1 Plate Butt Joint Welding Machine 4

Wuxi JACK Steel Plate Butt Joint Welding Machine, Joining Sheet Metals Most Reliably!

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Usage and Huge Value of Steel Plate Butt Joint Welding Machine

A. What can Steel Plate Butt Joint Welding Machine do for Customers:
 

1) The other names include Flat Butt Welding Machine, and Plate Flat Butt Welder, is for performing flat butt joining welding on 2 pieces of steel plates, by means of SAW submerged arc welding, so that a piece of longer and larger steel plate can be got;

2) A piece of longer steel plate joint from 2 pieces of shorter steel plates, delivered from Wuxi JACK MP20 Steel Plate Butt Joint Welding Machine: (Fig.1)

Fig1 Plate Butt Joint Welding Machine 1

 

B. Huge Benefit of Wuxi JACK Steel Plate Butt Joint Welding Machine:

 

1. Improvement on Plate Joining Operation from Wuxi JACK Flat Butt Welding Machine:

1) Simplifies process technology on steel plates joining;
2) Reduces 50% cycle time on steel plates joining;
3) Relieve operators from dangerous and hard jobs of steel plates 180° flipping;
4) Reduce number of operators from 2 people to 1 people;

 

2. Original Way of Plate Joining without Plate Flat Butt Welder:

Without the Plate Flat Butt Welding Machine, joining any two pieces of steel plate involves below steps:
1) First carry out SAW welding on one side of the 2 pieces of steel plate;
2) 180° overturning the half-finished joint plate: This is time consuming step, embedded with potential safety risk, involving 2 operators working together;
3) Implement SAW welding on the opposing sides of the 2 pieces of steel plate;
4) Implement carbon arc gouging on finished joint steel plate;

 

3. Improved Plate Joining Operation from Steel Plate Butt Joint Welding Machine:

Now, with powerful and efficient work of Plate Flat Butt Welding Machine,
1) One Time Going Through: The 2 pieces of steel plate can be beveled and joint with its passing through the Flat Butt Welder equipment, without the necessity of 180° flipping;
2) Only one side of SAW welding is necessary;
3) Only 1 operator is needed to complete the entire operation;
4) Cycle time is only 50% of original,
Delivering consistent and controllable joint seam quality from the Steel Plate Butt Joint Welding Machine;

4. Welding seam on the finished joint plate from Wuxi JACK MP series Steel Plate Butt Joint Welding Machine: (Fig.2)

Fig2 Flat Butt Welding Machine 22

5) Validated welding process control parameters (Welding Current/ Voltage/ Speed) and finished joint seam, acquired from Wuxi JACK Plate Flat Butt Welding Machine: (Fig.3)

Fig3 Plate Butt Joint Welding Machine 54- IMG_6783


 

C. Technical Leading Edge of Wuxi JACK Steel Plate Butt Joint Welding Machine:

1. Technical Know How: One of the core technologies applied in Wuxi JACK steel plate Flat Butt Welding Machine is “Melt-Thru”, which implies “Single side welding and double sides welding seam forming”;
2. This is Wuxi JACK patent technology accredited in 2016, being applied in MP series Steel Plate Butt Joint Welding Machine;
3. Detailed technical introduction on “Melt-Thru” in the steel plate Flat Butt Welder, is available in the product page of “Flat Butt Welding Machine”;

Melt-Thru technique being applied in Wuxi JACK steel plate Flat Butt Welding Machine: (Fig.4)

Fig4 Flat Butt Welding Machine 7

 

4. Summary on this featured product is demonstrated in report slides “The Powerful Wuxi JACK Steel Plate Butt Joint Welding Machine”.


 

 

 

Wide Variety Models of Wuxi JACK Steel Plate Butt Joint Welding Machine

Main Function Units in Wuxi JACK Steel Plate Flat Butt Welding Machine

1 Plate Butt Joint Welding Machine 66
2 Flat Butt Welding Machine 65- IMG_20210405_120345
3 Flat Butt Welder 51- IMG_5978
4 Plate Butt Joint Machine 32
5 Plate Joint Welding Machine 61- IMG_8195
6 Plate Butt Joint Welding Machine 59- IMG_7985
7 Flat Butt Welding Machine 37
8 Plate Butt Joint Welding Machine 16

Primary Components in Steel Plate Butt Joint Welding Machine

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The lefthand scrolling photos: Working cells/ elements/ finished workpieces delivered from Wuxi JACK Flat Butt Welding Machine

 

1. Making Welding Groove in Steel Plate Flat Butt Welding Machine:

1) Necessity: For steel plates with thickness higher than 15mm, welding grooves needs to be made on its edges before joint welding, to get ideal joining effect;

2) This can be made with the triple flame cutting system, installed at incoming side of steel Plate Butt Joint Machine gantry beam;
 

2. Critical: Melt-Thru Welding Unit in Sheet Steel Plate Butt Joint Machine:

1) Importance: This is the central working element in Steel Plate Butt Joint Welding Machine, fulfilling superior quality single side plate joining;
2) Welding Modes: Based on thickness of steel plates for joining, it can be either large current SAW submerged arc welding, or smaller current CO2 gas shielded welding;

 

3. Supplementary Function Units in Sheet Steel Plate Butt Joint Machine:

1) These include all the supporting function cells equipped in the Plate Flat Butt Welding Machine:
2) Such as: Welding power supply/ hydraulic system for steel plates clamp/ Cooling water recycling and refilling tank/ SAW welding flux recycling system, etc.

 

Working Videos of Wuxi JACK Steel Plate Butt Joint Welding Machine

Below are 6 working videos of Wuxi JACK MP series steel Plate Butt Joint Welding Machine. For more videos of this Flat Butt Welder, please visit thematic page “Operating videos of Plate Flat Butt Welding Machine”.

 

Triple Flame Cutting in Wuxi JACK MP20 steel Plate Butt Joint Welding Machine, for 45° V Groove Making on steel plates

Wuxi JACK Patent technology Melt Thru Submerged Arc Welding for Butt Joining Thick Plates in MP25 Flat Butt Welding Machine

Manipulating Melt-Thru Submerged Arc Welding by means of SAW Welding Power Supply Control Console in Wuxi JACK Exported MP30 Plate Butt Joint Machine

Melt-Thru CO2 Welding for Butt Joining on small thickness steel Plates in Wuxi JACK MP25 Flat Butt Welding Machine

Factory Acceptance on Wuxi JACK MP30 Exported Flat Butt Welding Machine, its Groove Flame Cutting function

Factory Commissioning on Wuxi JACK MP50 Exported steel Plate Butt Joint Welding Machine, on Melt Thru Submerged Arc Welding with Human Machine Interface and Control Console

Working Principle of Wuxi JACK Steel Plate Butt Joint Welding Machine

Wuxi JACK Patent Melt-Thru Technology in MP Series Flat Butt Welding Machine:

 

1. Copper Block Pad in Central Welding Unit of Steel Plate Butt Joint Machine:
 

1) The 1st Photo: Copper has good thermal conductivity, which can dissipate heating generated during SAW quickly;
2) As shown in this photo, there are 2 arrays of through holes, machined at lateral sides of the copper pads;
3) Through these through holes, water tubes go through internal side of the copper pads, forming a closed loop circulation;
4) During melt thru butt welding in the Plate Butt Joint Welding Machine, running water flows inside the water tubes, quickly taking away welding heat;

 

2. Hydraulic Drive Clamping Blocks for Tightening Steel Plates Firmly in Flat Butt Welding Machine:

1) The 2nd Photo: This photo reflects on the next step in assembly of melt thru welding unit, in the steel Flat Butt Welding Machine:
2) The black color block right above the copper pads, is used for pressing tightly steel plates to be joint, in the MP models Plate Butt Joint Machine;
3) There are grounding cables assembled onto these pressing blocks;

 

3. Overall View on Assembled Melt Thru Welding Unit in Wuxi JACK Steel Plate Butt Joint Welding Machine:

1) The 3rd Photo gives overall view on welding working table in the Flat Butt Welding Machine;
2) During butt welding in the Flat Butt Welder, the 2 pieces of steel plates will be positioner here, and welding torch move right above joint seam;
3) The flat black color grounding cable has larger contact area than conventional round shape;

 

4. Finished Joint Plate and Welding Seam from Wuxi JACK Steel Plate Butt Joint Machine:

1) The 4th Photo is on a piece of finished joint plate and welding seam, produced from melt through submerged arc welding, in Wuxi JACK Plate Butt Joint Welding Machine;
2) More information on this unique working unit of Wuxi JACK, is introduced in product Water Cool SAW MP20 Plate Butt Joint Welding Machine.

Structure and Layout in Wuxi JACK MP Models Plate Flat Butt Welding Machine

As a comprehensive function Flat Butt Welder, which incorporates triple flame cutting and melt-thru welding, assisted with water cool together with hydraulic clamp, MP series Steel Plate Butt Joint Welding Machine is a kind of sophisticated working complex:

 

1. Complete Working Area of the Flat Butt Welding Machine at Customer Site:

1) The 1st Photo: There is input conveyor at the front side, and output conveyor at the rear side of Flat Butt Welder main frame;
2) Input conveyor of the steel Plate Butt Joint Machine has 2 times length as that of the output conveyor, so as to accommodate joint steel plate;

2. Mechanical Main Frame of Steel Plate Butt Joint Machine:

1) The 2nd Photo is the close distance observance central operating unit;
2) The photo was taken on outlet melt-thru welding side of the Flat Butt Welder;
3) You can find the separately arranged water tank on the workshop floor, which serves as heat radiator for melt-thru welding, during running of the MP series Flat Butt Welding Machine;

3. Oxygen Acetylene Triple Flame Cutting in steel Plate Butt Joint Welding Machine:

1) The 3rd Photo: This is the optional function unit in the Plate Flat Butt Welding Machine, for joining steel plates in the thickness range of 15mm to 40mm;
2) So, this working group has similar function as Edge Milling Machine;
3) You can find Oxy-Fuel gas panel, installed at the incoming lateral side of the Flat Butt Welder main frame;

4. Central Melt-Thru Welding Unit in MP Series Plate Flat Butt Welding Machine:

1) The 3rd and 4th Photos: This is the core unit of the Flat Butt Welder. This unit includes:
2) Welding power supply, which is usually put on overhead platform of machine main frame;
3) There are several brands of welding power supply to choose from, such as: In the 3rd photo it is U.S.A Lincoln brand, and in the 4th photo it is Chinese AOTAI brand equipped for the Plate Butt Joint Machine);
4) SAW welding flux hopper and conveying tubes;
5) Welding flux recovery machine, also laid on overhead platform of the Flat Butt Welder.

Classification and Technical Parameters of Wuxi JACK MP Series Steel Plate Butt Joint Welding Machine

MP Series Plate Butt Joint Welding Machine

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1. Models and Structure of MP Steel Plate Flat Butt Welding Machine:

a) There is only one type of Steel Plate Butt Joint Welding Machine, with stationary mechanical main frame, incorporating both beveling and joint welding function units;
b) Difference among models of Flat Butt Welding Machine lies in below three aspects:

1) Max. Valid Joint Welding Seam Width available from the Steel Plate Butt Joint Machine:

a) Range: From the smallest specification 2000mm (MP20) to the largest specification 5000mm (MP50) Flat Butt Welder;
b) Tailor Made: Any max. metal plate width within this range (2000mm to 5000mm) is available for being special made into steel Plate Butt Joint Welding Machine;
c) Variation: Usually model of the Flat Butt Welder differs on 500mm interval;

2) Available Welding Modes in the Steel Plate Butt Joint Machine:

a) SAW: For joining medium to large thickness (8mm~ 40mm) steel plates, it should be SAW (Submerged arc welding) in the Flat Butt Welder;
b) SAW takes mainstream application in the melt-thru welding mode of the MP models Flat Butt Welding Machine;
c) Joining small thickness plate: As complement, there is small welding current CO2 GMAW for joining small thickness (3mm ~ 8mm) steel plates in Flat Butt Welding Machine. This takes supplementary position in application of the steel Plate Butt Joint Machine;

3) Optional Triple Flame Cutting for Selection in the Steel Plate Butt Joint Machine:

a) When Applicable: If steel plates thickness in the range of 15mm to 40mm, slant edge beveling should be made on edge of steel plate, ahead of melt-thru joint welding in the Flat Butt Welding Machine;
b) Reason on Beveling: This is for getting fully penetration welding effect on medium to thickness sheet metal plate;
c) Beveling Way: For application of steel Plate Butt Joint Welding Machine, beveling can be acquired either with flame triple cutting, or mechanical Edge Milling Machine;
d) Recommended Configuration: For the purpose of compact layout and flexible operation, majority applying cases have this optional flame triple cutting unit equipped in the Flat Butt Welder, installed at the incoming side of Plate Butt Joint Machine mechanical main frame.

 

 

 

2. Standard Models and Technical Parameters of MP Series Steel Plate Butt Joint Welding Machine:

1) The common seen models of the MP series steel Plate Flat Butt Welding Machine are MP20 / MP25 / MP30 / MP35/ MP40/ MP45, and MP50 steel Plate Butt Joint Machine;

2) Below are technical parameters of Wuxi JACK MP20~ MP50 steel Plate Butt Joint Welding Machine:

 Standard Models
 Plate Butt Joint Welding
 Machine
 MP20/ 25/ 30/ 35/ 40/ 45/ 50
 Applicable Width of Metal
 Plates for Butt Joint (Or, Length
 of Butt Joint Welding Seam)
 ≦ (2000/ 2500/ 3000/ 3500/
 4000/ 4500/ 5000) mm
 Applicable Thickness and
 Materials of Metal Plates for
 Flat Butt Joint
 Same for all models:
 Thickness: 6 ~ 40mm SAW,
 2~ 6mm CO2 welding
 Material: Low carbon steel,
 Stainless steel or Al alloy
 Applicable Thickness of
 Straight Edge Butt Welding
 without Beveling
 Same for all models:
 6 ~ 15 mm
 Applicable Speed of Flame
 Triple Cutting for Making
 Welding Groove 
 Same for all models:
100 ~ 800mm/min. A.C. Inverter control, Stepless Adjusted with knob
 Applicable Speed of Melt
 Through Welding
 Same for all models:
200 ~ 1000mm/min. A.C. Inverter control, Stepless Adjusted with knob
 Triple Cutting Torch and Butt
 Welding Torch Idle Speed
 2000 mm/min.
 Constant Speed
 Metal Plate Traveling Speed  2500 mm/min.
 Constant Speed
 Welding Mode  Melt thru Technology of
 Submerged Arc Welding /
 CO2 Gas Shielded
 Length of Single Piece Metal
 Plate for Butt Joint
 6000 ~ 9000 mm (Can be
 special made)

Application Range and Related Equipment of Steel Plate Flat Butt Welding Machine

1. Applicable Industries: MP Series steel Plate Butt Joint Welding Machine is used in industries and projects, when large sizes steel plates are necessary: Steel Structure/ Bridge Construction/ Hoisting Machinery/ Large Diameter Tanks, etc.;
2. Counterpart Machine: In terms of process technology, MP Series steel Plate Butt Joint Machine is the reverse equipment of CNC Strip Plate Cutting Machine, which cuts out steel plate into smaller ones;

3. Supplementary Machine with Steel Plate Butt Joint Welding Machine:

1) Replacement: As we mentioned earlier, for fulfilling plate joining in the Flat Butt Welder with thickness above 15mm, beveling is a must on edges of the steel plate. If customers do not select triple flame cutting into the MP models steel Plate Flat Butt Welding Machine, XBJ series Edge Milling Machine is a recommended equipment;
2) Similar Equipment: As for the Oxy-Acetylene triple cutting itself in the MP Series steel Plate Butt Joint Welding Machine, it has the same working principle and manner as conventional Flame Triple Cutting Machine.

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Put into Use on Sheet Metal Steel Plate Butt Joint Welding Machine

The successful running of steel Plate Flat Butt Welding Machine involves below 5 general steps and preconditions of:

 

1. Knowledge and Skill Necessary for Running the Plate Butt Joint Machine:

1) The 1st photo: This includes operating panel of the Plate Butt Joint Machine. And control console of SAW or GMAW welding power supply equipped in the Flat Butt Welder;
2) The 2nd photo: Ability to operate on flame triple cutting (Adjust cutting gas pressure) and modulate melt-thru welding process control parameters, during daily operation of the steel Plate Flat Butt Welding Machine;


2. Load in workpieces steel plates onto input conveyor of the steel Plate Butt Joint Machine;

 

3. Machining Melt-thru Welding Groove on Edges of Medium to Large Thickness Steel Plate in the Flat Butt Welding Machine:

1) Here we emphasize that, for the 2 pieces of steel plates to be joint in the Flat Butt Welder, please note that for the 1st piece of steel plate, it is the front edge need to be beveled;
2) And for the 2nd piece of steel plate, it is the rear edge need to be beveled;


4. The 3rd photo: Make adjustment on position of the 2 pieces of steel plate, so that the joint seam are located right below welding torch of the steel Plate Butt Joint Welding Machine;

 

5. Carry Out Melt-thru SAW Submerged Arc Welding in the Plate Flat Butt Welding Machine:

1) The 4th photo: The above listed steps are just the general guide on operation of the Flat Butt Welder;
2) Quality Management: Wuxi JACK takes series of measures, including welding torch position management/ laser tracing on welding torch/ welding wire straining..., to fully guarantee performance level of MP Series Plate Butt Joint Welding Machine.

 

 

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Other Series of Wuxi JACK Products besides Steel Plate Butt Joint Welding Machine

Flat Butt Welding Machine Blogs

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