The attached master picture (The first photo) is a set of Wuxi JACK designed and produced ZHJ18 model integrated function SAW welding mode, 3 in 1 I Beam Fabrication Machine. The photo was taken at front side, which is finished T Beam/ I Beam coming side of the machine.
A. Application and Major Technical Features of ZHJ18 Model 3 in 1 I Beam Welding Machine:
1. Output:
1) ZHJ18 is the medium size model in ZHJ series 3 in 1 T Beam Welder Machine also for producing Welded I Beam, for producing welded T Beam/ I Beam of max. web height of 1,800mm height:
2) The erected welded I Beam fabricated from Wuxi JACK ZHJ18 machine, at Russian customer facility: (Fig.1)
2. Market Share:
ZHJ18 model does not take the largest share of application. The most extensive selected model is ZHJ15 model, because welded I Beam/ T Beam with web height up to 1,500mm is the most popular used size of raw material in steel structure construction, while I Beam and T Beam with web height of 1,800mm (Corresponding to ZHJ18 model) and 2,000mm (Corresponding to ZHJ20 model) are only for minority of large size jobs;
3. I Beam Assembly Principle in 3 in 1 T Beam Welding Machine:
In the product section of “PHJ20 Symmetric and Asymmetric”, we discussed on major disparity between PHJ and ZHJ series 3 in 1 T Beam Welder Machine, in terms of workpiece/ operation (Flange and web alignment), as well as machine structure. Let us have a brief review that:
1) In PHJ series Integral function 3 in 1 I Beam Assembly Weld Straighten Machine, the alignment on flange with web are implemented with working mode of one side hydraulic drive, and the opposing side with manual handwheel:
Lateral view on assembling section of Wuxi JACK PHJ models 3 in 1 I Beam Fabrication Machine:(Fig.2)
2) Comparatively, in ZHJ series equipment, the T Beam and I Beam flange and web alignment are carried out in the manner of both sides in phase positioning and clamping, driven with hydraulic cylinders, and guided with moving horizontal guiding shafts:
Vertical close distance view on automatic symmetric assembling of ZHJ models: (Fig.3)
4. Running Video:
1) Please check attached video of a Wuxi JACK ZHJ18 model 3 in 1 T Beam Welding Machine: In the video, the eccentric alignment rollers are still not installed, just their guiding shafts. We can see that there are 2 pairs of guiding shafts (At the upper location) for guiding web alignment rollers, and 2 pairs of guiding shafts (At the lower location) for guiding flange alignment rollers;
2) Driven with oil cylinders, these guiding shafts move synchronously toward each other in each pair. And can be imagined, with alignment rollers installed at the terminal of these guiding shafts, these alignment rollers will position and assemble the flange and web in phase automatically. This explains major difference in precise assembling implemented between Wuxi JACK ZHJ series and PHJ series 3 in 1 I Beam Welding Machine.
B. Welding Operation of ZHJ18 Model 3 in 1 T Beam Welding Machine:
1. Integrated Running: The attached 2nd picture shows an instant of T Beam assembling/ welding/ straightening simultaneously carried out at a set of Wuxi JACK ZHJ18 model 3 in 1 T Beam Welder Machine. The three steps are implemented simultaneously in practical daily work, that we can only divide the three steps and make analysis on it during installation and validation process, as what is the case with the attached video:
Vertical view on commissioning moment of Wuxi JACK ZHJ18 model: (Fig.4)
2. Welding Modes in ZHJ series 3 in 1 T Beam Welder Machine:
Depending on thickness range of flange and web, there are 2 major types of welding mode:
1) SAW: Submerged arc welding, which takes over 90% of welding operation in T Beam and I Beam fabrication, for producing medium to thick plate I Beam and T Beam: (Fig.5)
2) CO2 Welding: Takes less than 10% application in steel structure welding, for fabricating thin plate workpieces, with high strength: (Fig.6)
The attached 3rd and 4th photos take welding seam and welding moment of SAW and CO2 respectively in this 3 in 1 I Beam Assembly Weld Straighten Machine;
3. Hydraulic Drive Manipulator: The attached 4h picture is the close distance shooting on machine hand (Hydraulic drive manipulator, or pulling rod boxes) deployed along input conveyor of the machine. They serve as preliminary fit up of flange and web during its feeding into the machine:
Groups of hydraulic drive pulling rod boxes at Wuxi JACK painting shop: (Fig.7)
C. Technical Parameters of ZHJ18 Model 3 in 1 T Beam Welder Machine:
Technical Parameter | ZHJ18 Model Medium Size 3 in 1 I Beam Fabrication Machine |
T Beam and I Beam Web Height | 200 ∼ 1,800 mm |
T Beam and I Beam Web Thickness | 6 ∼ 32 mm |
T Beam and I Beam Flange Width | 150 ∼ 750 mm |
T Beam and I Beam Flange Thickness | 6 ∼ 40 mm |
Workpiece (Welded T Beam and I Beam) Length | 3 ∼ 15 m (At customer demand, can be shorter or longer) |
Integral Working Speed of Assembly/ Welding Straightening | 200∼1200 mm/min. for both SAW and CO2 （Stepless, Inverter Control） |
Height of Single Pass Welding Seam on Fabricated T Beam and I Beam | Max. 8~12 mm, flat fillet welding of SAW/ CO2 |
Workpiece (Welded T Beam and I Beam) Cross Section Type | Symmetric Only (Refers to Flange joint with Web) |
Machine Overall Dimension（L× W × H） | 28m×4m×4.5 m |
Input and Output Conveyor Roller Table | Input and Output Roller Table of 10 ~11m length，3 segments each; Input Conveyor: One segment motor driving for sending, two segments Idling type; Output Conveyor: One segment hydraulic oil cylinder driving for uplift, two segments Idling type; Input conveyor roller tables are equipped with machine hand (Manipulator) |
Driving Mode | Assembly/ Straightening: Hydraulic Cylinder; Welding: Electric D.C. Motor |
Welding Mode | Most majority: SAW (Submerged Arc Welding, Φ2.5/ Φ3/ Φ4 mm diameter welding wire), Single Arc Minority: CO2 Gas shielded Welding |
Max. Welding Current | Up to 1000 A for SAW; 420A for CO2 |
