Suitable work piece web height h:  200-1500mm

● Suitable work piece web thickness a:     6-32 mm

● Suitable work piece flange width b:      200-800mm

● Suitable work piece flange thickness s:  6-40 mm

● Suitable work piece length:            4000-15000mm

● Assembly 、welding and straightening speed:   0.2-2m/min

● Welding manner:  Flat fillet weld at two sides, welding joints height ≤8mm

● Input conveyor:                              2600mm/section, 3sections conveyorsï¼Âˆone is drive conveyorï¼Â‰

● Output conveyor:                           10m (Inc. Elevating type conveyor)

● Machine power:                             mainframe: about 20kW, SAW welder: 80kw×2sets

2. Structure character

PHJ15 H-beam Assembly-Welding-Straightening Integrating machine is an advanced and high efficiency equipment for welding H-beam production, integrating precision assembly, stable SAW welding, flange deformation straightening and welding of H-beam together. It has merits of compact structure, small area occupying, high automatic and high productivity. It mainly consists of assembly unit、welding unit、straightening unit、conveyor、hydraulic system and electrical control system, etc.

2.1 Assembly unit:

There is 1 each centering positioning clamp unit of web and flange set, adopts mechanical interlocked unit realizing synchronization motion, one side is located by lead-screw while the other side clamp by hydraulic pressure, lead-screw position is measured by rotation encoder and digital display shows the data. The clamping for wed and flange is powered by hydraulic cylinder, not only with powerful strength, but also adding flexible of web and flange clamping to accommodate flange width varies caused by cutting or other reasons and web thickness varies due to web prolong welding seam by means of automatic retraction to avoid work piece block.  

There are 3 sets web and flange initial centering pulling rod at the end of input conveyor, when hoist the flange and web to main machine, it can make initial automatic centering for the central line of machine and support the web, avoiding swing or overturn of web and increasing the safety rate of operation.

The swing block rack at the end of H-beam assembly input can ensure the end alignment of web and flange when assembling.

2.2 Welding unit

The main machine of Assembly-Welding-Straightening Integrating Machine adopts flat welding to weld I-beam and H-beam, each one set of SAW power at both sides. It adopts seam mechanical tracing, tracing welding of both seams at both sides at same time.

Welding system collected by U.S.A LINCOLN DC-1000 power source and NA-3S control box and wire feeder, which adopts twin arc welding technology to achieve high welding efficiency and reliable quality.

There are 2 sets welding flux automatic feeding and recovering unit, which can improve the welding automatization level.

Welding speed, that means work piece transportation speed adjusting by variable frequency way, choose the reasonable weld speed according to welding technology.

2.3 Straightening unit:

There will be distortion of H-beam flange for heat radiation, continuous roller press straightening after seam cooling and solidification. The straightening specification of work piece that is straightening capacity refer to Fig1 and the table below ( work piece material is Q235, tensile strengthσb=400Mpa, the other material can adjust suitable according to material tensile strength. For example, when tensile strength isσb=600MPa, s=400/600=0.667, the flange width, flange thickness will be 0.667 times of figure in the following table):

The lower straightening roller drives work piece forward when the upper roller straighten work piece by pressing downward. The straighten capacity can be adjusted accordingly to flange thickness and deformation condition to make continuous roller press straightening.   

All straightening rollers are made by good quality alloy steel, and finished by advanced heat-treating to avoiding the defect of creating cranny easy, ensuring stability and long time using of straightening.

The straightening speed is same as assembly speed, which are driven by the same motor reducer and controlled by variable frequency speed controller.

The hydraulic elevation conveyor is set at the output side, which can be elevated to certain height according to deformation of welded H-beam and support the work piece to finish the whole assembly, welding and straightening process.

Straightening speed and assembling speed is same, driven by same motor and reducer, and adjusted by inverter. The speed of drive motor is adjusted via Japanese “MITSUBISHI” A.C. inverter. Hydraulic system equipped with fine filter is the standard product of professional producer, which ensures the long and reliable performance of solenoid valves.

Supply range

● Assembly unit inc.: Mainframe, upper gantry, web and flange clamp and center positioning system, drive unit, etc.

● Input conveyor inc.: drive and idler conveyor 2.6m×3sets, 3sets web and flange initial center positioning pulling rod.

● Output conveyor inc.: Elevating type conveyor 10m

● Hydraulic system inc.: Oil pump station, high-pressure tube, hydraulic cylinder, etc.

● Electric system inc.: Electric cabinet, PLC encoder, AC inverter, control box, etc.

● Welding unit inc.: 2 sets U.S.A. Lincoln DC-1000 welder, 2 sets flux feeding and recovery unit

● Straightening unit       Inc.: 2sets upper straightening roller, lower straightening roller and reducer

● Spare parts        1 set

Technical documents

● Operating manualï¼Âˆinc. electrical diagram、hydraulic diagram, etc.ï¼Â‰

● PLC manual, inverter manual, hydraulic pump station manual, SAW welder manual

● Delivery list

● Certificate

● Foundations drawing

Key station

● Inverter:                               Japan Mitsubishi

● PLC:                  Japan Mitsubishi

● SAW welder:                          U.S.A LINCOLN