Machine Overview
The "RockMaster" H-Beam Semi-Automatic Producion line by ZMDE redefines steel fabrication with its advanced capabilities. This system integrates intelligent turning and centering technologies, ensuring precise component positioning and eficient operaions. Designed for enhanced productivity, it features a compact footprint ideal for space-constrained environments and incorporates ZMDE's advanced control system for safe and user-friendly operation.
Safety is paramount with automatic power falure selflocking mechanisms during fips, preventing accidents and ensuring uninterrupted production. Constructed from durable cast components, the RockMaster guarantees reliability and longevity, backed by ZMDE's 15+ years of industry expertise and a proven track record of over 10,000 units deployed globally.
The RockMaster excels in eficiency, faclitating swift T-beam turnovers and integrating seamlessly with optional systems like automatictowing and welding. lts adaptive welding parameters accommodate various plate thicknesses and complex welding scenariosensuring versatlity across diverse production needs. Patented technologies such as hot-straightening and bevelfree submerged-arcwelding further enhance its appeal as a leader in steel fabrication innovation.
Core Parameters
Web plate height: 200-1500 mm
Web plate thickness: 6-30 mm (30 mm with double wire double arc welding machine)
Flange plate width: 200-600 mm
Flange plate thickness: 8-40 mm
Length of workpiece: 6000-15000 mm
Basic Information
Installation Parameters of the Whole Machine
Width: 5700 mm (including equipment on both sides of the main machine, range 5500 mm - 6500 mm)
Length: 126000 mm
Height: 4700 mm
Operating power: Approx. 260 KW
H-Beam Production Process Flowchart
1. Material Preparation and Manual Assembly:
Material Preparation: Raw materials (steel plates and sections) are cut and beveled to the required sizes and shapes.
Manual Assembly: Workers use jigs or positioning devices to manually assemble the steel plates or sections into an initial T-shaped structure, ensuring accurate positioning and fixation.
2. First Welding and Straightening:
First integrated Machine: The T-shaped structure enters the first integrated machine for welding and straightening, ensuring the straightness and dimensional accuracy.
3. Automatic Flipping:
Automatic Flipping Machine: The welded and straightened T-shaped structure is fipped by the automatic fipping machine to asuitable position for the next operation.
4. Assembly into H-Beam:
Assembly Machine: The flipped T-shaped structure is assembled with another steel plate to form the H-shaped structure, ensuring accurate positioning of all components.
5. Second Welding and Straightening:
Second lntegrated Machine: The assembled H-shaped structure enters the second integrated machine for final welding andstraightening, ensuring the final product's straightness and dimensional accuracy.
6. Quality Inspection and Control:
Automated Inspection: Automated inspection equipment checks the dimensions, welding quality, and other parameters of the H-beam to ensure it meets the standards.
Smart loT Platform: The smart loT platform provides realtime monitoring of production progress and quality parameters, enablingfull-process tracking and control.
7. Final Product Handling:
Product Handling: The corrected H-beams are transferred to the finished product area for packaging or direct transport tosubsequent processes or customers.
RockMaster" Rotator
The "RockMaster" Rotator is an innovative mobile 180° flipping bracket designed to revolutionize the H-Beamproduction process. This advanced device integrates seamlessly into modern production lines, delivering exceptionaefficiency and precision.
Comprehensive System Integration:
The machine is composed of the main unit, a hydraulic system, and an electrical control system.
The main unit features a 90° flipping arm, a base frame, a set of walking wheels, a walking motor reducer, and guiderails.
Operational Efficiency:
During operation, the flipping bracket lifts off the roller path.
The walking motor drives two sets of flipping brackets to move synchronously, relocating the workpiece next to thecentral roller path.
A hydraulic cylinder then pushes the arm to flip the workpiece 180°, followed by transferring it to the central path for further processing.
Advanced Design:
The cables and hydraulic pipes are arranged using a drag chain layout, ensuring safety, aesthetic appeal, and reliability.
The entire machine boasts a compact structure and user-friendly operation.
Advantages:
Safety and Reliability: The drag chain layout for cables and hydraulic pipes enhances safety and reliability.
Compact and User-Friendly: lts compact structure and simple operation make it an ideal choice for modern production lines.
Enhanced Productivity: Automating the flipping process reduces manual handling and increases overall productionefficiency.
Rotator Parameters
Main Product Models
Core Components
Product Details
Core Strength
01 Integration of Intelligent Technologies: Innovative Industry Products
43 patents with independent intellectual property rights;
Independent research and development of distributed computing control system, H-beam steel one-shot molding;
Optional six-wire six-arc heavy steel "ZMDE WuZhui" welding machine to realize the heavy steel molding; Optional equipped with "ZMDE JueYing" double-wire double-arc welding machine, processing speed increased by about 80%;
The hot welding and hot straightening process can realize digital control, which can automatically match the welding current and voltage and other parameters according to the thickness of the plate. With the hot welding and hot straightening process, the plate can be straightened directly to meet the quality standard without cooling, which solves the problem of deformation of welding;
There is no need to weld the arc-guiding plate, and it is directly welded to both ends of the plate;
Independent research and development of the web plate below 18mm groove-free welding technology, improve welding accuracy and welding efficiency;
The equipment adopts distributed computing control system, reasonable layout, modular distributed computing control. Easy to quickly and accurately find the fault point, more convenient and efficient maintenance;
Equipment equipped with automatic lubrication system and local graphite self-lubrication. Routine maintenance is more simple;
Equipped with automatic flux control system, reduce artificial dependence, intelligent control of flux flow;
Provide intelligent after-sales service, reduce the failure rate, and maintenance is more convenient.
02 Automatic Production, High Production Efficiency
Intelligent loading, intelligent clamping, intelligent correcting, intelligent towing, intelligent fastening, intelligent inspection, intelligent flux discharging, intelligent welding, intelligent straightening, intelligent lifting, intelligent turning, realizing the whole process of intelligent production;
The production process does not need tack welding, no plate lifting, no need to weld the arc-guiding plate, groove-free welding for the web plate below 18mm, no need to manually control the flow of flux, and no need for the flow of multi-equipment. Reduce the operating procedures and production capacity increases dramatically. ZMDE self-developed distributed computing control system, with touch screen, remote control, and other control modes, easy to operate and learn;
It can be networked with ZMDE intelligent digital welding machine to realize intelligent current and voltage automatic adjustment;
This system can be upgraded with a ZMDE smart, heavy AGV (Automated Guided Vehicle) for logistics, which can significantly enhance the speed and efficiency of moving parts;
Intelligent factory management system can be combined with ZMDE H-beam steel intelligent robotic riveting and welding assembly line, intelligent spraying and polishing machine, etc., to realize the construction of an intelligent factory and production standardization.
03 Cost Saving, Short Payback Period
Intelligent production in the whole process, few operators, saving laborers, effectively reducing the risk of work-related injuries, protecting the operating staff, and higher per capita production capacity;
No need for plate lifting in the production process, less effort than traditional equipment;
Under the same area, the production efficiency of a fully automatic one-shot production line for steel beams of prefabricated buildings is higher, and the production capacity per unit area is doubled;
Equipped with an intelligent flux discharging system, no need to weld the arc-guiding plate, no need for tack welding, greatly saving material;
Compared with traditional equipment, under the same production capacity, the power consumption of welding machines and others is greatly reduced;
Intelligent matching of current, voltage, and other parameters, the overall power consumption is reduced by about 50%;
The equipment adopts a distributed computing control system, and each unit can independently control and complete the production, adapting to the needs of each H-beam processing, avoiding equipment maintenance and delaying the schedule.
04 One Purchase, No Worries After the Sale
Upgradeable System: Enhance the system to cut down on future equipment update costs;
Comprehensive Training: With each equipment purchase, receive training for its entire lifecycle to maintain production consistency, even with staff turnover;
Full-Service Maintenance: Benefit from complete installation, training, and warranty services, plus nationwide on-site maintenance for steady production;
Manufacturer Support: Gain lifelong maintenance for equipment parts and components directly from the manufacturers.
05 Multiple Certifications, High Quality
Authentic Materials: The equipment’s core structural components are made from cast parts to prevent deformation from welding stress, ensuring both precision and longevity;
ISO9001 Certified: The equipment meets the international quality system standards set by ISO9001;
CE Certified: It complies with the European Union’s safety, health, and environmental protection standards;
Industry Leader: Recognized as a top-quality brand in the national building intelligent equipment industry;
Quality Assured: Consistently passes national quality inspections and is certified as a stable and reliable product;
Trusted Quality: Nationally acknowledged for its quality and reliability, guaranteeing customer satisfaction.