{"id":590,"date":"2025-05-24T00:23:01","date_gmt":"2025-05-23T16:23:01","guid":{"rendered":"http:\/\/111.170.148.214:8095\/?post_type=product&p=590"},"modified":"2025-09-12T14:37:50","modified_gmt":"2025-09-12T06:37:50","slug":"machine-a-souder-les-panneaux-de-membrane","status":"publish","type":"product","link":"https:\/\/www.weldmc.com\/fr\/product\/machine-a-souder-les-panneaux-de-membrane\/","title":{"rendered":"Machine \u00e0 souder les panneaux de membrane"},"content":{"rendered":"

Membrane Panel Welding Machine Product Introduction<\/strong><\/p>\n

Les\u00a0standard membrane panel welder<\/strong>\u00a0is engineered for high-performance fabrication, featuring a\u00a01600mm working width<\/strong>\u00a0et\u00a04 welding torches<\/strong>\u00a0utilizing advanced\u00a0submerged arc welding (SAW) technology<\/strong>. This configuration is widely preferred due to its\u00a0exceptional productivity, cost-efficiency, and compliance with transportation limits<\/strong>. However, ABK offers\u00a0fully customizable welding solutions<\/strong>, adapting to specific requirements in\u00a0panel width, welding head count (2\u20136 torches), and hybrid SAW\/MIG-MAG processes<\/strong>, powered by industry-leading\u00a0Lincoln PowerWave\u00ae systems<\/strong>.<\/p>\n

1. Core Technical Advantages<\/strong><\/h3>\n

\u2460 High-Efficiency Welding System<\/strong><\/h4>\n
    \n
  • \n

    4\u00d7 Lincoln PowerWave\u00ae AC\/DC Twin-Wire SAW Systems<\/strong>\u00a0ensure\u00a0ultra-high deposition rates (\u226528 kg\/h per torch)<\/strong>.<\/p>\n<\/li>\n

  • \n

    Stepless welding speed adjustment (400\u20131200 mm\/min)<\/strong>\u00a0for optimized performance across\u00a03\u201312mm panel thicknesses<\/strong>.<\/p>\n<\/li>\n

  • \n

    Auto-seam tracking (\u00b10.5mm precision)<\/strong>\u00a0guarantees consistent weld quality.<\/p>\n<\/li>\n<\/ul>\n

    \u2461 Robust Structural Design<\/strong><\/h4>\n
      \n
    • \n

      Modular Q690 high-strength steel frame<\/strong>\u00a0avec\u00a0stress-relieved construction<\/strong>\u00a0for long-term durability.<\/p>\n<\/li>\n

    • \n

      Dual HIWIN C3-grade linear guide rails<\/strong>\u00a0ensure smooth,\u00a0\u00b10.2mm\/m positioning accuracy<\/strong>.<\/p>\n<\/li>\n

    • \n

      Hydraulic clamping system (21 MPa pressure)<\/strong>\u00a0secures panels firmly during welding.<\/p>\n<\/li>\n<\/ul>\n

      \u2462 Intelligent Control System<\/strong><\/h4>\n
        \n
      • \n

        Siemens SIMATIC HMI touchscreen<\/strong>\u00a0avec\u00a050+ preloaded welding profiles<\/strong>\u00a0for rapid setup.<\/p>\n<\/li>\n

      • \n

        Real-time monitoring<\/strong>\u00a0de\u00a0welding current\/voltage, flux recovery, and machine temperature<\/strong>.<\/p>\n<\/li>\n<\/ul>\n

        2. Standard Technical Specifications<\/strong><\/h3>\n
        \n\n\n\n\n\n\n\n\n\n
        Parameter<\/strong><\/th>\nSpecification<\/strong><\/th>\n<\/tr>\n<\/thead>\n
        Panel Thickness<\/strong><\/td>\n3\u201312 mm<\/td>\n<\/tr>\n
        Processus de soudage<\/strong><\/td>\nTwin-Wire SAW<\/td>\n<\/tr>\n
        Wire Diameter<\/strong><\/td>\n2.4 \/ 3.2 mm (optional)<\/td>\n<\/tr>\n
        Power Capacity<\/strong><\/td>\n4\u00d7650A (100% duty cycle)<\/td>\n<\/tr>\n
        Air Pressure<\/strong><\/td>\n0.6 MPa, 200 L\/min<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

        3. Customization & Automation Upgrades<\/strong><\/h3>\n
          \n
        • \n

          Extended Working Width (up to 2500mm)<\/strong>\u00a0pour\u00a0large-scale panel fabrication<\/strong>.<\/p>\n<\/li>\n

        • \n

          Hybrid Welding (SAW + MAG)<\/strong>\u00a0pour\u00a0multi-process compatibility<\/strong>.<\/p>\n<\/li>\n

        • \n

          Automated Loading Robot (500kg payload)<\/strong>\u00a0reduces manual handling.<\/p>\n<\/li>\n

        • \n

          AI Vision Inspection<\/strong>\u00a0pour\u00a0real-time weld defect detection<\/strong>.<\/p>\n<\/li>\n

        • \n

          MES-integrated Digital Dashboard<\/strong>\u00a0pour\u00a0production analytics<\/strong>.<\/p>\n<\/li>\n<\/ul>\n

          4. Economic & Operational Benefits<\/strong><\/h3>\n
            \n
          • \n

            400% higher efficiency<\/strong>\u00a0vs. manual welding.<\/p>\n<\/li>\n

          • \n

            15\u201320% material savings<\/strong>\u00a0with optimized\u00a0flux and wire consumption<\/strong>.<\/p>\n<\/li>\n

          • \n

            70% labor reduction<\/strong>\u2014only\u00a01 operator required<\/strong>\u00a0per shift.<\/p>\n<\/li>\n

          • \n

            ROI \u22648 months<\/strong>\u00a0en\u00a0two-shift operations<\/strong>.<\/p>\n<\/li>\n<\/ul>\n

            5. Key Industry Applications<\/strong><\/h3>\n
              \n
            • \n

              Power Plants:<\/strong>\u00a0Water wall panel welding<\/strong>\u00a0for boilers.<\/p>\n<\/li>\n

            • \n

              Chemical Vessels:<\/strong>\u00a0Compartment diaphragm fabrication<\/strong>.<\/p>\n<\/li>\n

            • \n

              Shipbuilding:<\/strong>\u00a0Bulkhead panel assembly<\/strong>.<\/p>\n<\/li>\n

            • \n

              Steel Construction:<\/strong>\u00a0Curtain wall substrate welding<\/strong>.<\/p>\n<\/li>\n<\/ul>\n

              ABK\u2019s\u00a0Machine \u00e0 souder les panneaux de membrane<\/strong>\u00a0integrates\u00a0cutting-edge SAW technology, modular automation, and smart controls<\/strong>, making it the\u00a0preferred choice for high-output, precision welding applications<\/strong>.<\/p>\n

               <\/p>\n

              \"Membrane<\/p>\n

              Comparison Table between SAW and MIG\/MAG we hope would help you better decide on your investment<\/b><\/strong><\/p>\n

               <\/p>\n

              \"Membrane<\/p>\n

              Overview of Specification<\/b><\/strong><\/p>\n

               <\/p>\n

              \"Membrane<\/p>\n

              Membrane Panel Welding System<\/b><\/strong><\/p>\n

              A basic membrane panel production line consists of 4 basic equipment. They are:
              \n– Membrane panel welding machine
              \n– Fin bar calibration machine
              \n– Tube polishing machine
              \n– Panel bending machine<\/p>\n

              Introduction<\/b><\/u><\/strong><\/p>\n

               <\/p>\n

              \"Membrane<\/p>\n

              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.
              \n2) The polished tube and fin bar then enters the panel welding machine to be joint by welding.
              \nAn example of the typical sequence of welding a 10 tubes membrane panel.
              \ni) Pairs are joint and accummulated.\u00a0It’s essential to note:\u00a0a) Always maximize the 4 torches when possible\u00a0for maximum efficiency. b) To minimize the change in machine setting.
              \nStep One<\/b><\/strong>
              \n– Pairs are joint in this manner O–<\/b><\/strong>OO–<\/b><\/strong>O utilizing all 4 torches of the welder
              \n– Accummucate multiples of O-O
              \nStep Two<\/b><\/strong>
              \n– With the completed pairs\u00a0O-O, take 3 pairs and joint in becoming 6 \u00a0as seen here O-O–<\/b><\/strong>O-O–<\/b><\/strong>O-O still utilizing all 4 torches of the welder
              \nStep Three<\/b><\/strong>
              \n– With the completed 6 tubes panel\u00a0O-O-O-O-O-O, joint to it 2 completed pairs from step one. Still, we are utilizing all 4 torches of the welder
              \n– \u00a0O-O–<\/b><\/strong>O-O-O-O-O-O–<\/b><\/strong>O-O We now have a 10 tubes panel.
              \nYou 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\u00a0weld at a position that’s equal distance apart.
              \n8 Tubes panel<\/b><\/strong>
              \nFor an 8-tube membrane panel<\/b><\/strong>, follow these steps while maintaining equal spacing<\/b><\/strong>\u00a0between components:<\/p>\n

                \n
              1. <\/b>Step 1 & 2:<\/b><\/strong><\/li>\n<\/ol>\n
                  \n
                • Complete initial tube and fin bar alignment as per standard procedure.<\/li>\n<\/ul>\n
                    \n
                  1. <\/b>Step 3 (Modified for 8 Tubes):<\/b><\/strong><\/li>\n<\/ol>\n
                      \n
                    • Instead of pairing tubes, place a single tube and fin bar on both outer ends of the 6-tube base structure.<\/li>\n
                    • Final configuration: O\u2500O\u2500O\u2500O\u2500O\u2500O\u2500O\u2500O (8 evenly spaced tubes).<\/li>\n<\/ul>\n

                      Production Capacity Analysis<\/b><\/strong><\/p>\n

                      Notre 4-torch membrane panel<\/b><\/strong>\u00a0welder<\/b><\/strong>\u00a0delivers:<\/p>\n

                      \u2714 Experienced Operators: 1,000+ meters of weld per 8-hour shift<\/b><\/strong><\/p>\n

                      \u2714 New Operators: <\/b><\/strong>~500 meters (efficiency improves with training)<\/p>\n

                      Industry Benchmark<\/b><\/strong><\/p>\n

                        \n
                      • Large boiler manufacturers typically operate 8\u201310 welding machines<\/b><\/strong>for mass production.<\/li>\n<\/ul>\n

                        How do we position a fin bar during the welding process<\/b><\/u><\/strong>
                        \nThis is a question I get a lot, let us discuss this a little.
                        \nThere are mainly 2 methods commonly seen or used in the industry. Please refer to the picture below:<\/p>\n

                        Method 1<\/b><\/u><\/strong><\/p>\n

                         <\/p>\n

                        \"Membrane<\/p>\n

                        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\u00a0change 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.
                        \nMethod 2<\/b><\/u><\/strong><\/p>\n

                         <\/p>\n

                        \"Membrane<\/p>\n

                        Our innovative quick-change fin bar alignment system ensures precision while offering unmatched flexibility:<\/p>\n

                          \n
                        1. Interchangeable Tooling (Yellow Components)<\/li>\n<\/ol>\n

                          Top & Bottom Dies:<\/b><\/strong><\/p>\n

                            \n
                          • Removable\/replaceable design for rapid adaptation<\/li>\n
                          • Standardized machining for cost-effective production<\/li>\n<\/ul>\n

                            2.Multi-Point Support Structure<\/p>\n\n\n\n\n\n\n
                            Composant<\/strong><\/td>\nFunction<\/strong><\/td>\nAdjustability<\/strong><\/td>\n<\/tr>\n
                            Bottom Shim Plate<\/strong><\/td>\nSets fin bar\u00a0height<\/strong><\/td>\nReplaceable thickness (0.5\u20135mm steps)<\/td>\n<\/tr>\n
                            Top Guide Ring<\/strong><\/td>\nControls\u00a0vertical alignment<\/strong><\/td>\nSlide-adjustable clamp mechanism<\/td>\n<\/tr>\n
                            Roller Wheels<\/strong><\/td>\nSupports\u00a0width variations<\/strong>\u00a0(2x support)<\/td>\nQuick-swap for different fin widths<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

                             <\/p>\n

                              \n
                            1. Cost-Effective Customization<\/li>\n<\/ol>\n

                              Full die sets<\/b><\/strong>\u00a0for all standard sizes: $200\u2013500<\/b><\/strong>\u00a0per set<\/p>\n

                              Typical variants in stock:<\/b><\/strong><\/p>\n

                                \n
                              • <\/b>Tube diameters:<\/b><\/strong>25mm, 38mm, 50mm<\/li>\n
                              • <\/b>Fin widths:<\/b><\/strong>10mm, 15mm, 20mm<\/li>\n
                              • <\/b>Thicknesses: <\/b><\/strong>5mm, 2mm, 3mm<\/li>\n<\/ul>\n

                                Operational Advantages<\/b><\/strong><\/p>\n

                                \u2705 <5-minute changeover between fin bar profiles<\/p>\n

                                \u2705 Zero machining delays \u2013 dies pre-made for common specs<\/p>\n

                                \u2705 Error-proof positioning \u2013 eliminates manual measurement<\/p>\n

                                Recommended Inventory Strategy<\/b><\/strong><\/p>\n

                                For 24\/7 production flexibility, maintain:<\/p>\n

                                  \n
                                • 3x top rings (cover 90% of tube diameters)<\/li>\n
                                • 5x shim plates (0.5mm\/1mm\/2mm\/3mm\/5mm)<\/li>\n
                                • 2\u20133 roller wheel sets (matched to fin width)<\/li>\n<\/ul>","protected":false},"excerpt":{"rendered":"

                                  La machine \u00e0 souder les panneaux de membranes de WUXI ABK offre des solutions de soudage efficaces et pr\u00e9cises pour les parois des membranes de chaudi\u00e8res et les panneaux d'\u00e9changeurs de chaleur. Gr\u00e2ce au suivi automatis\u00e9 des joints et au fonctionnement contr\u00f4l\u00e9 par automate programmable, elle garantit une qualit\u00e9 de soudage constante avec une distorsion minimale. Con\u00e7ue pour les applications de soudage de l'acier au carbone, de l'acier inoxydable et des alliages, cette machine am\u00e9liore la productivit\u00e9 des centrales \u00e9lectriques et des secteurs de fabrication industrielle.<\/p>","protected":false},"featured_media":1983,"comment_status":"open","ping_status":"closed","template":"","meta":{"_acf_changed":false},"product_brand":[],"product_cat":[23,49],"product_tag":[],"class_list":{"0":"post-590","1":"product","2":"type-product","3":"status-publish","4":"has-post-thumbnail","6":"product_cat-boiler-production-equipment","7":"product_cat-membrane-panel-welding-machine","9":"first","10":"instock","11":"shipping-taxable","12":"product-type-simple"},"acf":[],"_links":{"self":[{"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/product\/590","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/product"}],"about":[{"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/types\/product"}],"replies":[{"embeddable":true,"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/comments?post=590"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/media\/1983"}],"wp:attachment":[{"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/media?parent=590"}],"wp:term":[{"taxonomy":"product_brand","embeddable":true,"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/product_brand?post=590"},{"taxonomy":"product_cat","embeddable":true,"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/product_cat?post=590"},{"taxonomy":"product_tag","embeddable":true,"href":"https:\/\/www.weldmc.com\/fr\/wp-json\/wp\/v2\/product_tag?post=590"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}