How to Operate Plate Butt Joint Welding Machine Properly?

Purpose of This Blog on Plate Butt Joint Welding Machine:

Why, you may wonder, that why take this topic as subject of the blog?

1)       Rapid Growth: Application of Flat Butt Welding Machine sees large step development over the past decades. It has advantages of: Multi-function/ user friendly operation/ high productivity, which is widely welcomed by customers;

2)       Daily Operation: Meanwhile, to set up proper TPM (Total Preventative Maintenance) affect directly service life and performance of this Plate Flat Joint Butt Welding Machine, which integrates function cells of triple flame cutting/ Melt thru Welding/ Water circulation/ Compressed air/ Hydraulic system, etc.;

3)       Topics: In This Short Blog, let us have a brief discussion on Flat Butt Welder:

•  Task/ Functions / Technical Features/ Functional Units in Plate Flat Butt Welding Machine;

•  Qualification on Operators of Plate Flat Joint Butt Welding Machine;

•  General Steps in Operating Plate Flat Butt Welder;

•  Tips on Operating Plate Butt Joint Welding Machine;

•  Summary on Wuxi JACK Flat Butt Welding Machine

A.       Task/ Functions / Technical Features/ Functional Units in Wuxi JACK Plate Flat Butt Welding Machine:

1.       Task: This Flat Butt Welder is for flat joining 2 pieces of sheet metal into an integral larger piece, by means of fully penetration welding;

Finished workpiece from Wuxi JACK MP20 Plate Butt Joint Welding Machine: (Fig.1)

2.       Other Common Used Names: Flat Butt Welder/ Plate Flat Joint Butt Welding Machine/ Flat Butt Welding Machine;

3.       Functions: Combination of both beveling (With flame triple cutting) and Melt thru Welding (Single side welding and double side forming);

4.       Technical Features of Wuxi JACK Plate Butt Joint Welding Machine:

1)      Sophisticated Configuration: MP series Plate Flat Butt Welding Machine is a kind of composite equipment integrating several functions;

2)       Wuxi JACK Patent Technology: The core step in the Flat Butt Welder: fully penetration welding, is adopted with Wuxi JACK patent technology credited in 2017;

3)       Operation of the Plate Butt Joint Welding Machine entails skill/ knowledge/ experience of operators, on aspect of triple cutting and melt thru welding;

4)       Multiple Energy Source: The melt thru welding cell adopts running water as radiation media. So, you can see that Plate Butt Joint Welding Machine is a multiple energy source equipment;

5.       Two Major Function Units in Plate Flat Joint Butt Welding Machine:

1)      Oxy-Fuel Triple Cutting: The beveling group uses Oxygen and Acetylene as preheating and cutting media, which has similar working principle as Triple Flame Plate Cutting Machine;

Flame beveling in Wuxi JACK Plate Butt Joint Welding Machine: (Fig.2)

2)       Melt Thru Welding: This means single side welding and double side forming. It brings huge on plate joining process, including: Safe operation/ Superior plate joint quality/ High efficiency. Detail is illustrated in blog: “Benefit of Plate Butt Joint Welding Machine Compared with Traditional Way of Plate Joining”;

Fully Penetration Welding carried out in Wuxi JACK Flat Butt Welding Machine: (Fig.3)

6.       Structure of Plate Flat Joint Butt Welding Machine:

1)       The two primary function groups are distributed at both sides of the mechanical main body of Flat Butt Welder;

2)       The beveling group is at material incoming side of the gantry beam, and fully penetration welding is at material outlet side;

3)       Vertical view on Wuxi JACK MP20 Plate Butt Joint Welding Machine: (Fig.4)

B.       Qualification on Operators of Plate Flat Joint Butt Welding Machine:

Operators of this Flat Butt Welder should command working skills as below:

1)       Triple Cutting Management: Ability on adjusting tilting angle of the triple torches, and pressure/flames of Preheating Oxygen/ Cutting Oxygen/ Cutting Gas in the Flat Butt Welder;

Flame triple cutting in Plate Butt Joint Welding Machine: (Fig.5)

2)       Fully Penetration Welding: Knowledge on parameter setting in melt thru welding (Single side welding and double side forming), and capability on judging the eligibility of welding seam formed in the Flat Butt Welder:

Parameters set up in Flat Butt Welding Machine: (Fig.6)

C.       General Steps in Operating the Plate Flat Butt Welder:

In a nutshell, for delivering satisfactory joint plate from the Plate Flat Joint Butt Welding Machine, you need to complete the basic steps of:

1.       Material Handling in Plate Butt Joint Welding Machine:

This includes:

1)       Loading on two pieces of metal plates onto input conveyor of Flat Butt Welder;

2)       Loading finished joint plate off output conveyor;

2.       Alignment on Metal Plates in Flat Butt Welding Machine:

1)       This is critical for guaranteeing eligible melt thru welding quality in the Flat Butt Welding Machine;

2)       It includes aligning two pieces of metal plates along its length direction, so that lateral side of the two metal plates are collinear;

3)       And aligning width side of metal plates, for joint against centerline of copper pads in the Plate Butt Joint Welding Machine;

3.       Flame Triple Cutting Process: Properly setting pressure/ flame of Oxygen and cutting gas, and angle of triple cutting torches;

4.       Melt thru Welding: This is “Core of the core” in operating the Flat Butt Welding Machine: Welding current/ welding voltage/ wire feeding speed.

D.      Tips on Operating Plate Butt Joint Welding Machine:

1.       Preparation Work for Running Plate Flat Joint Butt Welding Machine:

1)       Operator should be familiar with all the buttons/ selection switches of Plate Flat Joint Butt Welding Machine;

2)       Make sure all the components/ Subassemblies of the Flat Butt Welder are in normal state for running;

3)       Modulate process parameters of triple cutting/ butt welding in the Plate Butt Joint Welding Machine;

4)      Switch on supply of preheating oxygen/ cutting oxygen/ acetylene or propane and adjust its pressure based on thickness and chamfer type of the workpieces in Plate Butt Joint Welding Machine:

a)       0.5 ~ 1.0 MPa for preheating oxygen;

b)       1.0~ 1.2 MPa for cutting oxygen;

c)       0.25 MPa for Acetylene;

5)       Start on water cooling system for copper pads, and adjust water pressure (0.2~0.4 MPa);

2.       Material Handling in Flat Butt Welding Machine:

1)       Logic Interlock: To fully make sure safety operation on the Flat Butt Welder, and best quality delivered, in control system of Plate Flat Joint Butt Welding Machine, there are interlock logic between input and output conveyors and function units;

2)       For example, when the working mode selection switch is at “Cutting” or “Welding”, managing input and output conveyors is invalid;

3)       Operator should understand and follow these logics for proper handling and position control on plates;

3.       Flame Triple Cutting Technology in Plate Flat Joint Butt Welding Machine:

1)       Based on thickness of metal plates, triple cutting in the Flat Butt Welder can be divided into two broad groups of (thinner than 28mm) and (between 28mm and 40mm) of metal plates;

2)       We give detailed instruction on pressure and flames adjustment in manual book of the Plate Butt Joint Welding Machine;

4.       Melt Thru Welding in the Flat Butt Welding Machine:

1)       Two layers of dedicated welding flux need to be deposited on the copper pads, and on the workpieces respectively;

2)       Two layers welding flux are of different grade, which we give recommendation based on accumulated empirical data and years of experience on Flat Butt Welder, which varies on material and thickness of metal plates;

3)       Also, we will give a rule of thumb on suggested key process parameters including Butt Joint clearance/ Welding current/ Welding Voltage/ Wire feeding speed in manual book of the Plate Butt Joint Welding Machine.

E.        Summary on Wuxi JACK Flat Butt Welding Machine:

1.       Operation of MP series Plate Butt Joint Welding Machine involves series of skill/ technique/ experience on machine itself and process technology;

2.       Ss leading producer of Flat Butt Welder, Wuxi JACK is willing to share technical know-hows to customers worldwide who have demand and interest on it.