无锡洲翔成套焊接设备有限公司

ISO9001
certificate

Please read carefully before operating

H-beam Assembling, Welding

and Straightening Machine
PHJ0820

Wuxi Zhouxiang Complete Set of Welding Equipment Co., Ltd

Address: Donghu Industry Garden, Donggang Town, Wuxi City, Jiangsu, China
TEL: 0086-510-88794887 FAX: 0086-510-88791142
EMAIL: [email protected] ZIP: 214196
无锡洲翔成套焊接设备有限公司
 无锡洲翔成套焊接设备有限公司

Ⅰ. Summary
The welded H beam is welded by two flanges which on the up and down side and a web in
the middle side ,the normal H beam welding line is composed of assembling
machine 、 gantry type welding machine 、 straightening machine and other machines.
Thought the producing line can satisfy the technical requirements for welding the H beam,
it asks the more machines, and the production efficiency is low.
Assembling, welding and straightening integral machine is combines the assembling,
welding, straightening into one machine, reduce cost, save the installation space, improve
productivity.
Ⅱ. Main technical parameter
2.1 H beam spec. (Unit: mm)
flange plate width web plate height web thickness flange thickness
200~800 200~2000 6~14 6~20
2.2 Power (excluding welding power and wire feeder)
main transmission power ： 3 kW
main driving rolling power ： 0.75 kW×4
the flux recycling power ： 3 kW×2
Hydraulic pump power 5.5 kW
2.3 Welding speed： 0.35-3 m/min
2.4 Working pressure of hydraulic system：10MPa
Ⅲ. Structure and feature
3.1 Structures:
Assembling, welding, straightening integral machine is composed of main welding
machine, straightening device, pre-centering device, driving roller, idle roller, driving
elevating roller, hydraulic system, and electric control system and welding power.
The main welding machine is composed of base, main transmission device, flange and
web clamping device, frame upper-press device, welding torch adjust device, feeding
device and electric conduction device.
Machine base is composed of structural steel and plate steel, fixed with transmission
roller, flange and web clamping system, welding torch adjust device, wire feeding device,
electric conduction device and so on. Below the base fixed with transmission shaft, chain
wheel cycle chain.
Main transmission system is drove by one speed reducer with chain wheel cycle chain and
transmission shaft, making the main transmission roller and the lower straightening wheel
rotating, it adopts frequency control of speed and can adjust the speed within
0.35-3m/min.
Flange and web clamping device is the key component to the precision of assembling and

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welding, it adopts hydraulic motor to drive two sets of worm reducer, each worm reducer
drives one set of gear transmission device which drives of two symmetrical flange and
web clamping device, thus, the forward and reverse screw and nut in the symmetrical
flange and web clamping device can push the flange and web of the work piece to center
of the main machine.
Frame upper-press device adopts oil cylinder to push the upper-roller to clamp the work
piece, the moving of the elevating beam adopts the pulley guide rail structure which can
make the moving more stable.
Welding torch adjust device is mainly used to adjust the position of two welding torches,
so that the welding torch can aim the welding seam accurately, two torches can staggered
at a fixed distance an the same time (about 140mm). The oil cylinder on the welding torch
which is fixed 45°can control the torch to approach or leave the welding seam.
Wire feeding device is used to fix wire reel, and feed wire into the welding torch. Axle of
wire reel has the function of damping to prevent the welding stick getting debouched.
Electric conduction is placed below the main transmission roller, it can connecting the
welding loop to prevent the welding current from burning the bearing.
The assistant straightening device is fixed in front of the machine to straighten the flange.
It is composed of upper straightening roller, lower straightening roller, and flange
centering device. The upper roller uses hydraulic cylinder to push eccentric shaft and
clamp the web of work piece. The lower straightening roller is drove by the main chain.
Upper straightening device can move according to the width of the flange, the screw and
the nut can fix moving position through the position displayer.
Pre-centering device is used to centering the flange and web before assemble, which is
placed on the input end. It adopts oil cylinder to push the relevant flange and web turning
arm, and make the guiding wheel to toward the surface of work piece.
Input and output ends of the main machine are equipped with different input rollers. On
the input ends is equipped with 2pcs of driving roller and 1pc of idle roller. On the output
ends is equipped with 2pcs of elevating driving roller and 1pc of idle roller. Driving
elevating roller can still hold the work piece after the deformation.
Hydraulic system controls the elevating of upper-pressure cylinder, the elevating and
clamping of oil cylinder, forward and reverse turning of the flange and web motor, moving
of welding torch, the elevating of oil cylinder, clamp and tense of straightening assistant
and straightening cylinder. The clamp and tense of pre-centers oil cylinder.
3.2 Structure features：
3.2.1 The main body of assembling and welding adopts automatic cantering structure
which is transferred by hydraulic motor gear of new type assembling machine, improving
the reliability and precision of transmission.
3.2.2 The auxiliary body of straightening adopting hydraulic cylinder driving eccentric

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shaft structure makes sure compact structure, big strengthening force, and convenient
adjustment.
3.2.3 The output end adopts active lift roller, in order to adapt the transmitting work piece
after welding deformation.
Ⅳ.Operation and working
4.1 Plate blank of the flange is put on the input roller by traveling cart, starting “flange
fasten” switch of the pre-centering system, making the guide pulley of the flange and the
edge of the flange contacted.
4.2 Plate blank of the web is put on the flange, starting “web fasten” switch of the pre-
centering system, making the guide pulley of the web and the edge of the web contacted.
4.3 Press down “main roller forward” button, the web and the flange forward the
strengthening auxiliary position at the same time. The web and the flange end are aligned
by manual. (Or can be aligned by the flange guide roller of straighten device)
4.4 Press down “clamp flange” and “clamp web” buttons to fasten the work-piece.
4.5 Press down “loosen flange” and “loosen web” buttons to loosen the work piece a litter.
4.6 End of flange and web is aligned by manual. (Or can be aligned by the flange guide
roller of straighten device)
4.7 Press down “clamp flange” and” clamp web” buttons again to fasten the work piece.
4.8 Adjusting the welding gun position, starting welding gun moving button, and making
the welding gun approach the welding seam.
4.9 Press down “automatic circle” button, and the electric control system will start to work
according to the preset program, starting automatic spot welding forming. When the end
of the steel breaks away the flange fastening pulley, the upper pressure roller will loosen
automatic. And this moment turn the “automatic circle” to “manual operation”, finishing
the last spot welding about 700mm distance.
Notes:
1) Before the work piece leaves the clamping device, you should switch the “manual
operation” mode, in order to avoid dangerous.
2）When workpiece’s web height is larger than 1800mm, assistant support device should
be used.
3) When workpiece’s web height is less than 650mm, upper press cylinder should add
extension bar.
4) Increasing bars of the upper pressure cylinder once the height of work piece is less than
400mm.
Ⅴ. Maintenance
5.1 Maintenance requirements
1. The position of operator and machine is relative fixed; the operator should be trained,
and know the operation processing and machine performance.

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2. Forbidden operating the machine not according to the rules, it’s not allowed to assemble
the H-beam size which is exceeding the machine capacity.
3. All the rotating and sliding parts should be added with lubricating oil, all the screws
should be tight.
4. In daily working, machine should be tested first, and start to work after machine runs
well.
5. Keep the machine clean, nothing can be put on the machine. And no person stands
before the machine during work. Not to start the machine without right operator.
5.2 Maintenance points
1. Check the machine in a fix-cycle, when the components are not well, please changes it
in time.
2. The maintenance of hydraulic system refers to the hydraulic drawing. Keep the
hydraulic oil clean, and the oil position is at the 2/3 of oil ruler. Air filter of the hydraulic
system should be kept clean, avoid the block up inside.
5.3 Disassemble and transport
Before transport the hydraulic system, all the related pipes should be disassembled, and
the oil holes should be closed.
5.4 Use instruction:
1. Hydraulic oil NO.: N32
2. Oil position: 2/3 of oil ruler
3. Use 120 mesh strainer when fill the oil to the tank.
4. Change the oil, please note:
1). the oil should be changed when the first 3 months, and after then, it will be 6 months to
change the oil. When under continuous working and high-temperature, dusty environment,
please shorten the cycle time for change the oil.
2). Pull out all the oil and clean the tanks before add new oil into it.
5.5 Hydraulic system pressure adjusted explanation
System pressure
P2 Second
Plate thickness P1 Max pressure MPA
pressure
Number
1 ≥6～10 4～5 2～3
2 ≥10～20 5～6 3～4
Notes: P1 sets pressure of overflow valve. P2 sets pressure of reducing valve.
5.6 Wearing parts.：
1. HZJA20.04-09 upper roller
2. HZJ1020.01.01-13 main drive roller
3. HZJ1020.01.01.10-00 driven roller of main machine

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4. HZJ1020.01.01.09-00 idle roller of main machine

5. HZJ1020.02.04-00 driven roller of conveyor
6. HZJ1020.03.01-00 idle roller of conveyor
7. HZJ1020.01.05-19 guiding roller of web
8. HZJ1020.01.08-04 guiding roller of flange
9. HZJ15.11-14 guiding roller of draw-bar box
5.7 Bearings

No Model Name Qty Installation parts

1 GB/T276-1994 Deep groove ball bearing 6306-2Z 28 Flange and web clamp roller

2 GB/T276-1994 Deep groove ball bearing 6209-2Z 36 Guiding roller of draw-bar box

3 GB/T276-1994 Deep groove ball bearing 6210-2Z 6 Transition of chain wheel

4 GB/T276-1994 Deep groove ball bearing 6207 8 Transmission of web plate

5 GB/T276-1994 Deep groove ball bearing 6210 8 Guiding wheel of door-frame

6 GB/T276-1994 Deep groove ball bearing 6216 12 Draw-bar box

Support roller of main
7 GB/T288-1994 Self-aligning roller bearing 22210 4
machine
8 GB/T288-1994 Self-aligning roller bearing 22214 2 Transmission axle

9 GB/T288-1994 Self-aligning roller bearing 22217 2 Main transmission roller

Transmission of flange and
10 GB/T288-1994 Self-aligning roller bearing 22208 10
web plate
self-aligning roller bearing
11 GB/T288-1994 2 Upper roller
22212C/W33
transmission of flange and web
12 GB/T297-1994 conical roller bearing 32007 20
plate
13 UCP210 unit bearing assembly 48 convey

5.8 Hydraulic sealing element

No Model Name Qty Installation parts

1 JB982-77 Obturating ring assembly 18 36 Get in and out of oil

2 JB982-77 Obturating ring assembly 14 3 For pressure tapping connecting

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3 GB2345-76 O-ring packing 16*2.4 8 Used for Manifold block

4 JB982-77 obturating ring assembly33 2 used for oil suction pipe
5 HG4-335-66 Yx type polyurethane Seal ring D2 100 2

6 HG4-335-66 Yx type polyurethane Seal ring d50 1

7 GB3452.1-82 O -type rubber Seal ring d1 50*3.1 2

upper pressure oil cylinder
8 GB3452.1-82 O -type rubber Seal ring D2 100*5.7 2

9 GB3452.1-82 O -type rubber Seal ring d1 60*5.7 1

10 dust ring d50 1

Yx type polyurethane Seal ring D2
11 HG4-335-66 4
80
12 HG4-335-66 Yx type polyurethane Seal ring d45 2

13 GB3452.1-82 O -type rubber Seal ring d32*3.1 2 oil cylinder of draw-bar box
Ps.2 sets of oil cylinder
14 GB3452.1-82 O -type rubber Seal ring d80*3.1 4

15 GB3452.1-82 O -type rubber Seal ring d60*3.1 2

16 dust ring d45 2

Yx type polyurethane Seal ring D2
17 HG4-335-66 8
40
18 HG4-335-66 Yx type polyurethane Seal ring d22 4 oil cylinder of cutting torch
Ps: 4 sets of oil cylinder
19 GB3452.1-82 O -type rubber Seal ring d22*3.1 8

20 GB3452.1-82 O -type rubber Seal ring D2 40*3.1 8

Yx type polyurethane Seal ring D2
21 HG4-335-66 8
50
22 HG4-335-66 Yx type polyurethane Seal ring d28 4 support the oil cylinder
Ps. 4 sets of oil cylinder
23 GB3452.1-82 O -type rubber Seal ring d28*3.1 8

24 GB3452.1-82 O -type rubber Seal ring D2 50*3.1 8

5.9 Common errors and solutions
1. Shaft of web centering
Cause: transmission screw not mix up

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Solution: disboard the gear cover of transmission screw, loosen transmission screw and
swelling cover, move transmission screw, adjust guiding wheel, intensify swelling cover,
fit on gear cover.
2. Web tilt, out of plumb
Cause 1： Clamping wheel of flange and web and the center line of the upper and down
roller are not in the same plane.
Solution1: adjust the clamping wheel
Cause2: plate is thin; pressure of the upper roller is more
Solution2: smaller the pressure of upper oil cylinder
3. Trouble removal for welder according to operation manual.