Subject of This Blog on H Beam 3 in 1 Assembly Welding Straightening Machine:
1) For final acceptance at customer site, at the completion of machine installation, the next step is commissioning;
2) It is the transitional period from delivery to official running, and validation on H Beam 3 in 1 Production Line plays key role in the process;
3) Wuxi JACK has all the machines and equipment commissioned at our workshop before shipment, and commissioning at customer site is the second time trial run after its transportation and re-installation. This is especially important for Integral Function H Beam Welding Machine, a sophisticated equipment integrating 3 functions in a row;
4) Topics: This Short Blog Explores on Proper Commissioning on H Beam 3 in 1 Fabrication Machine:
Before Trial Run of the machine;
Parameter Setting in Inverter of the machine;
General Commissioning Steps of H Beam 3 in 1 Production Line;
Matters for Attention during Commissioning on the machine;
Summary on Wuxi JACK H Beam 3 in 1 Assembly Welding Straightening Machine
A. Before Trial Run of 3 in 1 H Beam Fabrication Machine:
1. Hardware and Utilities Availability on H Beam 3 in 1 Production Line:
1) Layout: The mechanical main body/ input and output conveyors roller table/ Electric Control board/ Hydraulic pump station of the machine should be laid in place and installed securely, based on layout drawing made by Wuxi JACK engineering team;
2) Power capacity and fluctuation of workshop should accommodate total KVA of the machine;
3) Environmental Humidity: If customer city has high humidity, for example, yearly average 80% plus, welding flux heating machine should be equipped with the machine, to guarantee on its stable and high level SAW welding quality;
4) Operator watches on assembled Wuxi JACK ZHJ15 model H Beam 3 in 1 Production Line: (Fig.1)
2. Operator Capability for Managing on Integral Function H Beam Welding Machine:
1) Read and understand manual book of H Beam 3 in 1 Fabrication Machine, being familiar with structure and operating way of all the components/ subassemblies;
2) Grasp on operation and adjustment way of SAW (Submerged arc welding) power supply and its control console, the main outsourced working units of the machine;
3) Be acquainted with buttons/ switches/ knobs of operating panel/ control console/ remote boxes of the H Beam 3 in 1 Production Line;
4) Grasp on how to set up proper welding parameters (Welding current/ voltage/ wire feeding speed), based on workpiece specifications, especially flange thickness and web thickness, for start on the machine;
5) Overseas customer operators work on Wuxi JACK PHJ15 model H Beam 3 in 1 Assembly Welding Straightening Machine: (Fig.2)
B. Parameter Setting in Inverter of Integral Function H Beam Welding Machine:
1. Importance: Inverter is key control element in H Beam 3 in 1 Assembly Welding Straightening Machine, managing on working speed of assembling/ SAW/ straightening/ workpiece traveling during work;
2. Document: Its manual is supplied to customer as part of technical documents of the machine, very important on commissioning/ daily running/ trouble shooting of the machine;
3. A.C. Inverter Parameters for Running on H Beam 3 in 1 Fabrication Machine:
1) There are around 30 parameters embedded inside A.C. inverter for its normal work, which can be adjusted with the small LED at the left upper corner of the inverter;
2) Of which 10 designated parameters need to be set up specifically from its default value, to accommodate on running condition of the integral function H Beam Welding Machine, including frequency of electricity power/ rated current of main driving motor, etc.;
3) Wuxi JACK gives detailed instruction in manual book of the machine;
4) Control panel and operating pendant of Wuxi JACK H Beam 3 in 1 Fabrication Machine: (Fig.3)
C. General Commissioning Steps of H Beam 3 in 1 Production Line:
1. Step 1: Confirming Phenomena in H Beam 3 in 1 Production Line:
1) Whether transportation direction of input and output conveyor are correct and uniform;
2) Whether revolution direction of hydraulic pump motor of the machine is correct;
3) Whether there is suction force with welding flux recovery unit;
4) Whether there is abnormal noise or vibration with the machine;
If abnormal condition exists, please find out root cause and eliminate it immediately;
Installation site of Wuxi JACK PHJ15 model H Beam 3 in 1 Production Line at customer facility: (Fig.4)
2. Step 2: Components of Integral Function H Beam Welding Machine:
1) Check on running condition of all the subassemblies/ units in the H Beam 3 in 1 Production Line;
2) Confirm all the transmission parts are lubricated with oil or grease;
3. Step 3: Test on Driving Motors of H Beam 3 in 1 Production Line:
Now, start on:
1) Main driving motor;
2) Input and output conveyors driving motors respectively；
Of the machine;
3) Make these motors in inching running of forward and reverse revolving direction three times in a row, and confirm normal condition;
Site validation on Wuxi JACK PHJ18 model H Beam 3 in 1 Assembly Welding Straightening Machine at Russian customer plant: (Fig.5)
4. Step 4: Check on Hydraulic Pump Station of H Beam 3 in 1 Assembly Welding Straightening Machine:
1) Start on oil pump motor;
2) Have it running in inching mode, to check its running direction same as mark on fan;
3) Then make the oil pump motor into continuous revolving;
5. Step 4: Test on Hydraulic System of 3 in 1 H Beam Fabrication Machine:
1) Adjust on pressure of hydraulic system to around 5MPa, having it in idle running around 4 minutes;
2) Start on all the cylinders of the machine one by one, including cylinders for driving manipulators/ flange and web fitting up rollers/ straightening roller/ output conveyor elevating roller;
3) Have these cylinders running in inching mode for 5 times, to confirm its normal condition;
Hydraulic pump station of Wuxi JACK H Beam Fabrication Machine: (Fig.6)
6. Step 5: Trail Run in H Beam 3 in 1 Assembly Welding Straightening Machine:
1) Load on raw materials flange and web;
2) Start on trial run of assembling/ SAW/ Straightening motions in the machine.
D. Matters for Attention during Commissioning on H Beam 3 in 1 Fabrication Machine:
1. Monitor on 3 in 1 H Beam Fabrication Machine:
1) During commissioning, watch closely on running condition all the while;
2) If ever any improper condition happens, stop the machine, find out the cause, and have trouble shooting right away;
2. Safe Operation on Integral Function H Beam Welding Machine:
1) This involves: Feeding in/ send out/ hoist of raw materials/ WIP (Working in process) and finished product among different units of the H Beam 3 in 1 Production Line;
2) For safety purpose, do not go through main body/ input and output conveyors of the machine during its working;
3) Customer workshop trial run on Wuxi JACK PHJ15 model H Beam 3 in 1 Assembly Welding Straightening Machine: (Fig.7)
E. Summary on Wuxi JACK H Beam 3 in 1 Assembly Welding Straightening Machine:
1. Significance of Proper Commissioning on 3 in 1 H Beam Fabrication Machine:
This is perfect opportunity to:
1) Identify status of the machine line group;
2) Operators get familiar with the machine;
For this reason, a well planned and performed commissioning is the first step toward satisfactory use of Integral Function H Beam Welding Machine;
2. Wuxi JACK is the leading supplier in the field of this machine. More detail on our leading edge is in “Advantages of Wuxi JACK H Beam 3 in 1 Fabrication Machine”.
