A basic membrane panel production line consists of 4 basic equipment. They are:
- Tube polishing machine
- Fin bar calibration machine
- Membrane panel welding 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.
Design of membrane panel production line
The 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 acheving only 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.
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How do we position a fin bar during the welding process
Please refer to the picture below:
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.
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