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1 Steel Plate Flat Butt Welding Machine - 5

Wuxi JACK Steel Plate Flat Butt Welding Machine, 

Cost Effective and Top Quality Equipment on Sheet Metal Joint

1 Steel Plate Joint Welding Machine 19
2 Steel Plate Flat Butt Welding Machine 43- IMG_4903
3 Steel Plate Joint Welding Machine 57- IMG_7538
4 Steel Plate Butt Joining Machine 12
5 Steel Plate Butt Joining Welding Machine 50- IMG_5971
6 Steel Plate Flat Butt Welding Machine 62- IMG_8196
7 Steel Plate Butt Joining Machine 67
8 Steel Plate Butt Joining Welding Machine 71

Getting Improvement on Sheet Metal Joint with Steel Plate Flat Butt Welding Machine

With introduction of Steel Plate Flat Butt Welding Machine, the great Improvement on sheet metal joining can be summarized mainly at four key areas of People Safety/ Quality / Productivity / Cost:
1. People Safety: Removing potential risk of steel plate bumping during its 180° flipping with traveling crane, for the 2nd time reverse side welding;

2. Quality: Perfect Effect of Sheet Metal Joining from Steel Plate Butt Joining Welding Machine:

1) Welding Seam: The mechanical strength of butt welding seam on joint plate is higher than that of base metal. This has been validated from tensile test on working part, finished from the Steel Plate Joint Welding Machine:

2) Finished joint steel plate and joint welding seam, fabricated from Wuxi JACK Steel Plate Butt Joining Welding Machine: (Fig.1)

 -- Length/ width/ thickness of test piece are marked on the steel plate with chalk;
 -- Process welding current and voltage are marked on test piece, for being validated in the Steel Plate Flat Butt Welding Machine:

Fig1 Plate Joint Welding Machine 38

3) Melt-Thru welding seam on joint piece from Wuxi JACK Steel Plate Joint Welding Machine: (Fig.2)

Fig2 Plate Butt Joining Welding Machine 21

3. Productivity: 2 Times Efficiency Raising with Steel Plate Flat Butt Welding Machine:

The total CT (Cycle time) on plate joining can be reduced to 40% of original duration, which means 2.5 times efficiency raise;

4. Cost Reduction on Sheet Metal Joint from Steel Plate Butt Joining Machine:

1) Variable Labor Cost Reduction: From 2 operators to 1 operator;

2) Variable Operating Cost Reduction from Steel Plate Joint Welding Machine:

 -- From 2 times both sides butt welding to single side 1 time;
 -- Removing carbon gouging and workpiece flipping in the middle;
3) Period Utility Cost Reduction: Remove equipment for welding groove making, and travel crane for workpiece flipping;
1) This web page is the complement on “Steel Plate Butt Joining Welding Machine”, focusing on technical aspect of the Flat Butt Welder;
2) Quick reviewing on merits of this product is illustrated in summary slides “The Powerful Wuxi JACK Steel Plate Flat Butt Welding Machine”.

 

Wide Variety Models and Production Stages of Wuxi JACK Steel Plate Flat Butt Welding Machine

Selecting Proper Models of Wuxi JACK MP Series Steel Plate Flat Butt Welding Machine

1 Steel Plate Joint Welding Machine 18
2 Steel Plate Flat Butt Welding Machine 32A
3 Steel Plate Butt Joining Welding Machine 12

1. Critical Specifications: From customer perspective, the key index for selecting suitable models of Steel Plate Butt Joining Welding Machine are width and thickness of sheet metals to be joint;

 

2. Available Models of MP Series Steel Plate Butt Joining Machine:

1) These are distinguished based on workpieces sheet metals width. In other words, length of joint welding seams to be delivered from:
2) MP20: Delivering max. 2000mm length of joint welding seam/ sheet metal width, the same as other models:
3) Other typical models: MP23, and MP25, and MP30, and MP35, and MP40, and MP45, and MP50 Steel Plate Butt Joining Machine;

 

3. Technical Specifications of Wuxi JACK MP20 ~ MP50 Steel Plate Butt Joining Welding Machine:

 Models of Steel Plate 
 Flat Butt Welding Machine		  MP20/ 23/ 25/ 30/ 35/ 40/ 45/ 50
 Max. Width of Sheet Metal for
 Joint (Max. Length of Butt Joint
 Welding Seam)		  2,000/ 2,300/ 2,500 / 3,000/ 3,500 / 4,000 / 4,500 / 5,000 mm 
 Thickness and Material of Sheet Metal Plates for Joint  Thickness: 6 ~ 40mm for SAW;  2~ 6mm for CO2 welding
 Material: Low carbon steel,
 Stainless steel or Al alloy
 Butt Welding of Straight Edge
 Thickness without Groove		  6 ~ 15 mm
 Optional Flame Triple Cutting
 Velocity for Grooving		  100 ~ 800mm/min. Stepless
 Adjusting, A.C. Inverter control
 Fully Penetration Welding Melt-
 thru Velocity		  200 ~ 1000mm/min. Stepless
 Adjusting, A.C. Inverter control
 Sheet Metal Feeding Speed  2500 mm/min.
 Butt Welding Mode  Submerged Arc Welding / CO2
 Gas Shielded Fully Penetration
 Welding Melt thru
 Length of Single Piece Sheet Metal before Joint  6000 ~ 15000 mm
 (Can be special made)

 

Working Video of Wuxi JACK Steel Plate Butt Joining Welding Machine

1) Here we pick up 6 operating videos of Wuxi JACK MP series Steel Plate Flat Butt Welding Machine;
2) More videos of this series Steel Plate Butt Joining Machine are available in specific web page: “Working Video of Steel Plate Butt Joining Welding Machine”.

 

Designing Wuxi JACK MP Series Steel Plate Butt Joining Welding Machine

A. General Layout of Steel Plate Joint Welding Machine:

The righthand 1st design drawing gives sketch on disposing Wuxi JACK Steel Plate Flat Butt Welding Machine at customer site:

1. Workpiece Sheet Metal Flow in Steel Plate Flat Butt Welding Machine:

1) This is demonstrated with red color arrow in the print: From left to right;
2) Such material flow can also be identified with length of output conveyors at right side of steel Plate Joint Welding Machine main frame;
3) It is 2 times length that of input conveyor at left side of the Flat Butt Welder machine main frame;
2. Oxygen fuel flame triple cutting system is installed at left side of main frame gantry, the inlet side of the Steel Plate Butt Joining Machine;
3. Melt-thru welding system is installed at right side of main frame gantry, the outlet side of the Steel Plate Joint Welding Machine.
 

B. Mechanical Main Frame of Steel Plate Butt Joining Welding Machine:

The righthand 2nd design drawing gives detailed structure on mechanical main frame of the Steel Plate Butt Joining Machine:
1. Mechanical main frame of the Flat Butt Welder is in the structure of stationary box gantry beam, with its both sides installed with working groups;

2. Two Core Function Units in Steel Plate Butt Joining Welding Machine:

1) Flame triple cutting torch system and melt-thru welding torch complex are assembled onto horizontal beam of the main frame at both sides;
2) The movement of the 2 function units are guided with precise linear guiderail, and transmitted with rack;
3) This fully guarantees smooth and precise running of the working unit carriages, during working of the Steel Plate Flat Butt Welding Machine:

4) Motor drive function units on horizontal beam of the Steel Plate Flat Butt Welding Machine: (Fig.1)

Fig1 Steel Plate Flat Butt Welding Machine 41- IMG_4763

 

3. Melt-Thru Welding Worktable of Steel Plate Joint Welding Machine:

1) This section is an individual standing bench isolated from the mechanical main frame;
2) At installation of the Steel Plate Butt Joining Machine, exact position of the welding table should be accurately managed, so as to make sure that:
3) For carrying out melt-thru welding in the Steel Plate Flat Butt Welding Machine, centerline of copper cushion should be exactly beneath welding torch tip;
4) This is illustrated in righthand 2nd design drawing: Side view on mechanical main frame of the Steel Plate Flat Butt Welding Machine;

 

C. Working Energy Source in Steel Plate Flat Butt Welding Machine:

MP series Steel Plate Butt Joining Welding Machine is a sophisticated Flat Butt Welder, integrating electricity/ hydraulic cylinder/ Oxy-Acetylene cutting gas, and circulating water:

1. Electric Control Cycloidal A.C. Motor in Steel Plate Joint Welding Machine:

1) Workpiece sheet metal feeding and transport on input and output conveyors;
2) Welding power supply management;
2. Oxygen Acetylene Thermal Cutting Gas: Welding groove beveling on 15mm plus thickness sheet metal;
3. Hydraulic Oil Cylinder and Pump Station: Workpiece sheet metal being clamped firmly onto work bench, during melt-thru welding in the Steel Plate Butt Joining Machine. Constant pressure is 8 MPa;
4. Cooling Water Circulating Circuit: This unit is for heat dissipation during large current melt-thru SAW welding in Melt-thru welding. Cooling water run through copper pads of the Steel Plate Joint Welding Machine;
D. The typical overall arrangement of Wuxi JACK Steel Plate Butt Joining Welding Machine is demonstrated in the righthand photo.

1 Steel Plate Flat Butt Welding Machine 72
2 Steel Plate Joint Welding Machine 27
3 Steel Plate Butt Joining Welding Machine 21
4 Steel Plate Flat Butt Welding Machine 26
5 Steel Plate Butt Joint Welding Machine 76
6 Steel Plate Butt Joint Welding Machine 10

Operating Tips on Wuxi JACK Steel Plate Butt Joining Welding Machine

A. The 1st and 2nd Photos: Optional Unit Oxygen Fuel Triple Flame Cutting in Steel Plate Flat Butt Welding Machine:

1. For Sheet Metal Thickness Less Than 15mm in Steel Plate Joint Welding Machine:

1) This thickness range sheet metal does not need welding groove. So, triple cutting is not necessary;
2) Before melt-thru welding in the steel plate Flat Butt Welding Machine, just leave 3mm clearance between the 2 pieces of sheet metal, and directly perform welding;

2. For 15mm to 28mm Thickness Sheet Metal in Steel Plate Flat Butt Welding Machine:

1) Straight edge and slant edge beveling can be made simultaneously in the Steel Plate Butt Joining Machine;
2) This means, one time flame triple cutting can complete straight and slant grooving together on workpieces;

3. For 28mm to 40mm Thickness Sheet Metal in Steel Plate Butt Joining Welding Machine:

To acquire eligible welding groove on edges of sheet metal:
1) First implement straight edge cutting;
2) Recede the flame cutting torch, and tilt it 150°;
3) Finally cut slant edge on workpiece sheet metal;
 

B. The 3rd and 4th Photos: Melt-Thru Welding in Steel Plate Joint Welding Machine:

1. SAW Welding Flux Deposition in Steel Plate Flat Butt Welding Machine:

1) The 3rd photo: For successfully implementing melt-thru welding (One side welding, and both sides welding seam formation) in the Steel Plate Butt Joining Welding Machine, 2 layers of welding flux need to be deposited;

2) Before Melt-thru Welding in Steel Plate Flat Butt Welding Machine:

a) The top layer welding flux should be deposited on top surface of sheet metal workpiece;
b) The bottom layer welding flux should be deposited on top surface of copper pads, right beneath bottom surface of sheet metal workpiece;
3) Model of welding flux recommended for Chinese customers are FCB-1R and FCB-1 respectively;

2. Process Control Parameters of Melt-thru Welding in Steel Plate Flat Butt Welding Machine:

Take 8mm to 20mm thickness range carbon steel plate as example, the critical process control parameters for single side welding and both sides completion, in Steel Plate Butt Joining Welding Machine include:
1) 680~ 760A welding current;
2) 35~ 37V welding voltage;
3) 420 ~ 585 mm/min. continuously adjustable welding speed;
4) 1 ~ 2.5mm butt welding clearance;
5) 0°~ 20° welding torch angle;
6) 0~ 4mm welding edge blunt side size;
3. The 4th Photo: Finished test piece joint plate, fabricated from Wuxi JACK MP25 Steel Plate Flat Butt Welding Machine. There are validated process control parameters chalk marked on the sample piece.

Workpiece Sheet Metal Transportation and Positioning in Wuxi JACK Steel Plate Flat Butt Welding Machine

Significance: The smooth transportation/ accurate positioning/ reliable clamping of workpiece sheet metals are preconditions on successful running of the Steel Plate Butt Joining Welding Machine:

A. Safely and Reliably Transporting Workpiece Sheet Metal forward along Conveyors of Steel Plate Joint Welding Machine

1. Sending Reliability Assurance (The 1st Photo) in the Wuxi JACK Steel Plate Butt Joining Machine:

1) There are alignment rollers installed along input and output conveyors of the Flat Butt Welder;
2) This can fully guarantee correct position of sheet metal during its sending forward, especially completed joint steel plate with long length;
2. Acting Unit (The 2nd Photo): Sending forward workpieces sheet metal through mechanical main frame of Steel Plate Joint Welding Machine is fulfilled with 2 pieces of transmission rollers, which are driven with A.C. cycloidal motor;

3. Height Management (The 3rd Sketch) in Steel Plate Butt Joining Welding Machine:

1) Top surface of copper cushions should be flush with top surface of input/ output conveyors;
2) Besides, there is interlock between height of copper cushion and conveyors: If top surface of the copper pads is higher, the conveyors of the Steel Plate Flat Butt Welding Machine will not work;

4. Logic Management (The 4th Photo) in Steel Plate Joint Welding Machine:

1) There is also interlock between function units (Flame triple cutting torch/ welding complex) and input/ output conveyors:
2) If flame triple cutting or melt-thru welding is in operation, the workpiece sheet metal can not be moved forward or backward on the conveyors.

B. Correct Positioning and Tightly Clamping on Workpiece Sheet Metal inside Melt-Thru Welding Table of Steel Plate Butt Joining Welding Machine

1. Locating Workpiece (The 1st Photo) into Welding Bench of Steel Plate Butt Joining Machine:

Where: During melt-thru welding, steel plates are pressed firmly onto copper cushion array; Here copper cushion has 2 functions:
1) One is to hold on the 2 pieces of steel plates;
2) The second is more critical: Copper pads help accomplishing melt-thru welding in the Steel Plate Flat Butt Welding Machine, with double layers of welding flux, together with cooling water heat dissipating tubes going through inside the copper cushion;

2. Controlling Vertical Position of Copper Pad (The 2nd Photo) in the Steel Plate Joint Welding Machine:

1) When not in welding, the copper blocks are lowered down to its original bottom position;
2) When melt-thru welding is about to be implemented, the copper blocks will be lifted up under worm gear motor drive;
3) To catering on varied thickness of workpiece sheet metal in the Steel Plate Flat Butt Welding Machine, there are top and bottom limit switches installed along vertical stroke of the copper pads;

3. Fitting Up Copper Blocks (The 3rd Photo) When Assembling Steel Plate Butt Joining Welding Machine:

You can identify the blue color water tubes that were about to be inserted into and pulled through the entire length of copper cushions, going through the lateral through holes;

4. Hydraulic Drive Clamp Blocks (The 4th Photo) in Steel Plate Butt Joining Welding Machine:

1) During melt-thru welding, the steel plates will be laid right above the copper blocks;
2) Firmly clamping the steel plates is secured with black color blocks, which are distributed in regular interval along the entire length of copper pads in the Steel Plate Flat Butt Welding Machine;
3) Heavy force drive: These black pressing blocks are driven with 2 arrays of oil cylinders, which are installed inside the V slot of welding table of the Steel Plate Flat Butt Welding Machine.

Welding Torch Position Control in Wuxi JACK Steel Plate Flat Butt Welding Machine:

Significance: Precise position of welding torch directly determines performance level of melt-thru welding from Steel Plate Joint Welding Machine:

1. Managing on Vertical Level (The 1st Photo) of Welding Torch in Steel Plate Butt Joining Machine:

According to thickness of joint workpiece sheet metal, up and down movement of welding torch is fulfilled in 2 stages:
1) First: High speed descend welding torch under motor drive;
2) Second: Precisely adjust in inching mode along cross slide of welding torch;

2. The 2nd Photo: Precisely Tracing on Welding Seam During Melt Thru Welding in Steel Plate Butt Joining Welding Machine:

1) In the process of melt-thru welding, there is a laser light spot moving ahead of welding torch tip:
2) This moving red color laser spot is for indicating correct position of welding seam, to guide the welding torch movement, and help operator checking on proper trace of the welding torch;

3. Melt Thru Welding Supplementary Unit (The 3rd Photo) in Steel Plate Joint Welding Machine:

1) The laser tracer generator and its white color pushbutton;
2) The welding wire feeder and its managing knacks, for selecting proper diameter of welding wire;
3) The welding wire straining condition modulating unit;

4. Overall View (The 4th Photo) on Melt-thru Welding Carried Out in Steel Plate Flat Butt Welding Machine:

Dynamic coordination of all the above introduced working elements.
 

Plate Joint Welding Machine
01

Flat Butt Welding Machine
02

Plate Butt Joining Welding Machine
03

FAQ on Wuxi JACK Steel Plate Flat Butt Welding Machine:

  • Q What does Product Name “Steel Plate Flat Butt Welding Machine” Refer to? And Its Usage for Customers?

    A
    1. 1) Because 2 pieces of raw material: Sheet metal, will be joint into an integral larger and longer piece, in the form of “flat butt joint”, with 180° joint angle. This is equipment name “Sheet Metal Flat Butt Welding Machine” implies;
    2. 2) Benefitting from this challenging task, customers can acquire larger size of sheet metal, from smaller ones;
    3. 3) Majority conditions, clients want to get longer sheet metal from shorter pieces, by using Steel Plate Flat Butt Welding Machine.

  • Q Which Specifications of Sheet Metals can be Joint in Steel Plate Joint Welding Machine?

    A
    1. 1) As its name suggests, most majority of sheet metal for joint are steel plates, especially carbon steel;
    2. 2) The applicable thickness of these steel plates is from 6mm to 40mm;
    3. 3) In theory, any width range of sheet metal can be joint in Steel Plate Butt Joining Machine;
    4. 4) In practical application, sheet metal Plate Joint Welding Machine are divided based on its max. workpiece width: From MP20 (Max. width 2000mm) to MP50.
     

  • Q What are Technical Superiorities of Wuxi JACK Steel Plate Butt Joining Welding Machine?

    A
    1. 1) Patent Technology Melt-Thru: This means only Wuxi JACK has capability to deliver such delicate welding for customers. It means one side welding on the 2 pieces of joint steel plate, and welding seam can be formed in strong intensity with fully penetration;
    2. 2) Multi-Functional Arrangement: For workpiece thickness from 15mm to 40mm, certain angle slant groove should be beveled ahead of time before fully penetration welding. In Wuxi JACK Steel Plate Butt Joining Welding Machine, Oxygen fuel thermal triple cutting unit is equipped, thus helps customers saving investment on beveling equipment.

  • Q Why Investment on Wuxi JACK Steel Plate Butt Joining Machine Can Bring Great Financial Benefit for Customers?

    A By introducing Wuxi JACK Steel Plate Butt Joining Machine, customers can:
    1. 1) Reducing number of operators;
    2. 2) Remove potential safety risk;
    3. 3) Improve production efficiency 2.5 times;
    4. 4) Acquire consistent controllable plate butt joining effect
    On operation of sheet metal plate flat butt joining.

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2. Structure and Working Principle of MP Series Plate Butt Welding Joint Machine:
3. Technical Parameters of MP20 Plate Butt Weld Joining Machine:
 
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3. Technical Parameters of DX1520 H Beam End Face Milling Machine:
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B. Structure and Working Principle of Automatic Hydraulic Drive Assistant Loading Brackets in Large Size Plate Edge Milling Equipment:
C. Usage of SXBJ-16 Large Size Plate Edge Milling Machine:
D. Technical Parameters of SXBJ-16 Large Size Plate Edge Milling Machine:
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4. Technical View on ASM63 Angle Steel Straightening Machine:
5. Technical Parameters of ASM63 Angle Steel Straightening Machine:
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B. The Challenge on Developing Mature 7 Axis 3000/12 Heavy duty Oxy-fuel Plasma CNC Pipe Intersection Cutting Machine:
C. The 7 Axis of CNC in Heavy duty Oxy-fuel Plasma CNC Pipe Intersection Cutting Machine:
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E. Technical Parameters of 7 Axis 3000/12 Heavy duty Oxy-fuel Plasma CNC Pipe Intersection Cutting Machine:
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