High Frequency Welded Pipe Mill Ff Ffx Forming Style Cold Roll

I. New design

According to the designing guideline of improving the operating character & environment and the safety & producing character , reducing the cost of the roller to guarantee high efficiency,HG60 production line adopts the double-radius hole style of design .

• Main Parameters and Specifications:

• Material Specifications:

Conforming to the YB189-64 standard

Material : Low carbon steel and low alloy constructional steel

Mechanical properties: σb≤520Mpa,σs≤365MPa

Strip Width:60-190mm

Strip Thickness:1.0-3.5mm

Inner Diameter of Coils:φ480～φ520mm

Outer Diameter of Coils:φ1000～φ1800mm

Coil Weight:≤2.5T

• Welded Pipe Specification:

(1) Round pipe φ20-φ60mm, thickness 1.0-3.5mm

(2) Fixed Cutting length:4-9m

(3) Pipe-cutting Precision:0-3mm

• Forming Speed:90m/min
• Power, Water & Air Supply

Workshop: 6m wide, 80m long, at least 5m high from Ceiling Rails to Ground.

Procedure

Coil Loading → Uncoiling →Cutting and Welding →Horizontal Spiral Accumulator → Forming, HF welding, Deburring, Cooling, Sizing, Straightening →STD Cold-cutting saw →Transmitting → Packing → Storage

Parameters of each machine

1. Uncoiler

The uncoiler is of the structure of double expansion and cantilever mandrels. It contains two main parts: main body and the fixed base. The main body is equipped with pneumatic system to satisfy the needs of expanding, contracting and braking of the mandrels.

There are two mandrels on the main body. Each mandrel consists of four-bar linkages that could move radially at the same time. The four-bar linkages in two groups are fitted on two shafts respectively. Powered by air cylinder, they expand and contract radially. When one mandrel is uncoiling , the other one on the other end contracts to load a new coil and sustain it by expansion, which is then fitted with shield arm on the mandrel to prevent the coil from loosening during uncoiling. When the uncoiling operation of the mandrel in working is finished, pull down the positioning pin shaft and turn the mandrel for 180°manually. Then push the pin shaft back to its positioning slot. Now the new coil is in the working position. The cycles repeat in this way.

Automatic shear and selder is used to cut the irregular ends of the strips and then connect the strips by welding.

Spiral Accumulator

This unit is main include in press& carry material device, accumulator assemble, carry off material unit, electric control unit.

press & carry material device:It is main include frame, electric motor, brake unit, circling direction transfer power axle of the reduce velocity, press & carry roll, pressure air system of guide roll, inspected velocity unit; it can supply the strip steel to accumulator and the mean times it will transfer the carry velocity information to electric control system, when we demand stop carry the material to this unit, it will stop roll to the electric motor and press& carry material roll by the break, and also could adjust the velocity to carry electric motor and the unit carry material velocity.

Accumulator frame assemble: include the electric motor, frame , inner circle roll, out circle roll and pressure roll. It can be used to storage the strip steel material from press& carry unit and it could be draw from the center send-off material roll.

Send-off material device: include frame, guide direction rolls, guide out roll of high or lower place. It can carry the strip steel to shape system and send the carry out material velocity information to electric control device.

Technical parameters:

advantage:storage material more, no strike to strip steel suface. Dia:3.5m

steel coil thickness:1.0-3.5mm; width:60-190mm

carry material going velocity:Vmax=200m/min

hydraulic oil pressure:7Mpa

directly electric motor power of the press & carry:13KW

the electric motor of the accumulator frame : 15KW

Forming & Sizing Mill

Forming & Sizing Mill adopts roller type forming principle and high-frequency induction welding. The strip is fed into the forming machine by the feeding device in the mill and the forming roller continuously rotate and press the strip into the required shape. Due to the skin and the kindred effect, the high-frequency current is concentrated on the weld joint that is heated rapidly and reaches the welding temperature. The tube seam is welded under the pressure of squeeze rollers. The finished welded tube with required size can obtained after the cooling, sizing and primary straightening

Cold Saw

It is used to precisely cut the pipe to length automatically under the condition that the pipe continuously delivered from the mill at high speed.

Drive motor: 11KW servo motor

Cutting motor: 7.5KW variable frequency

Feed motor, servo motor 2.2 KW

Roll Table, Bench & Packing Machine

The finished pipes run along the Roll Table and to be automatically moved onto the Bench. Then simple Packing Machine packs the pipes in hexagon shape.

The simple packing machine contains container and pneumatically driven alignment equipment.

Motor of Roll Bench: 3KW.

7,200KW High frequency Solid-state Welder

Ⅰ. Technical Parameters

Output power: Pout＞200kW

Designed frequency: f=400~450KHZ

① Designed parameters

• Nominal power: 100kW
• Rated DC power: Pd=120kW
• Rated DC voltage: UdN=450V
• Rated DC current: IdN=250A
• The whole efficiency: η≥85%
• Pout >100kw
• MOSFET inverter: 60kW×2
• Tank circuit output mode: no welding transformer output, secondary resonance

② Power distribution requirements

• Nominal power: 100kW
• Rated DC power: Pd=120kW
• Line-in power factor: COSφ≥0.85
• Power distribution capacity: S≤180kVA
• Power supply voltage: 3-phase 380V/50Hz (equipment could work at the voltage 380V±10%)
• Line-in current: I=220 A
• Line-in cable: each phase adopts 185mm² copper cable, 3-phase 4-line

Roller :

The material :Cr12