Background of This Blog on SAW Welding Flux Heating Machine for 3 in 1 H Beam Fabrication Machine:
1. Business Case: In Oct. 2023, Wuxi JACK finished producing a tailor made ZHJ-12 model 3 in 1 H Beam Fabrication Machine for a South American customer. The supplied equipment includes a set of SAW Welding Flux Heating Oven, which is not common seen equipment equipped in H Beam Fabrication Line;
2. Topics Here on Welding Flux Heating Oven being Applied with 3 in 1 H Beam Fabrication Machine:
a) Main Equipment in ZHJ-12 model 3 in 1 H Beam Fabrication Line;
b) Usage and Technical Strong Points of Welding Flux Heating Machine being Applied for 3 in 1 H Beam Assembly Welding Straightening Machine;
c) Structure and Main Units of SAW Welding Flux Heating Oven in 3 in 1 H Beam Fabrication Line;
d) Main Technical Specifications of Welding Flux Heating Machine in 3 in 1 H Beam Fabrication Machine;
e) Operation on SAW Welding Flux Heating Oven for 3 in 1 H Beam Assembly Welding Straightening Machine;
f) Matters for Attention on Daily Use of SAW Welding Flux Heating Machine in 3 in 1 H Beam Fabrication Line
A. Main Equipment in ZHJ-12 Model 3 in 1 H Beam Fabrication Line:
1. This includes:
1) 1 set of ZHJ-12 model 3 in 1 H Beam Assembly Welding Straightening Machine: (Fig.1)
2) 1 group of hydraulic drive 90° Overturning Equipment: 3 sets: (Fig.2)
3) 1 set of ZYDH-100 SAW Welding Flux Heating Machine: (Fig.3)
2. The expected layout of ZHJ-12 model 3 in 1 H Beam Fabrication Line at customer facility: (Fig.4)
B. Usage and Technical Strong Points of Welding Flux Heating Machine being Applied for 3 in 1 H Beam Assembly Welding Straightening Machine:
1. Why Need SAW Welding Flux Heating Oven for 3 in 1 H Beam Fabrication Machine:
1) SAW (Submerged arc welding) flux and electrode absorbs moisture during transportation and storage, which should be heated before welding;
2) Without heating, residual hydrogen will be left in the base metal with decomposition of water during welding, leading to cracks in welding seam;
2. Technical Strong Points of SAW Welding Flux Heating Machine in 3 in 1 H Beam Fabrication Line:
1) Operation on this Welding Flux Heating Machine is by pouring flux into the oven, convenient and reliable;
2) The stainless steel heating elements are distributed evenly inside Welding Flux Heating Oven, making sure uniform heating on welding flux. Its installation and dismantle is easy to perform;
3) The heating temperature inside the Welding Flux Heating Oven is controlled automatically with high precision. The water content in heated welding flux can be maintained less than 0.1%.
C. Structure and Main Units of SAW Welding Flux Heating Oven in 3 in 1 H Beam Fabrication Line:
1. Structure and Composition: This SAW Welding Flux Heating Machine is composed of heating oven/ external box/ heating temperature control system;
1) The external box of Welding Flux Heating Machine is fabricated from high quality thin steel plates;
2) The Welding Flux Heating Oven is fabricated from heat resistant stainless steel plates, and stuffed with superior quality rock wool as insulation material;
3) Stainless steel heating elements are distributed evenly inside the Welding Flux Heating Oven;
4) Heated welding flux outlet is located at bottom of the Welding Flux Heating Oven, which consists of valve/ rotation shaft/ handle/ spring;
5) When it is necessary to discharge heating finished welding flux, just turn on the handle, the valve will be switched on accordingly, and heated welding flux will be discharged from the Welding Flux Heating Oven automatically;
6) When not in use, the valve is shut off under the action of spring;
7) Temperature control system of the SAW Welding Flux Heating Machine is composed of temperature controller/ control buttons and A.C. contactors.
D. Main Technical Specifications of Welding Flux Heating Machine in 3 in 1 H Beam Fabrication Machine:
1. Electricity: AC440V/ 60Hz 3Phase 4 Line (Tailor made for customer country)
2. Rated Power: 4 kW;
3. Rated Temperature: 450 °C;
4. Rated Capacity: 100 kg;
5. Overall Dimension (Width x Depth x Height): 920mm x 600mm x 1350mm
E. Operation on SAW Welding Flux Heating Oven for 3 in 1 H Beam Assembly Welding Straightening Machine:
1. Preparation Work before Formal Operation on SAW Welding Flux Heating Machine for 3 in 1 H Beam Fabrication Line:
1) Location and Fixation: This Welding Flux Heating Machine should be located at indoor dry zone, and laid onto level plane, without additional fixation;
a) There should be a piece of dedicated use A.C breaker installed in electric power supply line of the Welding Flux Heating Machine;
b) And cables with same diameter of power line should be used as grounding wire of the Welding Flux Heating Machine;
3) Before Power On: Inspect electric performance of the control board, making sure there is no failure phenomenon happened, including open circuit/ electricity leakage, etc.;
4) Adding in Welding Flux: When everything is ready for work, open the top cover of the Welding Flux Heating Oven, and pour in welding flux, then close on the top cover;
2. Operation After Power On of Welding Flux Heating Machine in 3 in 1 H Beam Fabrication Machine:
1) Select “High Temperature”: Turn on the electricity, switch the “Temperature Low High” switch to “High”;
a) Target high temperature for heating;
b) Heating temperature holding time;
c) Heating holding temperature;
Note: The detailed way of parameters setting up please check on manual book of Temperature Controller;
3) Start On: Upon completion of parameters setting, and confirm on correct setting, press on “Heating On” button. The SAW Welding Flux Heating Machine initiates on work;
4) Operating panel of SAW Welding Flux Heating Oven for 3 in 1 H Beam Fabrication Line: (Fig.5)
5) Finish Heating: At the completion of welding flux heating, shut off electricity of the Welding Flux Heating Oven, turn on handle of the Welding Flux Heating Oven to open its valve, the heated welding flux can be discharged out of the oven, and being poured into container
F. Matters for Attention on Daily Use of SAW Welding Flux Heating Machine in 3 in 1 H Beam Fabrication Line:
1. Coating Protection on SAW Welding Flux Heating Machine in 3 in 1 H Beam Assembly Welding Straightening Machine:
1) Main body of this SAW Welding Flux Heating Machine is fabricated from steel plates, and painted with flat paint;
2) During daily use, do not scratch or spoil coating film of the main body, which will lead to corrosion of Welding Flux Heating Oven main body;
2. Heating Capacity Management in SAW Welding Flux Heating Oven of 3 in 1 H Beam Fabrication Machine:
1) The welding flux inside the Welding Flux Heating Oven for heating, its level height should be above top surface of electric heating tubes. Which means, the added welding flux should fully cover electric heating tubes;
2) Besides, when pouring welding flux into the Welding Flux Heating Oven, be sure not to spoil the heating tubes;
3. New SAW Welding Flux Heating Machine Put into Use in 3 in 1 H Beam Fabrication Line:
For the newly purchased Welding Flux Heating Machine, or the Welding Flux Heating Machine being resumed on for use after long term storage, it should be:
1) The empty Welding Flux Heating Oven should be heated at the set temperature 40°C to 80°C for 2 hours, for the purpose of moisture dissipation, and enhance insulation performance of the SAW Welding Flux Heating Machine;
2) Only after this can put the SAW Welding Flux Heating Machine into normal use.
