1. Purpose: This page is originated from introduction slides on our I H Beam Production Welding Line. It is for quick review on Usage/ Workpiece Specifications/ Technical Strong Points/ Process Technology/ Layout and Main types of Machine for H Beam Production, deployed in Wuxi JACK delivered I H Beam Line;
2. Goal: We expect this page of slides can be helpful to anyone who have interest on I H Beam Line and related equipment, and want to spend the least time to get a general picture on involved Machine for H Beam Production, either for the purpose of successful and high rewarding purchase, or just plan to have an overall idea first.
1) Finished Workpieces: As its name suggests, I H Beam Line produces welded T/ I/ H Beam of light/ medium/ heavy duties, from the minimum 200mm web height, to the maximum 3000mm web height. These are the primary and fundamental workpieces applied in Steel Structure industry:
2) A piece of large welded H Beam, being manufactured from Wuxi JACK SAW welding Machine for H Beam Production: (Fig.1)
a) Z15/ Z18/ Z20 I H Beam Assembly and Tack Welding Machine;
b) LHC/ LHA/ LHT I H Beam Submerged Arc Welding Machine;
c) HYJ800/ HYJ40 motor drive, and YTJ40/ YTJ50/ YTJ60/ YTJ80 hydraulic drive I H Beam Flange Straightening Machine;
d) DX15xx series I H Beam End Face Milling Machine;
2) New Generation Machine for H Beam Production: Over the past 2 decades, there is a kind of newly developed efficient, compact and cost effective Equipment: PHJ and ZHJ models 3 in 1 H Beam Assembly Welding Straightening Integral Machine (H Beam 3 in 1 Fabrication Machine). This machine has numerous advantages in replacing traditional H Beam Production Welding Line, for producing light and medium duty welded T/ I/ H Beams;
1) Meanwhile, in the field of producing heavy duty welded H Beam, the long term applied H Beam Production Welding Line still is the solitary solution for steel structure customers:
2) Here, heavy duty welded H Beam means welding seam bigger than 12mm on finished T/ I/ H Beam, and needs to be completed with more than single time welding pass on finished working parts;
3) Such process technology entails application of 45° fillet welding in I H Beam Submerged Arc Welding Machine, which is the 2nd set of Machine for H Beam Production in traditional I H Beam Line:
4) 45° fillet welding on producing H Beam, in Wuxi JACK Submerged Arc Welding Machine for H Beam Production: (Fig.2)
Based on internal material transferring way among assembly/ welding/ straightening working zones of Machine for H Beam Production, the I H Beam Line can be classified into 2 general types of automatic and semi-automatic:
1) Feature: Workpieces flow through work stations by means of logistics units: Overturning equipment: 60°/ 90°/ 180° stationary or motor drive moving type, steel conveyor, etc.; The entire welded H Beam production is implemented fully automatically;
2) Advantages: Automatic I H Beam Line has the least degree of human intervention. WIP (Work In Progress) workpieces are manipulated for operation under machine control. The entire process is fulfilled with fully automatic and safe mode;
3) “Disadvantage”: Automatic I H Beam Line involves relative larger workshop land occupation and more investment on equipment and Machine for H Beam Production. Besides, update on its layout involves longer time;
1) Feature: The 3 core types of Machine for H Beam Production: Assembly/ welding/ straightening are arranged individually and flexibly;
2) Material Flow: WIP workpieces flow through H Beam Production Welding Line with operator hard job, with the help of traveling crane/ travel cart, and other types of overturning equipment;
3) Business Advantages: Compared with automatic line, semi-Automatic I H Beam Line has smaller land occupation, more flexible layout, and less investment. It is more applicable for MGPP (Multi-Generation Production Plan) on introducing Machine for H Beam Production step by step at customer site.
For deep down exploration on technical details of Wuxi JACK various Machine for H Beam Production, are introduced in product pages of:
1) I H Beam Production Welding Line;
2) Automatic and Manual I H Beam Line;
3) Equipment and Machine for H Beam Production;
4) H Beam Assembly Machine;
5) H Beam SAW Welding Machine;
6) H Beam Straightening Machine;
7) Steel Structure Overturning Equipment
1. Finished Welded H Beam Sizes: There are standard models HB1500/ HB1800/ HB2000, which produces 3 grades of Max. welded T I H Beam: Max. web height of 1500mm/ 1800mm/ 2000mm;
2. Selling Volume: Of which, the 1500mm web height grade (HB1500) model produces the most widely applied welded H Beam, and has the widest application;
3. Special Models: For customer special demand, and with special design, Wuxi JACK also produce I H Beam Production Welding Line, with finished welding H Beam up to 3000mm web height;
4. Strong Points: This page of slides also lists main superiorities of Wuxi JACK I H Beam Line. In general, this turnkey project builds up a modern workshop for Steel Structure manufacture at customer site;
5. Business Case: The photo in this page of slides presents a line of HB1500 fully automatic line, exported by Wuxi JACK to a Russian client in the year 2014.
1. The 1st Step: 1st Operation Plate Cut Off with CNC Strip Plate Cutting Machine:
This page of slides gives typical layout of I H Beam Line, which occupies workshop land area in the range of 2000 m2 to 5000 m2:
The four sets of central Machine for H Beam Production in the sequence of material flow:
1) I H Beam Assembly and Tack Welding Machine;
2) I H Beam SAW Welding Machine;
3) I H Beam Flange Straightening Machine;
4) I H Beam End Face Milling Machine;
Are installed according to process technology, so that H Beams can flow work stations of I H Beam Line along the shortest path;
2. CNC Strip Plate Cutting Machine, which is a kind of more general purpose 1st operation equipment, which is not confined to I H Beam Line use, is arranged in another span along side the main trunk of H Beam Line. There is also carbon steel plate raw materials storage area;
1) The minimum required least area is: 95m length x 24m width (2 arrays of 11m span, together with 2m width walking passage) = 2280m2;
2) The ideal occupied area is: 200m length x 24m width= 4800m2.
CNC Strip Plate Cutting Machine and I H Beam Assembly and Tack Welding Machine:
From this page of slides, photos of main Machine for H Beam Production are pasted in sequence:
1. CNC Strip Plate Cutting Machine:
1) Working Nature: As mentioned previously, this machine is kind of universal equipment, which can be served in not only I H Beam Line, but also in other process technology;
2) Running Position: CNC Strip Plate Cutting Machine is deployed at start working station of I H Beam Line: 1st Operation zone;
3) Varied Specifications: There are numerous configurations of CNC Strip Plate Cutting Machine, divided on: Max. valid cutting width (Gantry span)/ Cutting way (Flame or Plasma)/ Cutting torch quantity, etc.;
4) Model for being applied in I H Beam Line: The CNC Strip Plate Cutting Machine is usually with model and configuration of: CNC-CG4000 (4000mm span of cutting rails), Oxygen flame cutting, 9 sets of strip cutting torches, and 2 pieces of CNC cutting torches;
2. H Beam Assembly Machine:
1) Significance: This is the first set of central Machine for H Beam Production;
2) Technical Specialty of I H Beam Assembly Machine is high precision: Controlled with PLC (Programmable logic controller) and A.C. inverter, for managing on H Beam fitting up steps and working velocity, accuracy and reliability of H Beam assembling operation is fully guaranteed;
3) Sophistication: I H Beam Assembly and Tack Welding Machine is a “complicated” equipment: Hydraulic drive on workpieces alignment, PLC control on logic working, and A.C. inverter for managing on working speed control.
I H Beam Assembly and Tack Welding Machine, plus I H Beam SAW Welding Machine:
I H Beam SAW Welding Machine and I H Beam Flange Straightening Machine:
1. Closer View: In this page of slides, the LHC trolley moving I H Beam Submerged Arc Welding Machine can be observed in closer distance and more clear view: The H Beam is laid onto a group of hydraulic drive 60° Overturning Racks, for performing on 45° fillet welding on H Beam;
2. I H Beam Flange Straightening Machine:
1) This is the 3rd set of essential Machine for H Beam Production;
2) There are 2 general groups of I H Beam Straightening Machine:
a) HYJ series motor drive, for straightening on medium duty H Beam: Flange Max. thickness of 40mm, with tensile strength 510 MPa;
b) YTJ series hydraulic cylinder drive, for straightening on heavy duty H Beam: Flange Max. thickness of 80mm, with tensile strength 600 MPa;
3) Model in This Slides: In the right side photo is a set of HYJ-800 motor drive I H Beam Straightening Machine. It is the largest selling model of straightening Machine for H Beam Production.
I H Beam End Face Milling Machine and Hydraulic Drive 60°/ 90°/ 180° Overturning Equipment:
1. DX Series I H Beam End Face Milling Machine:
1) Wide Application: Besides being applied in I H Beam Production Welding Line, I H Beam End Face Milling Machine can also be used on many other kinds of steel structure workpieces: BOX Beam/ Cross Beam/ Pipe/ Special shape structure members... etc.;
2) Applicable Models for H Beam Production: When used in I H Beam Line, the often selected models of machine are DX12xx (Such as DX1215), or DX15xx (Such as DX1520);
2. Business Case on Wuxi JACK CNC I H Beam End Face Milling Machine:
1) This page of slides (Left side photo) shows a complex of Milling and Facing Center exported from Wuxi JACK to Belarus in the year 2014;
2) As can be observed from the photo, there is H Beam being clamped with several hydraulic clamp tables: This machine group is also applied in H Beam Line;
3) The Milling and Facing Center is Composed of:
a) 2 sets of CNC-DX1540 CNC I H Beam End Face Milling Machine;
b) 2 sets of tailor made turning tables;
c) 5 sets of tailor made hydraulic drive workpiece clamp tables;
This page of slides (Right side photo) also reflects on working moment of motor drive moving hydraulic 90° Overturning Equipment, working at SAW welding station.