First collect the site boundaries, then draw the equipment location
The layout plan should be to scale and coordinates, indicating building lengths and widths, column grids, doorways, pits or foundations, existing equipment, overhead crane coverage, clearances, and water and electrical connections. When renovating an old factory, areas that cannot be decommissioned during construction should also be marked. Having only a sketch of the empty plant dimensions is usually not enough to freeze where the equipment will be installed.
Workpiece information includes at least the longest beam, heaviest beam, largest cross-section and typical batch size. The heaviest workpiece is not necessarily the longest, and the longest workpiece does not necessarily require the largest opening. Check these boundaries separately to avoid replacing all logistics conditions with just one "max item".
The preliminary arrangement of the plan can refer to the split traditional straight line layout of about 75–80 m and the integrated machine route of about 25 m. Both items are length, not floor space. The total area also needs to be calculated based on the layout width, raw materials and finished products, transfer turning and supporting equipment areas. The length ratio cannot be directly used to express the area savings.
Main beam processing and supporting small parts should be expressed separately
The main line of splits includes plate strip cutting, assembly tack welding, ship type submerged-arc welding, flange straightening and surface treatment, oriented to heavy steel structures; suitable light steel workpieces can use integrated assembly, welding and straightening machines to centralize related processes. The integrated machine uses 45° fillet welding to achieve a maximum web full penetration of 14 mm. This configuration does not support expanding this range through beveling. Small parts such as support plates can be independently supplied by the steel plate laser cutting station.
H-beam laser cutting is used for agreed holes, slots, ends and contour processing. The location of the workstation should be determined based on the finished product drawings, assembly process and surface treatment requirements. It is not a fixing process that every beam must go through. The layout should mark which workpieces go on the main line and which ones enter the branch roads to avoid repeated handling.
Draw three floors of occupied areas for each workstation.
The first layer is the fixed footprint of the main machine, roller conveyors and ancillary equipment; the second is the dynamic envelope for infeed, outfeed, lifting, turning and tooling movement; the third is the space for operation, inspection, maintenance and component removal. The equipment genuinely fits only when all three are accommodated.
| area | The object that needs to be expressed | Key points to check |
|---|---|---|
| Cutting into strips | Raw boards, cutting tables, loading and unloading areas, residual material and smoke extraction equipment | Can the strips be sent to the assembly station in sets? |
| assembly or integrated machine | Incoming and outgoing roller conveyor, positioning area and panels to be assembled | The longest workpiece support and loading and unloading conflicts |
| Submerged arc welding | Track, workpiece support, turning zone and welding material location | Welding orientation, overhead crane coverage and cable routing |
| straightening | Entrance and exit support and inspection area | Elevation centerline connection and storage of parts to be inspected |
| 拋丸 | Cleaning room, roller conveyor, dust removal and abrasive circulation system | Dynamic envelope, access doors and external interfaces |
| Buffer finished product | To-be-processed, to-be-inspected, inspected and abnormal parts area | Batch identification and main channel unblocked |
Clarify who will move, turn, and stage workpieces
When the workpiece changes direction, elevation or orientation, it should be clear whether it is done by an overhead crane, roller conveyor, transfer trolley or special turning device. Whether parallel processing is established also depends on whether these resources are shared. For example, if an overhead crane is used for unloading at the welding station and loading at the assembly station at the same time, scheduling conflicts need to be checked.
The buffer zone is set at an interface that is easy to wait to absorb reasonable fluctuations. The infinite increase in work in progress cannot be used to replace the beat analysis. Cross-aisle handling and turning actions should be carried out by the on-site team to complete hoisting and operation assessment according to local requirements. The specific width of the aisle cannot be determined solely by the website instructions.
Split flat-position fillet welding needs to draw the workpiece placement, turning and support range; the integrated machine cannot omit the space for loading, necessary turning and finished product removal. A short mainline doesn't mean the action isn't occupied.
Freeze installation interface before foundation construction
Installation preparation is more than just power distribution. Equipment positioning, foundation and footings, roller conveyor elevation, power supply branch, grounding, compressed air, welding and cutting smoke exhaust, shot blasting dust removal and necessary cooling conditions should all have clear technical requirements and responsible parties according to the final configuration.
| interface | Equipment solution provided | On-site feedback |
|---|---|---|
| Basic positioning | Foundation diagram, load and positioning datum | Ground conditions, construction scope and duration |
| Power supply energy | Capacity, access location and technical requirements | Available capacity, voltage frequency and gas source |
| Smoke exhaust and dust removal | Random system range and connection conditions | External piping locations and local requirements |
| Transportation and hoisting | Packaging weight, outline and installation and lifting requirements | Factory entry routes, doorways and lifting equipment |
| Maintenance supplies | Disassembly parts, service locations and storage requirements | Peripheral obstacles and daily maintenance access |
Complete layout walkthrough along a beam
- From which door do the raw materials enter? How do the web and flange plate arrive in sets at the assembly station?
- Is the longest beam supported, does it hit a column or cross a channel?
- How to turn before and after welding, and which equipment is used to complete it?
- When a machine is paused, where are the workpieces at the front and rear stations placed?
- Does finished product inspection and repair require retrograde travel through the normal production area?
- When replacing rollers, motors or dust removal components, is there room for lifting and removal?
- Are the layout version, scope of supply, installation interface and items to be confirmed synchronized?
日期為本次預覽的擬定編輯排程，不代表過往實際發布日期。