With the continuous development of the domestic steel structure industry, H-beam has been widely used in many steel structure plants, airports, high-rise buildings and bridges. H-shaped steel was originally rolled by steel mills, but because of the limited specifications of rolled steel and the price is much higher than ordinary high-quality steel, the welded H-beam has gradually become the preferred structural profile in the design and production of steel structures, welding H-beam The demand has increased significantly year by year. The method of producing welded H-beam by manual mechanical assembly welding is far from meeting the needs of high-speed development of building steel structure due to low production efficiency. Therefore, in order to improve the production efficiency of welded H-beams, it is an inevitable development trend to organize production in the form of automatic production lines.
Since 1994, Wuxi Yangtong Machinery Equipment Co., Ltd. has been producing welding equipment for H-beam assembly, welding, correction and multi-head cutting machines for light steel production. So far, it has been successfully applied in more than 400 user units. At the beginning of 1996, Shanghai COSCO Kawasaki Steel Structure Co., Ltd. first ordered the medium-sized welded H-beam automatic production line from our company. In the first half of the year, the design, trial production and commissioning were successful, and it was put into production normally, and achieved good economic benefits. So far, our company has produced more than ten similar automatic production lines for welded H-beams. The main users are: WISCO Metal Structure Factory, Tangshan 22 Metallurgical Metal Structure Co., Ltd., Zhejiang Zhongnan Group, Shanghai Zhenhua Port Machinery and Shanghai Mingzhu Stone. The actual production application proves that the automatic production line of welded H-beam has achieved the expected results.
First, welding H-beam assembly welding process
The welding process of welding H-beam assembly is in various forms according to the specifications and technical requirements of the H-beams produced. Figure 1 shows a block diagram of a process flow for assembling a medium-sized welded H-beam assembly. The main processes include cutting and unloading, assembly forming, spot welding, automatic welding of fillet welds, workpiece turning, automatic welding of the fillet welds on the other side and flange correction. According to different technical requirements, pre-weld pre-treatment or post-weld shot blasting treatment and correction of cutting blanks can be added.
The working procedure of the automatic production line is as follows:
1 The raw steel plate is suspended from the workshop bridge crane to the cutting platform, and the multi-head cutting machine cuts the steel plate into flange plates and webs of different specifications, which are respectively stacked in the wing and web blank stacking area.
2 Hang a flange plate and web to the input roller of the H-beam assembly point welder, and initially clamp the wing and web by three sets of tie rod clamping mechanism, and input the workpiece into the host by the active input roller. The workpiece is accurately positioned and centered and automatically spot welded according to a predetermined procedure.
3 Turn the T-shaped steel input inverting bracket formed by point solidification to 90°, and then lift another wing and T-shaped steel to the input roller by crane, repeat the same procedure above, and automatically fix the assembly into H-shaped steel.
4Assembled point forming H-shaped steel is fed into the translation machine 1 and 2 of the A welding zone by the conveying roller. The lifting device of the translation machine lifts the H-shaped steel off the roller surface and feeds the steel into the welding machine 1 The bracket is turned over, and then the translation machine is separated from the workpiece. The workpiece is rotated by 45° by the flip bracket, so that the seam is in the boat shape, and the first fillet weld is welded by the single arm welding machine.
5 After the first fillet weld is completed, the workpiece is restored by flipping the bracket, and then the workpiece is lifted by the translation machine into the flip bracket of the second welding machine, and the workpiece is transferred to the 45° ship position, and the second unit is The welding manipulator welds the second fillet weld.
6 After the second fillet weld is welded, the workpiece is sent to the conveying roller by the translation machine, and then the workpiece is fed into the 180° chain turning machine by the conveying roller, and is turned 180° and then sent to the B welding zone by the conveying roller. .
7 Repeat the same working procedure as the A weld zone to automatically complete the welding of the two fillet welds on the other side.
8 After the last fillet weld is welded, the workpiece is sent to the hydraulic flange corrector by the hydraulic conveying roller to correct it until the standard tolerance is specified.
Second, processing steel specifications
H-shaped steel flange plate width: 200 ~ 800mm
H-shaped steel flange plate height: 200 ~ 1200mm
H-shaped steel flange plate thickness: 6 ~ 40mm
H-beam length: 4000 ~ 15000mm
Third, the technical characteristics of the main equipment of the production line
1. CNC / multi-head straight flame cutting machine
CNC/multi-head straight flame cutting machine is a high-efficiency cutting and cutting equipment specially used for cutting steel plates into different width slats. It consists of T-frame, longitudinal rail, longitudinal and lateral moving drive mechanism, gas supply system, electrical Control system, torch holder and adjustment mechanism and torch. Adopting rack and pinion transmission, the walking and cutting are stable.
The track span of CNC/multi-head straight flame cutting machine can be selected from 3000~9000mm. The length of the track can be designed according to the length of the steel sheet feed, usually between 12 and 15 mm. The number of torches can be selected according to user requirements.
2.H-shaped steel assembly machine
The H-beam assembly machine features vertical assembly and solidification, which overcomes the problem of low assembly qualification of traditional horizontal assembly and solidification methods. The H-beam assembly point solid-welding machine designed by our company is automatically set by the gantry and positioning pressing mechanism, the tie rod clamping mechanism, the main drive system, the input roller, the output roller, the hydraulic system, the electronic control system and the CO2 gas protection. The welding machine is composed of eight parts.
The biggest feature of this machine is that the positioning of the wing plate and the web is hydraulically driven, and the left and right sides are mechanically clamped and centered synchronously, which can ensure the automatic and accurate positioning of the wings and webs of different widths. The entire assembly and spot welding process is fully controlled by the programmable logic controller (PLC). The solder joint length, welding speed, separation distance and the speed of the idle movement between the two-point welding can be preset.
3. Single arm welding machine
Submerged arc welding of four fillet welds of H-beams can be carried out by four single-arm welding machines, and the fillet welds 1, 2, 3, and 4 are welded in sequence. It is also possible to use a gantry type welding machine to weld two fillet welds of two H-beams at the same time. The welding H-beam automatic production line described in this paper is equipped with 4 single-arm welding operators, and its advantages are more suitable for the rhythm of the flow operation.
The single-arm welding operation machine is composed of a trolley body, a column, a beam, a skateboard running mechanism, a motor drive system, a welding gun tracking mechanism, a flux conveying recovery system, a welding head, a welding power source, and an electric control system. 2.
4. Chain flip machine
The chain-type turning machine is designed to invert the H-beam to be welded to the required position and prevent the workpiece from being distorted during the turning process. The turning machine is composed of two bases and four uprights. Each of the columns is equipped with a driving mechanism, and the main motor drives the sprocket through the cycloidal pinwheel reducer. Two upper pulleys are mounted above the sprocket, wherein the upper pulley is mounted on the swing arm. The role of the upper pulley is to change the direction of movement of the chain and the position of the chain. Two guide wheels are mounted on the lower part of the sprocket to increase the wrap angle of the chain on the sprocket, so that the sprocket can transmit power to the chain more effectively. A lower pulley is also mounted under the sprocket to change the position of the weight of the end of the chain. A swing arm and a weight device are arranged on the upper part of the column, and the function is to rotate the swing arm downward by an angle when the workpiece needs to be turned over. When the flipping is not required, the swing arm is lifted and the chain is loosened to facilitate the front and rear conveyance of the workpiece.
The two bases and the four uprights form a whole, and the workpiece is raised, lowered, inverted (180°) and the chain is reset by different combinations of the rotation directions of the active sprocket of each column. Each chain has a weighted block at the end so that the chain does not slip out due to external forces. There is also a travel switch on the column to avoid malfunction due to misoperation.
5.H-shaped steel flange correction machine
The H-shaped steel flange correction machine is composed of a base, a frame, a drive roller, a motor drive mechanism, an upper roller set, a lower pressing mechanism and a guide roller. It is mainly used for the correction of the angular deformation of the flange plate after the H-beam is welded. The straightening pressure is applied to the two sides of the flange by the two sets of upper and lower rollers to cause plastic deformation in the opposite direction during the continuous feeding process. Complete continuous correction of the H-beam flange.
The main operation steps of the H-beam flange correction machine are as follows:
(1) According to the width and thickness of the H-beam flange to be corrected, the position of the frame is adjusted, so that the correcting hole type formed by the upper roller and the driving roller meets the requirements of correction.
(2) According to the thickness of the web and the amount of longitudinal deformation, the guide roller is adjusted to the correct position so as not to be subjected to excessive axial force.
(3) After the correcting hole type is adjusted, the main motor is driven to drive the driving roller, so that the corrected H-shaped steel is sent to the straightening machine for continuous correction of the flange. When the flange thickness exceeds 25 mm, it is usually necessary to make multiple round trips to meet the standard requirements.
Fourth, H-beam automatic production supporting equipment
With the rapid development of the steel structure industry, the quality requirements for steel structure manufacturing are getting higher and higher. Especially the surface treatment before welding of H-beam after welding has become an important process in the production of steel structures. In response to this situation, the company developed the H-beam shot blasting machine at the end of 1998. It adopts the continuous conveying and cleaning method of the roller conveyor. The degree of automation is high, the surface cleanliness can reach Sa21/2, and the roughness is reached to make the H-beam paint. It is firmly attached and solves the anti-corrosion problem of H-beam. At present, the equipment has been applied in nearly 60 steel structure production plants and achieved good results.
V. Conclusion
(1) Many years of production practice has proved that the automatic production line of welded H-beam designed and produced by our company has greatly improved the production speed of welded H-beam. The dimensions and weld quality of the welded H-beams produced are in full compliance with relevant industry standards and professional standards, and are worthy of promotion and application.
(2) The welded H-beam automatic production line is a low-cost automated production equipment that can obtain considerable economic benefits, and can usually fully recover equipment investment within two years.
(3) Various improvement schemes can be adopted according to the needs of users, so that the equipment and production process layout of the welded H-beam automatic production line are more reasonable, the production efficiency is higher, and the welding quality is more easily guaranteed.
(4) For the production of high-quality welded H-beams, the automatic production line process should increase the pre-weld pre-weld or welded H-beam post-weld cleaning treatment and set up the corresponding shot blasting equipment.
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