What do the two routes accomplish?
The split route transfers assembly tack welding, ship type submerged-arc welding and post-weld flange straightening to independent workstations, which is suitable for heavy steel structures. The workpiece after tack welding is placed in a flat-position fillet welding position that is conducive to supporting the molten pool. The maximum single wire 16 mm and the double wire 1250AC+1600DC maximum 24 mm correspond to full penetration without beveling capabilities; thicker workpieces can use beveling, multi-layer, multi-pass welding processes, and are not limited by these two non-bevel thickness values. The actual application scope of the equipment, workpiece and welding process still needs to be met.
integrated assembly, welding and straightening machine centrally organizes assembly, welding and straightening, suitable for light steel projects. This solution uses 45° fillet welding, and the maximum web full penetration thickness is 14 mm; this configuration does not support the use of beveling to break through the upper limit of the capability. When this full penetration requirement is exceeded, a suitable split flat-position fillet welding solution should be turned to instead of considering the overall penetration range of the integrated machine as the welding capability.
Ordinary beams, tapered-section beams and asymmetric beams are reviewed separately
Provide a set of representative drawings for common specifications, upper order limits and special specifications. For ordinary constant-section beams, focus on checking the web height, flange width and thickness, plate thickness combination and beam length; for tapered-section beams, the height, direction of change and slope of the large and small ends must also be given; for asymmetric beams, the offset of the web, the size difference between the upper and lower flanges and the location of the welds must be indicated.
These conditions affect positioning datums, clamping actions, support points, and welding gun trajectories. TITANWELD production lines can be planned around three types of H-beams, but the specific machine combination must cover the target workpiece. The maximum height of one machine and the maximum thickness of another cannot be combined into the entire line capacity; the material grade and joint requirements should also be provided along with the drawings.
Compare device combinations using the same set of conditions
First eliminate routes that do not meet the workpiece and welding requirements, and then compare using the same product mix, shifts, quality requirements and logistics conditions. The length in the table below is a reference layout length; production capacity, number of people and investment amount need to be calculated according to the project.
| 항목 비교 | Split assembly — welding — straightening | 통합 조립, 용접 및 교정 기계 |
|---|---|---|
| 적용항목 | Heavy steel structure, thick web and orders requiring full penetration of grooves | Light steel structure, audited according to the upper limit of 14 mm web full penetration |
| 용접공정 | flat-position fillet welding; beveling, multi-layer, multi-pass welding can be used to process thick webs, confirmed by equipment and process | 45° fillet welding; this configuration does not support the use of groove welding to exceed the 14 mm upper limit |
| Productivity Organization | Independent stations can be scheduled in parallel, but the plan must match welding passes, handling and straightening cycle times. | The process is centralized and some intermediate transfers are reduced. The actual output still depends on the complete cycle and changeover. |
| Employment arrangements | Consider assembly, welding, straightening and turning transfer positions respectively. | Operations can be arranged centrally, but loading, turning, inspection and unloading still need to be covered; the number of people is calculated according to shifts |
| Reference layout length | Traditional linear arrangement approximately 75–80 m | Route layout approximately 25 m |
| Floor space | Calculation based on production line width, transfer and handling area, raw materials, finished products and auxiliary facilities | The main line is relatively compact, but storage, logistics, maintenance and auxiliary areas still need to be added. |
| 초기투자 | Multiple main machines and workstations are matched, and the investment is usually high | The initial investment of the integrated light steel solution is relatively low; the actual amount is compared with the same supply boundary |
| Extended maintenance | Can be expanded around the bottleneck station, need to check the site and interface | The expansion needs to match the complete machine cycle and arrange the processing of work-in-progress during shutdown |
Determine route priority based on order structure
When thick web heavy-duty components are mainly used, or when beveling, multi-layer, multi-pass welding is required, the split flat-position fillet welding route should be evaluated first. The bevel process cannot be capped at 16 mm or 24 mm without bevel, nor can it deviate from the machine and process boundaries. Based on light steel, the web full penetration requirement does not exceed 14 mm, and other dimensions and straightening conditions are applicable, the integrated machine solution can be evaluated.
Occasional out-of-range orders require separate write-in processing, such as arranging other processes or outsourcing, rather than requiring daily production lines to run at a maximum specification that rarely occurs. For product groups that have been determined to grow, expansion conditions should be reserved in the layout, power supply, and logistics interfaces.
Equipment tables and layout drawings should be compared together
Comparable whole-line solutions include at least the workpiece coverage table, model configuration of each station, process and turning sequence, incoming and outgoing material support, transfer method, utility interface, supply boundary and acceptance items. There is only a list of main-machine prices, but it cannot indicate how many roller conveyors, hoisting spaces and auxiliary facilities need to be prepared on site.
Simulate the entire process of the longest beam and the heaviest beam on the layout diagram to check whether the feed can be unfolded, whether it can wait before and after the work station, whether components can be removed during maintenance, and where the workpieces are placed after a piece of equipment is shut down. The total land area and supporting list obtained from this can be used for investment comparison.
For factory building comparison, the split traditional straight line of about 75–80 m and the integrated machine line of about 25 m are used as length references. They are not square meters, nor are they fixed lengths for all factories; auxiliary areas such as raw material finished products, cross-station transfer, cutting and shot blasting need to be included in the general plan according to the project scope.
Prepare these six pieces of information before making an inquiry
- Sectional drawings and beam lengths of conventional, largest and special workpieces, indicating steel type and unit weight.
- Joint drawings, weld dimensions, penetration requirements and agreed inspection methods.
- The proportion, batch size, shift and planned output of each product group.
- Factory column grid, doorways, overhead crane capabilities, existing equipment and energy location.
- Turning transfer methods allowed, and whether existing tooling can continue to be used.
- The scope of layout, installation, training and acceptance required by the supplier.
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