Product Description
We have absorbed the advanced technology of developed countries such as the United States, Japan, and Australia, and combined it with the specific conditions of my country's raw materials to copy and develop. The main machine of the pressure welding machine uses a welding power supply and a press machine in one, which greatly reduces the ineffective loss of electric energy [saving more than 30% of electricity than the main machines produced by developed countries in the world] (depending on the specifications), and most of the rest are designed and manufactured using Japanese technology.
2. Technical parameters
Input voltage 3-phase 380V±10% 50Hz
Rated input capacity 250KVA
Rated input current 365A
Rated pressure of compressed air 0.6Mpa
Cooling water flow >60L/min
Cooling water inlet temperature ≤30ºC
Production steel grating specifications
| Length × width (mm) |
6000×1000 (customizable) |
| Load flat steel spacing (mm) |
30, 40 (customizable) |
| Welding cross bar spacing (mm) |
50, 100 (customizable) |
Raw material specifications
Load flat steel width (mm) 25-60 (customizable)
Load flat steel thickness (mm) 2.5-6
Load flat steel length (mm) ≤6000
Cross bar (twisted steel) size (mm) (5×5-8×8)× 1050
Working cycle ≤2 /15 seconds (excluding welding time)
Welding parameter setting segment number: 3 segments Pulling parameter setting segment number: 20 segments
3. Function
Manual alignment of crossbars (twisted steel) and manual feeding.
Manual positioning and manual feeding of flat steel.
Automatic conveying of steel grating.
Automatically weld two crossbars each time, and automatically control the crossbars after 4-8 weldings.
Automatic correction of longitudinal welding deformation.
The operating table has two selection modes: manual and automatic.
The electric cabinet has a primary current and voltage display device.
The welding parameters can be set and stored in the PLC (power off will not be lost), and various parameters are intelligently set and digitally displayed.
3. Structure, features and uses of pressure welding machine
This welding machine is an automatic production line composed of several mechanical and electrical equipment. It inputs load flat steel and crossbar (twisted steel) and outputs fixed-length steel grating.
Flat steel feeding device
The flat steel feeding device is mainly used for stacking, sorting, guiding and conveying loaded flat steel. It consists of a feeding car, a flat steel conveying roller, a flat steel bearing rack, a flat steel guide rack, a reduction box and an electrode. The bundled loaded flat steel is unloaded by a crane onto the feeding car. The feeding car is equipped with wheels. The loaded flat steel moves forward and backward horizontally. The loaded flat steel on the conveying roller is manually sorted. A flat steel positioning plate with a positioning groove is installed at the output end of the conveying roller. The positioning plate should be replaced according to the different load flat steel spacing of the steel grating. When manually sorting, each load flat steel should be embedded in the positioning groove of the positioning plate. A flat steel bearing rack is placed in the output direction of the flat steel conveying roller, on which a flat steel guide rack is installed. The guide rack should be replaced according to the different load flat steel spacing of the steel grating. The sorted loaded flat steel is transported to the input end of the guide rack, and the loaded flat steel is manually placed in the guide groove of the guide rack, and then transported to the welding host by the conveyor roller.[The machine adopts a semi-automatic structure, which can reduce the labor intensity of the operator (one person operation), and can overcome the non-automatic factors in the belt of irregular shape and large size tolerance of the loaded flat steel. It has a simple structure and is easy to operate.]
Crossbar blanking mechanism
The crossbar blanking mechanism is mainly used for sorting crossbars. First, workers screen (remove bent crossbars), push them into the guide trough in parallel, and slide down to the blanking mechanism (the width of the guide trough can be adjusted according to the crossbar with an adjustment gasket). The blanking mechanism is equipped with a stopper and a stopper bar, which can be adjusted according to the size of the crossbar.
Press welding machine
The press welding machine is the core part of the whole production line. Its main purpose is to press and weld the arranged cross bars and load flat steel into fixed-length steel gratings and complete the longitudinal correction of the steel gratings after welding. It consists of an upper crossbeam, a lower base, a guide column, a slide block, a hydraulic cylinder, a welding power source, a conductive bar, an electrode holder, an electrode, a flat steel discharge positioning device (comb-shaped fixture), a pressure roller device, a correction pad and a cooling pipeline.
The upper crossbeam is connected to the lower base through four guide posts. The slider is connected to the upper crossbeam through a hydraulic cylinder and is also connected to the guide post through a guide sleeve. Under the control of the hydraulic system, the slider can slide up and down on the guide post and apply pressure to the crossbar and the load flat steel through the electrode holder and the electrode. The welding power supply is composed of two identical rectifier power supplies connected in parallel, and the two rectifier power supplies are symmetrically installed on both sides of the slider. The lower base is equipped with a lower electrode plate, a correction pad, a comb-shaped fixture, a crossbar support and an end positioning device. A pressure roller device is also installed at the output end of the welding host to guide and fix the load flat steel and assist in correcting the longitudinal deformation of the steel grating. [The moving part of the cooling pipe adopts a rigid sliding glove, which overcomes the defect of the elastic pipe changing its cross section when moving and affecting the water flow, and its service life is much longer than that of the elastic water pipe.]
The load flat steel delivered from the flat steel feeding device passes through the roller device and the comb-shaped clamp, and is clamped and positioned by the comb-shaped clamp after the ends are aligned on the end positioning device. The cross bar delivered from the cross bar blanking mechanism is pressed on the load flat steel together with the electrode under the positioning of the cross bar support, and the welding power supply and hydraulic system are started to press and weld the two cross bars and the load flat steel together. Repeat the pressure welding process to press and weld the load flat steel and the cross bar into a fixed-length steel grating.
[This welding host combines the welding power source and the press into one unit through a special connection method, which greatly shortens the welding circuit, reduces the point loss of the circuit, and greatly improves the electrical efficiency of the unit, which is incomparable to the current domestic similar products.
Steel grating mesh pulling mechanism
The steel grating mesh pulling mechanism is mainly used to pull the welded steel grating and convey the steel grating. After each pressure welding of two cross bars, the mesh pulling mechanism will pull a set distance until all the pressure welding is completed. It consists of a frame, a material pulling car and an encoder assembly. The material pulling car is equipped with rollers under it, which are driven by the motor through the chain and can move longitudinally on the frame guide rail. The material pulling car is equipped with an encoder assembly, which accurately measures the length through the rack on the frame, and the transmission chain controls the tightness of the chain through the tensioning device. A conveyor roller is installed under the frame to convey the welded steel grating.
After the pressure welding of the first row of cross bars of each steel grating is completed, the material pulling car automatically moves to the steel grating. The hook on the material pulling car automatically falls down, hooks the first cross bar, and is pressed by the pressure plate to move a set distance in the output direction, and then the second welding is performed, and then pulled... until all the welding pressure is completed, the hook automatically disengages. The crossbar pulling car moves to the initial position in the input direction and stops to prepare for the traction of the next steel grating. At the same time, the conveyor roller can be started to transport the steel grating to the next process.[Since the encoder is used to measure the length, the drawing accuracy is high and there is no cumulative error.
Electrical system
The electrical system is mainly used to control the action sequence of each component of the whole welding machine and set various welding parameters. It consists of three parts: program control circuit, welding power supply control circuit and graphic operation terminal (touch screen).
Program control circuit
It adopts PLC centralized control of Mitsubishi Corporation of Japan, and can realize manual control and automatic control modes. In manual control, the operator can start each component in sequence for welding, or can perform jog operation on a single component out of sequence to test the performance of each component. The circuit also has various working status displays and alarms.
Welding power supply control circuit
This circuit is composed of a trigger circuit board (Tianjin Business School), a medium frequency transformer (Tianjin Business School), a rectifier, etc. The welding voltage of the whole machine and the balanced trigger circuit of two sets of welding power supplies are controlled. The trigger circuit is composed of imported Siemens integrated circuits and other imported components, and the operation is stable. The transformer adopts C-type iron core, water-cooled winding, epoxy encapsulation, and non-magnetic shell for magnetic isolation. It has advanced technology, low loss and low interference. The rectifier components are integrated with imported chips, which are small in size, high in power and good in consistency.
Graphic operation terminal
All welding parameters and steel grating specification parameters of this machine are set, modified and monitored by the graphic operation terminal. The graphic operation terminal adopts F900 produced by Mitsubishi Corporation of Japan, which has excellent performance and reliable operation.
- Other configurations of steel grating project
Steel grating pressure welding equipment is the main production equipment of the steel grating project. In addition, many other configurations are required. Here is a constructive plan for reference (considered as one production line, excluding galvanizing).
Factory
Raw material stacking station: 10 square meters;
Crossbar production line: 10 square meters;
Pressure welding machine production line: 50 square meters;
Steel grating edge wrapping: 50 square meters;
Finished product stacking station: 50 square meters; Supporting equipment
1 twisted steel drawing, straightening and cutting machine (not required for twisted steel);
1 water cooling tower (0.5 cubic meters/minute);
1 water supply and drainage system;
2 carbon dioxide gas shielded welding machines;
1 200KVA/3~380V/50HZ independent power supply system;
1 air compressor (1 cubic meter/minute)
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