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;
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:
-- 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:
The total CT (Cycle time) on plate joining can be reduced to 40% of original duration, which means 2.5 times efficiency raise;
1) Variable Labor Cost Reduction: From 2 operators to 1 operator;
-- 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”.
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;
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;
| 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) |
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”.
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;
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) 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) 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;
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;
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;
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;
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;
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.
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:
Significance: Precise position of welding torch directly determines performance level of melt-thru welding from Steel Plate Joint Welding 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;
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;
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;
Dynamic coordination of all the above introduced working elements.