Beam Production Line Introduction
The beam production line is a manufacturing system that processes steel billets into profiles such as I-beams, channels, angles, and H-beams using a complete set of equipment. It primarily includes heating furnaces, roughing, intermediate, and finishing rolling mills, straighteners, cooling beds, and shearing (sawing) equipment. The production process involves billet heating, multi-pass rolling forming, straightening and cooling, cut-to-length shearing, and quality inspection. It can produce sections with heights ranging from tens to hundreds of millimeters. Small and medium-sized lines achieve annual outputs of tens of thousands of tons, while large-scale lines can reach hundreds of thousands of tons. Leveraging continuous rolling, automated temperature control, and high-precision straightening technologies, these lines offer advantages in efficient forming and dimensional accuracy.
Key Components
A typical beam production line consists of several specialized machines that work in unison:
CNC Cutting Machine: Used for cutting the raw steel plates.
Beam Assembly Machine: Positions and temporarily welds the web and flanges.
Automatic Welding Machine (Gantry Welder): Performs high-speed, high-quality welding.
Flange Straightening Machine: Corrects any bending or warping.
Conveyor System: Moves the beam from one workstation to the next.
Shot Blasting/Painting System: Cleans and applies protective coatings to the beam's surface.
How it Works: The Key Steps
The process of a beam production line is highly automated and follows a sequential series of steps:
1. Material Preparation: Raw steel plates are first cut to the precise dimensions required for the beam's components (the web and flanges). This is typically done using computer numerical control (CNC) cutting machines, which use technologies like plasma or flame cutting to ensure accuracy and minimize waste.
2. Assembly: The cut steel plates are then arranged and held in place by an assembly machine. The vertical web plate is centered between the two horizontal flange plates, forming the 'H' or 'I' shape of the beam. A tack-welding process may be used at this stage to temporarily hold the components together before full-scale welding.
3. Welding: Once assembled, the beam moves to an automated welding station. Gantry welding machines equipped with submerged arc welding (SAW) technology move along the length of the beam, simultaneously welding the web to both flanges to create a strong, continuous bond. This process is often performed horizontally to allow for simultaneous welding of two seams, which helps reduce deformation caused by welding heat.
4. Straightening: After welding, the heat can cause the flanges to warp or bend. A straightening machine is used to correct any deformation, ensuring the beam is perfectly straight and meets strict dimensional tolerances. This is a critical step for structural integrity.
5. Finishing and Quality Control: The final steps include surface treatments like shot blasting, which cleans the beam and prepares it for painting or coating. The beam may also undergo drilling, milling, or other machining processes for further customization. Finally, the finished beams are inspected for dimensional accuracy, weld quality, and overall integrity before being shipped out.
