Background of This Blog on 3 in 1 H Beam Assembly Weld Straighten Integral Machine
1. Recently, during commercial communication on ZHJ15 model 3 in 1 H Beam Fabrication Machine,
An African customer wanted to get answers on below 2 key questions:
1) How much does it cost to produce a piece of H Beam in automatic 3 in 1 H Beam Welding Machine?
2) How long does it take to produce a piece of H Beam in 3 in 1 Vertical H Beam Welder?
The above are the 2 critical points during planning on and introducing any equipment, including the 3 in 1 Integral Function H Beam Welding Machine, we discussed here;
2. Topics Here on Production Study of 3 in 1 Integral Function H Beam Welding Machine:
In this short blog, we present here the detailed procedure on calculation and analysis for the African customer, focusing on the subject of:
Manufacturing Cost and Cycle Time Calculation on Producing a piece of 12m Length 10mm Thickness H Beam, with Wuxi JACK 3 in 1 H Beam Fabrication Machine;
3. Correspondingly, the train of though to get the conclusion on 3 in 1 H Beam Fabrication Machine, covers below steps of:
1) Manufacturing Cost Factors on Variable Cost and Cycle Time study;
2) Cost of 3.2mm Diameter Welding Wire;
3) Cost of SJ101 Welding Flux;
4) Cost of Electricity;
5) Total Manufacturing Cost on Manufacturing 1 piece of 12m length and 10mm thickness H Beam in the 3 in 1 H Beam Assembly Weld Straighten Integral Machine;
6) Total Cycle Time on Manufacturing 1 piece of 12m length and 10mm thickness H Beam in the Vertical H Beam Welder;
7) Output of the 3 in 1 Integral Function H Beam Welding Machine per 8 Hours Shift;
8) Note and Summary on Manufacturing Cost and Cycle Time in the 3 in 1 H Beam Assembly Weld Straighten Integral Machine;
4. Hand Wring Drafts on Calculation and Analysis by Wuxi JACK Engineer on 3 in 1 H Beam Fabrication Machine: (Fig.1)
5. For comprehensive presentation on advantages and cost saving for customers brought along with this 3 in 1 Integral Function H Beam Welding Machine, please check web page “Quick Understanding on Wuxi JACK 3 in 1 H Beam Fabrication Machine”.
A. Manufacturing Cost Factors on Variable Cost and Cycle Time in 3 in 1 H Beam Fabrication Machine:
1. Workpiece H Beam Size for calculation and analysis in with 3 in 1 H Beam Assembly Weld Straighten Integral Machine:
1) 12m total length;
2) Web and flange thickness is 10mm;
3) Design sketch on typical H Beam to be delivered from Wuxi JACK automatic 3 in 1 H Beam Welding Machine: (Fig.2)
2. Variable Manufacturing Cost Factors in 3 in 1 H Beam Assembly Weld Straighten Integral Machine:
1) 3.2mm diameter Welding Wire consumed;
2) SJ101 Welding Flux consumed;
3) Electricity consumption in the manufacture of welding H Beam;
4) Manufacturing moment: Laying welding wire and flux in Wuxi JACK Automatic 3 in 1 H Beam Welding Machine: (Fig.3)
B. Cost of 3.2mm Diameter Welding Wire in 3 in 1 Integral Function H Beam Welding Machine:
1. There are 4 pieces of 12m length welding seam on 1 piece of the finished H Beam;
2. Size of Welding Seam Toe on 10mm Thickness H Beam:
8mm height x 8mm width, triangle cross section shape. As shown in hand made sketch;
3. Total welding wire consumed in each pass of welding seam:
(8mm x 8mm) /2 x 12m x 7.85 g/cm3 (Specific gravity of steel) = 3 kg
4. Total welding wire consumed in each piece of H Beam: 3 kg * 4 =12 kg
5. Total cost of 3.2mm diameter welding wire on fabricating 1 piece of H Beam: 7.1 RMB/kg x 12kg= 85.2 RMB
6. Laying 3.2mm diameter welding wire in Wuxi JACK 3 in 1 H Beam Assembly Weld Straighten Integral Machine: (Fig.4)
C. Cost of SJ101 Welding Flux in 3 in 1 H Beam Assembly Welding Straightening Integral Machine:
1. Total welding flux consumed on each pass of welding seam with 3 in 1 Integral Function H Beam Welding Machine :
Cross Section (6mm thickness x 15mm width) x 12m x 0.8g/cm3 (Specific gravity of welding flux) = 864 g
2. Total welding flux consumed in producing each piece of H Beam:
864 g x 4 = 3.5 kg
3. Total cost of SJ101 welding flux in producing each piece of H Beam:
3.6 RMB/kg x 3.5 kg= 12.6 RMB
4. Depositing SJ101 welding flux in 3 in 1 Integral Function H Beam Welding Machine: (Fig.5)
D. Cost of Electricity in 3 in 1 Vertical H Beam Welder:
1. Welding speed on fabricating 10mm thickness H Beam: 600 mm/ min.
2. Cycle Time on welding Single Pass of Welding Seam: 12m/ (0.6m/min.) = 20 min.
3. Cycle Time on welding one piece of H Beam in 3 in 1 Integral Function H Beam Welding Machine:
20 min. x 2= 40 min. ≈ 0.67 Hour
(Because 2 passes of welding seams to be fabricated at the same time)
4. Total Power of 3 in 1 Integral Function H Beam Welding Machine: 80kW
5. Total Electric Power Consumption on producing one piece of H Beam:
80kW x 0.67 Hour= 53.6 KWH
6. Total Electric Power Rate on Producing 1 Piece of H Beam in the 3 in 1 H Beam Fabrication Machine:
6 KWH x 1 RMB/ KWH (Chinese industrial electricity cost) = 53.6 RMB
E. Total Manufacturing Cost on Producing 1 piece of H Beam in 3 in 1 H Beam Assembly Weld Straighten Integral Machine:
Summing up, for producing a piece of 12m length and 10mm thickness welding H Beam in 3 in 1 H Beam Fabrication Machine, the total manufacturing cost equals to:
85.2 RMB for welding wire + 12.6 RMB for welding flux + 53.6 RMB for electricity= 151.4 RMB
F. Total Cycle Time on Manufacturing 1 piece of 12m length and 10mm thickness H Beam in 3 in 1 H Beam Fabrication Machine:
1. One Time Loading workpiece onto the 3 in 1 H Beam Fabrication Machine:
1 minute
2. One Time Unloading workpiece from the 3 in 1 H Beam Fabrication Machine: 1 minute
3. 1 piece of H Beam production needs 2 times of loading and unloading into and out of the 3 in 1 H Beam Fabrication Machine:
(1+1) x 2=4 minutes
4. Total Cycle Time on Manufacturing 1 piece of 12m length and 10mm thickness H Beam in 3 in 1 H Beam Assembly Weld Straighten Integral Machine:
40 minutes welding period + (4~5) minutes loading and unloading = 45 minutes = 0.75 Hour
G. Output of the 3 in 1 Integral Function H Beam Welding Machine per 8 Hours Shift:
1. Effective working time within one shift of 8 hours:
7 hours (Suppose 1 hour breaking time per shift)
2. Output of the 3 in 1 H Beam Fabrication Machine per 8 Hours Shift:
7 hours/ (0.75 Hour/ Piece) ≈ 9 piece/ Shift
3. Need 1 operator to operate the 3 in 1 H Beam Assembly Welding Straightening Integral Machine.
Note and Summary on Manufacturing Cost and Cycle Time on 3 in 1 H Beam Assembly Welding Straightening Integral Machine:
1. The above calculation and analysis is based on 3 in 1 H Beam Fabrication Machine:
1) Chinese common seen welding technology stipulation on fabricating H Beam, on sizes of welding seam produced. Here, 10mm thickness need 8mm leg size;
2) Quotation on 3.2mm diameter welding wire and SJ101 welding flux to customer;
3) Chinese industrial electricity rate: 1 RMB/ KWH;
2. PHJ and ZHJ series Vertical H Beam Welder are superior, box and advantageous product of Wuxi JACK. For more detail, please visit web page: Wuxi JACK 3 in 1 Integral Function H Beam Welding Machine.
