As an important steel product, The ERW Tube is widely used in construction , automobiles, furniture , oil, natural gas, electric power, chemical industry and other fields. So how to make ERW steel pipe? This article will introduce the process and the 9 important components of ERW Tube Mill Line.
1. Slitting Machine
Precisely this part is an independent production line, which consists of uncoiling, lead positioning, slitting longitudinal shear, winding and other parts. It is suitable for carrying out the longitudinal shearing work of strip and rewinding the slit narrow strip into coils.
According to different application scenarios and product requirements, the slitting machine can be divided into different types. For example, according to different cutting materials, the slitting machine can be divided into different models such as steel, iron, aluminum, etc.; according to different cutting widths, the slitting machine can be divided into different types such as large width, medium width and small width. For the complete production process, learn more about slitting machine
2. Un-coiler
The uncoiler is a special equipment for steel leveling. The body is a welded box structure. The working principle is that the variable frequency speed motor drives the reel shaft after decelerating through the gear box to provide the main power for the decoiler . One of its functions is to support the steel coil by tightening the inner hole of the steel coil; the other is to feed the steel strip head into the leveling machine through rotation with the cooperation of the straightening machine.
Uncoilers can be divided into five categories based on their design, function and application.
Heavy-duty uncoiler
This type of uncoiler is designed to handle wide plates and thick materials. It has a strong load-bearing capacity and can handle coils weighing up to 8 tons. It is divided into two types: powered and non-powered, selected according to production needs.
Hydraulic uncoiler
The main shaft adopts hydraulic expansion and contraction method, which is suitable for processing heavy coils, especially heavy coils of more than 2 tons. The hydraulic system provides stable expansion force and is suitable for applications requiring high precision and stability.
Double -head uncoiler
Equipped with two symmetrical drums, it can achieve rapid material change, reduce downtime and material change time, and improve production efficiency. Suitable for production lines that require frequent replacement of material rolls.
Light uncoiler
suitable for small material rolls, such as 100kg or 200kg. This type of uncoiler is mostly used in light industry or small-volume production and is affordable.
Disc horizontal uncoiler
Designed for high-speed and precision thin plate materials, capable of processing material rolls with widths from 5 to 120mm. This type of uncoiler is commonly used in the electronics industry and precision machining.
3. Strip-Head Shearer & Butt Welder
It is used to cut off the irregular parts of the tape head and tail, align the previous tape tail with the following tape head, and weld them together to continuously feed the looper. In the tube mill line, a roll of steel strip is filled into the looper. When the strip tail enters the shearing system of the shearing butt welding machine, the rear centering mechanism clamps the steel strip and positions it, and the shearing blade falls to complete the strip tail shearing. Then move the vehicle and adjust the welding seam.
When the tape head of another roll enters the shearing system of the equipment, the front centering mechanism clamps the steel strip, aligns the tape head with the tail of the previous roll, and cuts the tape head. Then move the vehicle until the welding gun is aligned with the welding seam, press the left and right pressure plates on the tail and head of the belt, adjust the position of the welding gun, and start welding. After automatic welding is completed, the entire system resets and waits for the next work cycle.
The Shearer& Butt Welder improves the quality of welding and makes it less likely to break. The system has the characteristics of simple structure, convenient operation, intelligent and fast joint alignment, and accurate and reliable movement. Depending on production needs, semi-automatic and fully automatic shearing and butt welding machines can be selected.
4. Loop Accumulator
Accumulator are divided into vertical, horizontal and floor-standing types. They are an important part of the welded pipe production line. Their main function is to store raw materials, provide loading time, and ensure uninterrupted production of the equipment. The accumulator has three main functions as below.
- Buffering changes in metal flow, giving time for control adjustment, and preventing stacks of steel.
- Adjusting the rolling speed of each stand to maintain continuous rolling constants. When various processes When the parameters fluctuate, signals and commands are sent for rapid adjustment.
- The strip maintains a constant small tension within a certain range to prevent necking, uneven width or even breakage caused by excessive tension.
5. Tube Mill Forming And Sizing Unit
As the most important part of the tube mill line, the forming and sizing mill is used to continuously roll the steel strip into tubes and weld them into tubes, and then use the skin effect and proximity effect of high-frequency current to highly concentrate the current on the edge of the tube for welding on the surface, the pipe edge is quickly heated to the welding temperature, and the welding is completed under the extrusion roller, and then it is cooled, sized and roughly straightened to become a steel pipe of the required specifications.
Steel pipe mill production line can produce different shapes of pipes, such as round pipes, rectangular pipes, oval pipes and special shapes of pipes.
Generally speaking, the forming and sizing machine can be divided into various models according to the size of the pipe, the diameter of the regular round pipe ranges from 4mm to 273mm, and some large pipes need to use larger equipment, such as the diameter of 500mm, 800mm and so on, and of course, as the size of the pipe becomes bigger, the thickness will be increased as well.
So in order to save costs, is it possible to produce tubes of different sizes on one machine? The answer is yes, and this can be achieved by changing the rolls!
Traditionally it takes several hours or even a day to change the rolls before they are back to normal. NEW VICTOR INDUSTRIAL has developed a RQCS roll change system that reduces this process to changing the rolls in 10 minutes and resuming production in 30 minutes, making it easy to produce different sizes of tubes on one machine.
6. Flying saw
Steel pipe flying saw is a commonly used cutting machine in tube mill production. The saw blade of the flying saw is mounted on a carriage that moves back and forth at high speed and is controlled by a computer, allowing it to accurately cut the steel pipe as it passes through the machine.
Flying saw is the last process of production equipment on the welded pipe production line , which has a great impact on product quality and production efficiency.
Flying saws are divided into cold flying saws and hot flying saws.
Cold flying saw means that the steel pipe is quickly cut off by a high-speed rotating circular saw blade at normal temperature, and the cut end surface is flat and smooth as a mirror.
Hot flying saw also called friction saw , high-speed cutting is accompanied by high temperature and sparks. The cut end surface is purple and has many flying burrs.
The cut surface of the cold flying saw is smoother and flatter than the hot flying saw. Therefore, the price of the cold flying saw is also much more expensive than the hot flying saw.
7. Conveyor Table
The Conveyor Table is a common production auxiliary tool. Its main function is to support the placement of raw materials, parts and other items during the production process. The use of Conveyor Tables can greatly improve production efficiency, streamline and order the production line, and help ensure product quality.
8. Stacking Machine
A Stacking Machine is a machine that can quickly and efficiently stack finished steel pipes neatly onto a pallet. In production, stacking is an important process, which plays a role in ensuring the safety of products and avoiding accidents , warehousing or shipping in the shortest time , and maximizing the use of warehouse space .
Stacking Machine can operate fully or semi-automatically. The fully automated stacking machine will be connected to a handling system that moves the goods or pallets to the target area. Semi-automatic stacking machine require workers to move the pallets to the desired location manually or with a forklift.
Automatic palletizers are divided into two types according to their level of intelligence: robotic palletizers and mechanical palletizers. Mechanical palletizers can be divided into: gantry-type palletizers , column-type palletizers, and robotic arm-type palletizers.
9. Strapping Machine
The strapping machine uses strapping tape to bundle steel pipes, then tightens and combines the two ends by means of hot melt bonding with a heat generating hot head. Its function is to reinforce the packaging of steel pipe, so that the steel pipe in the handling process, storage, not due to the strapping is not secure and fall apart, but also play a neat and beautiful role.
Strapping machine is mainly composed of feeding belt, retreating belt, joint connection cutting device, transmission system, rail frame and control device, is divided into automatic baler, semi-automatic baler, automatic baler, pressurized baler and so on.
The above are the 9 important components of the ERW Tube Mill Line . These machines make the manufacturing of steel pipes more portable, safe and efficient.
As a turnkey manufacturer of ERW tube mill machinery with 30 years of experience, NEW VICTOR INDUSTRIAL has more than 2,300 successful projects around the world, please contact us at erwpipemills@outlook.com.
In order to give the reader a better understanding of the production process of a welded pipe production line, the following is a list of relevant youtube video links