Profiled-pressed-fabricated-welded beams

This provided a solution it wasn't previously known was needed but was gladly received.

overall impression of this component

Seen in the first stage of fabrication:

The main structure is a "U" channel, 5mm thickness plate "profiled" and press-brake'd.
The "notched" end-regions take a bent plate inserted, as seen.

The "channel" serves as a strut (imposes a longitudinal distance) and a beam (takes loads "normal" (at right-angles to) the length dimension).

crucial points

The crucial issue in fabricating and welding this component: the "channel" pressing would have to be something like 1-in-2000 parts accurate for the fabrication to fit-together per the drawing taken literally.
Not achievable.
A press-brake accurate enough to make the "channel" fabricating "literally as per drawing" would repay over 100's of thousands of the components. The production run is in the high hundreds. Hence the welder intervening, mainly applying spirit-levels, to get the design intent, is the most economic solution.
That time is roughly about 15 minutes per component.

Another point: this component seemingly takes far too much work for what it is. However, its form simplifies everything else about the structure's design.

pressings first fitup

Fitting the "insert plates" with the 135degree fold:

Mark-up used during the welder intervention:

Both marking-up the results of applying spirit-levels

• the "innermost" round marking containing "bars" and with the arrow, above the trestle, indicates how many packers under that location, and if there is another packer at the other trestle (if so the arrow points to where it is). If the channels get knocked the level can be remade without using the spirit-level(s) again. This intervention has distributed the "twist" error about equally between the two ends.
• the "end" markings are how much depth in millimetres to grind from the locating notch at that side. An alternative intervention is to on the opposite side pad with a run of weld metal.

Another advantage gained by these interventions is no pressings discarded to scrap.
This component cannot be seen in-service, so within structural bounds there there is no issue doing significant corrections.

pressings second fitup

Fit the bolting-surface end-plates:

A "jig"; the long square with the two plates gauging the corrent separation of the end-plates, is seen on the far left-hand-side.
After the interventions / corrections applied at the first stage, the "jig" placement and the fit of the end-plates is "literal" - the fabrication is the ideal simplest case.

A spirit level is again used in a way not shown: by an intervening correction to make the end-plates "vertical". The correction being applied with a large adjustable spanner slightly bending the tack-welds. Transverse squareness was accurately given by the "jig". No reference surface was accurate enough to act as a reference for using a square. The "jig" is checked by putting it on its side on a flat surface and using a spirit-level looking for verticals on its end-plates.

weld pressings & endplates

A lot of welding. Various conditions: "spray" and "dip" using GMAW/MIG.

Example weld - "dip-transfer" in this case.

closing plate fit & weld

These custom "wedge-clamps" were "leap-frogged" along the component. Squeeze-up the fit; weld made; clamp freed and moved ahead of the next clamp.

Example cover-plate to channel weld. Is along the length of tabs.
The weld is seen to have good fluidity and therfore fusion, as evidenced by the brown "glass" on the surface of the weld. Without excessive heat melting the edge of the "channel".

Repetitive but satisfying job.
The components unconditionally fitting during product assembly freed effort to cosmetic aspects of the product for customer appeal.

(R. Smith, 01Sep2025)
(note - began copied from webpg. CV of 07Aug2025)