ERWΦ219 solid state welder  pipe production line, it is used to produce   welded steel pipes with OD89 ~ OD219mm and wall thickness of 2.75 ~ 8.0mm. It   has innovative design, high degree of automation, convenient operation and   maintenance, and is in a leading position in design level and manufacturing   quality.

2Production plan

2.1technical parameter

Name

Content

Product   standard

GB/T3091,  ASTM   A53, BS1387, JIS3466

Specifications

Round tubeOD89～OD219mm, Square tube 75*75,100*100,125*125,150*150,125*75,150*100,

Wall   thickness

2.75～8.0 mm

Pipe   length

6 m

Length   tolerance

±3 mm

Line   speed

25～45m/min

Feeding   type

○left ○right

2.2Raw material specification

Name

Content

Coil   material

hot rolled steel

Coil OD

Ø1500～Ø1800mm

Coil ID

Ø508、Ø610

Weight

Max 15ton

Strip   width

280～6700mm

Width   tolerance

0～0.5mm

Thickness  

2.75～8.0mm

Thickness   tolerance

Max.±5%

Strip   bending

Max.20mm/10m

Strip   edge

Longitudinal shear

Strip   grade

Q195、Q215、Q235、Q345

yield strength

 Max. 350Mpa / Min. 235Mpa

tensile strength

Max. 550Mpa

2.4total power requirement： 2,000KVA

Uncoiling → shear welder → horizontal accumulator storage → feeding →   forming → extrusion welding → cooling → sizing → cutting to length →   packaging → warehousing

Forming: 7 horizontal stands8 vertical stands

Sizing: 5 horizontal stands5 vertical stands ,  4 roll Turk head, 2 stands

WP   WL JP    WL  1CP 1CL  2CP    2CL  3CP  3CL    4CP  4CL  5CL    6CL  5CP   7CL    6CP8CL  7CP  HD    HJ  HB1, 2  HM      SL  1DL  1DP    2DL 2DP  3DL 3DP  4DL 4DP    5DL 5DP   T1  T2 

 WP—feeding horizontal rolls     JP — 5 roll leveling (no power)

 WL — feeding    vertical rolls, CL — forming   vertical rolls, CP — forming   horizontal rolls

HD — guiding   stands

HJ — squeeze   stand (2 roll type)

 HB — remove tube outside burr

HM — grinding   stands

SL — cooling   water tank

 DL — sizing vertical rolls

DP —  sizing    horizontal rolls

 T — Turk head

No.

Name

QTY

Remark

1

coil car

1

2

double cone uncoiler

1

3

coil opener

1

4

pinching and leveling machine

1

5

shear welder

1

6

spiral horizontal accumulator

1

7

forming machine

1

8

welding device

9

cooling tank

10

sizing machine

11

solid state welder

1

600KW

12

Milling cutter

1

13

run out table

14

end facing/chamfering machine

1

15

hydro tester

1

16

electric system

1

17

hydraulic system

1

18

rolls

9

9 set

（2 of   them are only half set）

total

22

6.1 coil car

Name

Content

Function  

Load the   steel coil and transport the steel coil to the uncoiler

technical   parameter

Trolley   lifting mode: Hydraulic cylinder

Trolley   operation mode: Electric 2m/min

Coil OD: Φ1500～Φ2200mm

Coil   width: 350～700mm

Max coil   weight: 15T

Protective   plates are added on both sides of the V-shaped groove of the lifting trolley.   The lifting guide column of the trolley is a double guide force column.

The   chain tension of the transmission motor is adjustable.

6.2uncoiler

Name

Content

Function  

double   cone uncoiler is used to support the coil and provide raw materials for the   production line. The machine has two cones. It mainly includes base,   pneumatic brake device and electrical control system. The machine is equipped   with direct feeding and guiding. The coil is first placed on the uncoiling   cone head. When guiding, the guiding roller is pressed down hydraulically,   and the coil is actively rotated by the motor. Under the action of the shovel   head machine, the coil enters shear butt welding; The braking mode is   controlled by the linkage of the whole line to ensure that the strip steel   does not loose during operation.

technical   parameter

Max coil   weight: 15 ton

Main   motor: 4KW

Coil   thickness: 2.75～8.0mm

Coil ID: Φ508, Φ610mm

Braking   mode :  Pneumatic

6.3 coil opener

Name

Content

Function  

Auxiliary   uncoiling, rough level the strip steel and smoothly send it to the pinch   leveler.

technical   parameter

Coil   thickness: 3～8mm

Roll OD: φ320 mm

Extended   length of shovel head:500mm

Press   roll drive: Hydraulic motor

6.4pinching, feeding and leveling machine

Name

Content

Function  

The   active pressing roller takes the steel plate apart from the steel coil, and   the pinch leveling roller flattens the disassembled steel plate.

technical   parameter

pinching,   feeding roller diameter×length               Ø160×750mm

leveling   roller diameter×length                  Ø120×750mm

roller   material: 42CrMo

roller   hardness:  HRC48°-52°

Pinching,   feeding and leveling transmission mode: The   clutch between the AC Y2 series motor drive distributor and the reducer, the   upper and lower lifting are equipped with synchronous gears, and the rack is   equipped with positioning keys. The modulus of the gear and rack shall meet   the requirements of forced synchronization.

Motor   power ：                     11KW

6.5shear welder

Name

Content

Function  

Hydraulic   shearing, automatic welding.  It is   composed of a front plate moving machine, a plate shearing machine, a rear   plate moving machine and a centering device; Hydraulic shear, alignment and   flattening. The centering before shearing is changed to have the function of   transverse movement, with oil cylinder clamping and motor transverse   movement.

technical   parameter

Maximum   shear width: 700mm

Shear   form : It is an up cut type, and the oil cylinder   is placed on it.

Welding   mode: CO2 gas shielded welding (3-year   warranty)

Shear   blade material: 6CrW2Si

Shear   oil tank diameter: φ200mm

Hydraulic   system: 16MPa

cylinder   stroke: 110m

6.6spiral horizontal accumulator

Name

Content

Function  

Store   the steel coil to ensure the continuous production of the unit. The  horizontal accumulator is equipped with a   mute room. The mute room shall be designed to facilitate maintenance and   monitor the internal operation. The sealing of horizontal accumulator   transmission system and gearbox shall not leak oil

technical   parameter

horizontal   accumulator form：   Outside in inside out, fixed circle type. The bottom roller is centrally   driven by a DC motor; the pinch roller is hydraulically clamped and driven by   a DC motor; the installation form of the DC drive mechanism of the pinch   roller is changed to be installed on the ground. Cylinder clamping, DC motor   drives. There are steel coil torsion devices at the front and rear of the  horizontal accumulator body 。

total   storage: 600m

effective   storage:    400m

horizontal   accumulator storage laps: 45

filling   speed: 100m/min

filling   motor:  DC75Kw

Bottom   roller diameter: φ180㎜

Bottom   rollermotor: DC 132Kw

6.7feeding and guiding device

Name

Content

Function  

Smoothly   guide the flat steel coil into the forming device

Composition  

feeding   flat roller、feeding   vertical roller、5hi   leveling machine、feeding   vertical roller

6.8forming machine

Name

Content

Function  

Bending   straight steel coils to the required cross-section, spacer sleeves with   matching rolls (including vertical rolls)

technical   parameter

horizontal   roll stands ：7 stands

vertical   roll stands ：8 stands

horizontal roll diameter：Ø130mm, Worm   gear pressing down.

horizontal roll material：  42CrMo

vertical roll diameter ： Ø 80mm,   Worm gear adjustment.

vertical roll material：                             40Cr

Forming speed：max 50m/min

Stand ： Casting ZG35

6.9welding device

Function ： The bent tube blank is welded into a hole   shape by high frequency, and the external burr is removed.

It consists guiding vertical roll, welder   guiding roll,4hi pinching roll, external burr removing machine, 2hi polishing   roll stand

Spacer sleeves with matched rolls

6.10 water cooling   tank

Cooling tank length ：6000mm

Air cooling section length：25m

Cooling mode： pool spray

6.11sizing machine

Name

Content

Function  

Eliminate   the internal stress of the tube and roll the round tube blank into the   required finished tube ，

technical parameter

Universal   stand：5 stands,   horizontal roll diameter Ø130, worm gearing is pressed down to ensure   machining accuracy

horizontal   roll material：                        42CrMo

horizontal   roll stand：5   stands, horizontal roll diameter Ø80, worm gearing adjustment

vertical   roll material ：                       40Cr

4hi leveling machine stand：4 roll   Turk stands2, shaft diameter Ø60mm

Sizing   speed：max 60m/min

Stand:   casting ZG35

Finishing   and sizing machine has function of quick change

6.12、driving device

Forming motor:160KW   1000 r/min    2 pcs，sizing   motor: 200KW   1000 r/min  2 pcs

Driving device consists of main reducer and   sub-gearbox. The arc-shaped bevel gear m=16 is used for the sub-speed box,   which has the advantages of stable transmission, strong overload resistance   and long service life. The material is 20CrMnTi, and the transmission shaft   is a heavy-duty transmission shaft.；

The main reducer adopts the ZLY type   reducer with hard teeth surface 。

6.13、milling cutter

Name

Content

Function  

cut the   continuously produced steel pipe to the required length, and with noise   reduction and silent room

technical parameter

Sizing   accuracy ：±3mm

Sizing   length ：    6m

Feeding motor：servo5.7 KW*2

Cutter   motor：  AC 110 KW    

dragging   motor： servo42   KW

2 TCT   blade cutting

6.14、solid state HF welder

It is used to heat the two edge metals of   the V-shaped mouth of the formed open steel pipe to the welding temperature,   closed-circuit distilled water cooling, and control the output power   according to the speed of the production line, requiring the use of series   solidstate high frequency.

technical parameter：

①   Design Parameters

l   Rated   DC power：P_d=600kW

l   Designed   frequency ：f=250~300kHz

l   Tank   output form： No welding transformer output , secondary   resonance

②   Power requirements

l   Rated   DC power：P_d=600kW

l   Rated   power factor ：COSφ≥0.9

l   Power   capacity ：S≥720kVA

l   Voltage   ：3ph 380V/50Hz

③   Circulating soft water cooling system

water-water heat exchanger

6.15、run   out table

It is used to transport   and store the sawed steel tube, and send the steel tube to the packaging   machine. The run out table is a "V" type table, and the structure   is electric run out. 。

6.16、Electric control system

(1)   The main machine forming and sizing electrical control system adopts bus   control and PLC control technology, and adopts man-machine interface to   realize the synchronous control of each grouping transmission motor. There is   necessary interlocking protection and communication interface between main   machine forming and sizing and high frequency and saw.

(2)   The PLC adopts Siemens S7 series, and the mainframe forming and sizing motor   adopts DC motor.

(3)   The main system (excluding the host computer) should realize command control   through the man-machine interface, display parameters such as the speed and   current of each motor in real time, and demonstrate the operation of the   unit.

6.17、Hydraulic system

1）   Pumps, hydraulic valve parts and valves are made of Huade, which conform to   international standards and are interchangeable. The oil needs to consider   the cooling device.

2）   The hydraulic system should ensure the smooth and reliable operation of the   hydraulic equipment, and there should be no oil leakage, oil seepage,   vibration and other undesirable phenomena.

6.18、rolls

Name

Content

technical   parameter

material：Cr12

Specifications

Heat   treatment hardness ：HRc58~62

Squeeze   roll: 2 sets, Fin pass rolls: 10 PCS, Guiding roll 2 sets, Fin pass rolls: 10   PCS

7、delivery time（It is recommended   to clarify the specific delivery time according to the equipment installation   progress ）

45 days after receiving down payment

8、Main component brands

8.1、PLC:  SIEMENS S200

8.3、DC   governor: PARKER 590

8.4、Servo   motor and controller: YASKAWA

8.5、DC   motor: Jiangsu Wangpai, Kedi

8.6、AC   motor:  HengshuiMengniu, YE3 series

8.9、Bearing:   HEB、ZWZ、LYC

8.11、Pneumatic   components: Jinan HuaNeng

8.12、Hydraulic   components: Beijing Huade

8.13、Frequency   converter: INVT, one model larger than motor

8.14、DC   driver: 590

8.16、Console   panel: stainless steel panel

No.

machine name

QTY

remarks

1

coil car

1

2

double cone uncoiler

1

3

coil opener

1

4

pinching and straightening machine

1

5

shear welder

1

6

spiral accumulator

1

7

forming machine

1

8

welding device

9

cooling    tank

10

sizing machine

11

solid state HF Welder

1

600KW

12

milling cutter

1

13

Conveyor, run out table

14

electric system

1

Including equipment room cables, excluding   main cables and electric control cabinets

15

emulsion system

1

16

hydraulic system

1

Including all pipelines

17

rolls

9

The final price is calculated according to   the actual weight

1

∅88.9mm

5

2

∅114.3mm

6

3

∅165.1mm

8

4

∅219.1mm

10

5

75*75mm

6

6

100*100mm

9

7

125*125mm

10

8

150*150mm

11

125*75mm

4

Half set

150*100mm

4.5

Half set

73.5

Approximate weight, the final price   is based on the actual weight