracing unit. This is also for guaranteeing always accurate position of welding tip, so as to promise top grade welding quality;
3) Quantity of the Machine and Welding System: One set of XQ12 Back BOX Beam Welding Machine is equipped with 2 sets of twin arc CO₂ welding power supply; In BOX Beam Production Line, there are 2 sets of XQ12 Back BOX Beam Welding Machine.

2. Technical Parameters of XQ12 Back BOX Beam Welding Machine:

Model of Back BOX Beam Welding Machine	XQ12
BOX Beam Cross Section Size	300ｘ300～1200ｘ1200 mm
BOX Beam Length	4000～15000mm
CO₂ Backing Welding Speed	240 ~ 2400 mm/min.
Idle Running Speed	3000 mm/min.

5. Electroslag BOX Beam Welding Machine:

1. Usage and Technical Characteristics of Electroslag BOX Beam Welding Machine:

1) Function: In process route of BOX Beam Production Line, Electroslag BOX Beam Welding Machine is for completing final welding of internal baffles into the BOX Beam. The preceding station is BOX Beam Assembly Machine: Assembling and tack welding internal baffles into BOX Beam;

2) Classification of Electroslag BOX Beam Welding Machine:

There are two types: Consumable nozzle type, and non-consumable wire electrode type:

a) Consumable nozzle type electroslag BOX Beam Welding Machine (Fig.7):

b) Non-consumable wire electrode type electroslag BOX Beam Welding Machine (Fig.8):

3) Technical and Running Specialties of Two Types of Electroslag BOX Beam Welding Machine:

a) Consumable nozzle type electroslag BOX Beam Welding Machine works in the way of consuming welding nozzle. It has lower machine price and relative higher running cost;
b) Non-consumable wire electrode type electroslag BOX Beam Welding Machine has relative higher machine price and lower running cost;
4) Advantages of the Machine: Welding Quality: For Electroslag BOX Beam Welding Machine of Wuxi JACK BOX Beam Production Line, cutting holes are cut out ahead of time at preceding stations. So that the quality issue of cutting fluid staying in the hole which bring negative effect can be removed, promising the best degree of welding performance;
5) Model of the Machine: Consumable nozzle type electroslag BOX Beam Welding Machine has 2 models of XD12 and XD15; Non-consumable wire electrode type electroslag BOX Beam Welding Machine has single model of XSD12;
6) Quantity of the Machine: In BOX Beam Production Line, there are 2 sets of Electroslag BOX Beam Welding Machine.

2. Technical Parameters of Electroslag BOX Beam Welding Machine:

Model of Electroslag BOX Beam Welding Machine	XD12 / XD15 / XSD12
Cross Size Size of BOX Beam	300ｘ300～(1200ｘ1200mm/ 1500ｘ1500mm/ 1200ｘ1200mm)
BOX Beam Length	4,000 ~ 15,000 mm
Trolley Rail Span	1,000 mm
Trolley Travel Speed	6,000 mm / min.
Trolley Travel Motor Power	0.55 / 0.75/ 0.55 kW

6. SAW BOX Beam Welding Machine:

1. Usage and Role of SAW BOX Beam Welding Machine:

1) Function and Welding Mode: SAW BOX Beam Welding Machine performs twin arc or triple arc submerged arc welding on the half-finished BOX Beam: Assembled, tack welded, back welded, and electroslag welded in the previous stations of BOX Beam Production Machine in the BOX Beam Production Line;
2) Classification: Based on structure of mechanical main frame, there are 2 major types of SAW BOX Beam Welding Machine: LHE12 Gantry structure and LHC12 Cantilever structure;

3) Working Way of SAW BOX Beam Welding Machine:

LHE12 and LHC12 machines operate in the same manner:
a) BOX Beam is put in stationary on conveyor of the BOX Beam Welding Machine;
b) Mechanical main frame of gantry or cantilever trolley moves in adjustable welding speed, performing twin arc or triple arc SAW (Submerged arc welding) at the same time;
4) Welding Quality Control: During working of the SAW BOX Beam Welding Machine, welding torch is controlled with air cylinder drive mechanical style welding seam tracing unit, guaranteeing welding quality and productivity of the BOX Beam Production Line;

5) Working Nature of SAW BOX Beam Welding Machine:

a) LHE12 gantry structure SAW BOX Beam Welding Machine has very similar machine structure and working principle as H Beam Gantry Welding Machine;
b) LHC12 cantilever structure SAW BOX Beam Welding Machine can be replaced as column structure H Beam Welding Machine which are deployed 4 sets in a group in automatic H Beam Production Line;
6) Quantity of the Machine: In BOX Beam Production Line, there are 2 sets of either LHE gantry structure or LHC cantilever structure SAW BOX Beam Welding Machine.

2. Technical Parameters of SAW BOX Beam Welding Machine:

Model of SAW BOX Beam Welding Machine	LHE12/ LHC12
Mechanical Main Frame Structure	Traveling Gantry/ Traveling Trolley and Boom
BOX Beam Cross Section Size	300ｘ300～1200ｘ1200 mm
BOX Beam Length	4,000～15,000 mm
Gantry Rail Length	18,000 mm
Gantry Rail Span	1400 mm
Gantry Travel Stroke	15,500 mm
Submerged Arc Welding Welding Speed	150 ~ 1500 mm/min.
Idle Traveling Speed	2400 mm/min.
Gas Pressure	0.4 ~ 0.8 MPa
Flux Recovery Unit Power	2 x 3 kW
BOX Beam SAW Welding Machine Power	3 kW

Application Range and Related Equipment of BOX Beam Production Line

1. Application Field: BOX Beam Production Line is applied in Steel Structure Industry / Bridge/ Offshore derrick/ Port Machinery, producing welding BOX Beams as working parts for big construction;

2. Other 2 Common Seen Steel Structure Lines besides BOX Beam Production Line:

1) H Beam Production Line;
2) T Beam Production Line;

3. Other Necessary BOX Beam Production Machine:

In the sequence of process technology:
1) CNC Flame Cutting Machine;
2) Edge Milling Machine;
3) Hydraulic drive 90° Overturning Rack Turntable;
4) Steel Structure Conveyor;
5) H and BOX Beam End Face Milling Machine.

Other Series of Products We Own besides BOX Beam Production Line

MP20 Automatic Plate Butt Joining Machine with Triple Cutting

DX1520 H Beam End Face Milling Machine for Steel Structure

Assistant Hydraulic Loading SXBJ-16 Sheet Metal Plate Edge Milling Machine

General Purpose Automatic Lengthwise ASM63 Angle Steel Straightening Machine

7-Axis 3000/12 Flame And Plasma Large Scale CNC Pipe Cutting Machine

HB-series Single Table Top Universal Welding Positioner with Chuck

BOX Beam Production Line Blogs

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