Membrane Panel Welding Machine

The standard membrane panel welder is designed to a width of 1600mm operating with 4 welding torches utilising submerged arc welding (SAW) technology. This is the most commonly ordered specification for good reasons:
– High productivity/efficiency in fabrication
– Panel products within transportation limits
– Practical and stable application
– Lower cost of machine and meeting sufficiency
We may however custom built to the customer’s requirement (owing to technical limitations). Our experiences span from panel welders with varying widths, number of welding heads , SAW or MIG/MAG or both utilizing your preferred power sources.

ABK continues today to innovate and adopt newer technology in achieving user friendliness with the introduction of digital touch screen panels. The panel welder will greatly increase outputs and reduce overheads with just 1 operator.

1. Core Technical Advantages

① High-Efficiency Welding System

• 4× Lincoln PowerWave® AC/DC Twin-Wire SAW Systems
• Welding Speed: 400–1200 mm/min (stepless adjustment)
• Deposition Rate: ≥28 kg/h (per torch)
• Standard Auto-Seam Tracking (±0.5mm precision)

② Structural Design Features

• Modular Frame: High-strength Q690 steel, stress-relieved
• Dual Linear Guide Rails (HIWIN, C3 precision grade)
• Hydraulic Clamping System (21 MPa working pressure)

③ Smart Control System

• 1″ Industrial Touchscreen (Siemens SIMATIC HMI)
• Preloaded 50+ Welding Parameter Profiles
• Real-Time Monitoring:

✓ Welding current/voltage stability

✓ Flux recovery status

✓ Machine operating temperature

2. Standard Technical Parameters

Parameter                 Specification

Panel Thickness           3–12 mm

Welding Process         Twin-Wire SAW

Wire Diameter             2.4 / 3.2 mm (optional)

Power Capacity             4×650A (100% duty cycle)

Positioning Accuracy     ±0.2 mm/m

Air Pressure Requirement 0.6 MPa, 200 L/min

3. Customization Options

① Configuration Expansion

• Working Width: Extendable to 2500mm
• Welding Heads: 2–6 torches (flexible setup)
• Hybrid Welding: SAW + MAG combination

② Automation Upgrades

• Automatic Loading Robot (500kg payload)
• AI Vision Inspection (weld quality analysis)
• Digital Production Dashboard (MES integration)

4. Economic Benefits

• Manual Welding:
• 400% higher efficiency
• 15–20% material savings
• 70% labor reduction (1 operator only)
• ROI Period: ≤8 months (2-shift operation)

5. Industry Applications

• Power Plant Boilers: Water wall panel fabrication
• Chemical Vessels: Compartment diaphragm welding
• Shipbuilding: Bulkhead panel assembly
• Steel Construction: High-rise curtain wall substrates

Comparison Table between SAW and MIG/MAG we hope would help you better decide on your investment

Overview of Specification

 Membrane Panel Welding System

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 machine

Introduction

1) 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 possible for 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-O
Step Two
– With the completed pairs O-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 welder
Step Three
– With the completed 6 tubes panel O-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 always weld at a position that’s equal distance apart.
8 Tubes panel
For an 8-tube membrane panel, follow these steps while maintaining equal spacing between components:

1. Step 1 & 2:

• Complete initial tube and fin bar alignment as per standard procedure.

2. Step 3 (Modified for 8 Tubes):

• Instead of pairing tubes, place a single tube and fin bar on both outer ends of the 6-tube base structure.
• Final configuration: O─O─O─O─O─O─O─O (8 evenly spaced tubes).

Production Capacity Analysis

Our 4-torch membrane panel welder delivers:

✔ Experienced Operators: 1,000+ meters of weld per 8-hour shift

✔ New Operators: ~500 meters (efficiency improves with training)

Industry Benchmark

• Large boiler manufacturers typically operate 8–10 welding machinesfor mass production.

How do we position a fin bar during the welding process
This 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 1

There 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, every change 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 2

Our innovative quick-change fin bar alignment system ensures precision while offering unmatched flexibility:

1. Interchangeable Tooling (Yellow Components)

Top & Bottom Dies:

• Removable/replaceable design for rapid adaptation
• Standardized machining for cost-effective production

2.Multi-Point Support Structure

Component	Function	Adjustability
Bottom Shim Plate	Sets fin bar height	Replaceable thickness (0.5–5mm steps)
Top Guide Ring	Controls vertical alignment	Slide-adjustable clamp mechanism
Roller Wheels	Supports width variations (2x support)	Quick-swap for different fin widths

 

3. Cost-Effective Customization

Full die sets for all standard sizes: $200–500 per set

Typical variants in stock:

• Tube diameters:25mm, 38mm, 50mm
• Fin widths:10mm, 15mm, 20mm
• Thicknesses: 5mm, 2mm, 3mm

Operational Advantages

✅ <5-minute changeover between fin bar profiles

✅ Zero machining delays – dies pre-made for common specs

✅ Error-proof positioning – eliminates manual measurement

Recommended Inventory Strategy

For 24/7 production flexibility, maintain:

• 3x top rings (cover 90% of tube diameters)
• 5x shim plates (0.5mm/1mm/2mm/3mm/5mm)
• 2–3 roller wheel sets (matched to fin width)