Shanghai Zhengzhuo Machinery Manufacturing Co., Ltd.  

Product Name: Membrane Panel Welding System Electric Current: DC Control: Automatic Origin: China Product Description A basic membrane panel production line consists of 4 basic equipment. They are:- Membrane panel welding machine- Fin bar calibration machine- Tube polishing machine- Panel bending machineIntroduction1) The first steps are i) Tubes are protected against rust and corrosion by a protective layer, this prohibits welding and requires them to be "cleaned" by either polishing or sand blasting. ii) Fin bars are required to be calibrated or sized to attain the desired consistency in a panel's final dimension.2) The polished tube and fin bar then enters the panel welding machine to be joint by welding.An example of the typical sequence of welding a 10 tubes membrane panel.i) Pairs are joint and accummulated.It's essential to note:a) Always maximize the 4 torches when possiblefor maximum efficiency. b) To minimize the change in machine setting.Step One- Pairs are joint in this manner O-OO-O utilizing all 4 torches of the welder- Accummucate multiples of O-OStep Two- With the completed pairsO-O, take 3 pairs and joint in becoming 6 as seen here O-O-O-O-O-O still utilizing all 4 torches of the welderStep Three- With the completed 6 tubes panelO-O-O-O-O-O, joint to it 2 completed pairs from step one. Still, we are utilizing all 4 torches of the welder- O-O-O-O-O-O-O-O-O-O We now have a 10 tubes panel.You should always remember!!! To avoid distortion, it's important to maintain a balanced heat input. To achieve this, firstly we maintain all 4 torches to have an equal input current and voltage setting, secondly we alwaysweld at a position that's equal distance apart.8 Tubes panelYou are probably asking about a 8 tube panel. So here's how we would do it.Complete Step one and Step two of the above instruction.What's different is (Remember equal distance apart), now for Step three of a 8 tube panel.Here we have it O-O-O-O-O-O-O-O, instead of a pair from Step one, we placed a single tube and fin bar ontoboth theouter ends of the 6 tubes panel.Design of membrane panel production lineThe question is how much do you need to produce? From experience, a single panel welder machine with 4 torches could run over 1000 meters of weld on an 8 hour shift. A new user could find themselves achevingonly 500 meters, and this number grows as the operator gains confidence over time.Big boiler manufacturers could have up to 10 membrane panel welding machines.So back to you, how much work do you have? Contact us for a solution.-----------------------------------------------------------------------------------------------------------------------------------------------------How do we position a fin bar during the welding processThis is a question I get a lot, let us discuss this a little.There are mainly 2 methods commonly seen or used in the industry. Please refer to the picture below:Method 1There are typically 2 sets of the above dies/mould installed at the front and back to hold into position the tube and fin bar. This would place the fin bar in the exact desired position during the welding process. However, everychange of tube diameter, fin bar width, fin bar thickness would require an extensive replacement/change of the dies. This can be a tideous and time consuming process, often very expensive. Perhaps for manufacturers of a fixed design, without any custom orders or design changes could they not be required to change such dies.Method 2This is our way. The parts in yellow are dies and can be removed and replaced. The fin bar is supported into position by 2 sets of wheels at the bottom, and a ring on the top.-The bottom rectangular piece (a shim plate- in yellow)adjusts the desired height to bring the fin bar intothe correct position from the bottom.- The top ring (in yellow) slides into the roller clamp, can be easily obtained by machining. It positions the fin bar from the top.- The bottom roller wheel (in yellow) changes when there is change in fin barwidth.You can afford to have different sizes in store, catering to different tube diameters, fin bar width and thickness.A complete set would cost just a few hundred dollars.