HIGH FREQUENCY AND STRAIGHT SEAM PIPE MAKING LINE
OPERATION
MANUAL
JIANGSU ZHANGJIAGANG ZHONGYUAN PIPE-MAKING CO., LTD. JIANGSU P.R., CHINA
Catalogue
1. Specifications 1
2. OPERATION MANUAL & STRUCTURE CHART 6
3. Attention 9
4. Specifications of 200Kw high frequency influence welding machine 10
5. Reference only, if any change, we have the right of final decision
Page:1
一、Specifications
1、Capacity:
(1) Pipe ID: ￠20mm-￠60mm
(2) Thickness: 0.8mm-2.5mm
(3) Speed: 70m/min-80m/min
2、Main spindle driving:
(1) House: Z4-225-31,132Kw DC motor.
(2) Speed-down device: ZLY200 reducer, speed rate9:1, double spindle drive.
(3) Drag: DC micro-motor
3、Double uncoiler (1 piece)
(1) Abstract: circumgyrate rotation, quickly change steel coil, pneumatic brake device.
(2) Technical data: Coil weight(Max.): 1000kg
Coil ID: 450mm-520mm
Coil OD(Max):1600mm
Coil width(Max):200mm
4、Horizontal spiral steel strip moveable cover(1):(according to the customers, can also equipped with cage case)
(1) Form:
a、 Frame of steel strip rotation
b、 Double spindle material feed machine
c、 Horizontal spiral steel strip moveable cover
d、 Frame supporting steel strip
(2) Feed speed: ≥200m/min
(3) Store capacity: ≥2000Kg
(4) Width range: 50mm-200mm
(5) Motor device:
a、 Motor for horizontal spiral steel strip moveable cover: 11kw(AC timing motor)
b、 Double material feed motor: 7.5kw(AC timing motor)
5、House base for shape:
(1) Base: (7 groups)
a、 Material: 45＃ steel
b、 Roller: ￠60mm
c、 Spindle: 40Cr page2-1
Notes: Base for shape is one of the most important device in welding machine, so you must select specifically machine tools to meet with the high precision.
(2) Roller shaped assembly: (9 groups)
a、 Roller shaped base: 20＃ steel
b、 Roller spindle: ￠40mm
c、 Spindle: 40Cr
(3) Gear box: (7 pieces)
a、 Material: cast iron
b、 Drive: Spiral gear drive, small volume but high carrying capacity, and low noise.
c、 Lubricate device: 18＃ double curve gear oil
d、 Connection way: gear and spindle joined element
e、 Gear spindle material: 45＃ steel
f、 Gear material: 40Cr
(4) Drive spindle(14 pieces)
a、 Model: B2-3
b、 Torque: 1940N.m
c、 Length: 300mm
(5) Material lead device(1 set)
6、Welding device:
(1) Assembly:
a、 Guide device(1 set): worm and worm wheel working together with a couple wheels defined the diameter to guide to the best position of welding.
b、 Extrusion wheel: 1 set, 2 pieces
c、 Supporting frame: Can be adjusted up and down, not necessary to change the wheel which defined the diameter, and easy to be operated.
d、 Scrap frame: 1 set, 2 knives to change scraping way.
(2) Way of welding: Influence extrusion melt welding
7、Diameter defined house base:
(1) Base assembly: (7 groups)
a、 Base: 45＃ steel
b、 Roller: ￠60mm
c、 Spindle: 40Cr
Note: Diameter defined house base is one of the most important device in welding machine, so you must select specifically machine tools to meet with the high precision. Page2-2
(2) Roller diameter defined assembly(6 groups):
a、 Roller base: 20＃ steel
b、 Roller spindle: ￠40mm
c、 Spindle: 40Cr
(3) Gear box: (7 pieces)
(4) Drive spindle(14 pieces)
(5) Perpendicular alignment roller assembly(1 group)、horizontal alignment roller assembly(1 group), for those steel requires little of straight can be delivered without alignment.
(6) Speed measure wheel assembly(1 group): The wheel is kept friction with the surface of steel because of the pressure of gas jar so as to get the best achievement of the measuring wheel.
8、Water box for cool down(1 piece)
9、Following device controlled by computer(1 piece):
(1) Power: 7.5Kw
(2) Following assembly:
a、 Cutting ability（diameter）: ￠60mm
b、 Cutting length: 4m-7m
c、 Cutting thickness:2.5mm
(3) Type: Circular metal saw blade, ￠450mm×￠70mm×￠2.5mm
(4) Power for cutting saw: 11Kw
10、Material discharged base: (1 piece)
Type: Roller device(3Kw, 6 electrode driving)
Page2-3
二、Operation manual
1、Material feed:
Gyral double head uncoil machine with gas driver brake device to meet with the requirement of quick change of steel coil of high speed of production line.
2、Material store:
Horizontal spiral steel strip moveable cover to ensure the continual production when change the steel strip. Speed of material feed is independence from the speed of material out.
3、House base for shaping:
(1) Adjust shape: First adjust the guide device of material feed;
(2) The speed should be slow down when steel strip being sent to the shaping housing and the roller of base should be adjust to right place.
(3) Adjust welding slot guide device so as to center the welding slot above the steel pipe.
(4) After adjusting the shape device, confirm whether the rollers are of same height and examine if any imprint on the surface of steel strip. If have, must find the cause.
4、Cool down:
When machine normally working, the part, such as extrusion wheel, and etc. need to be cooled down should be dipped into cool liquid. Cool liquid should be kept pressured condition. Pointed diameter part should be sprayed by liquid to get the best effect.
5、Diameter defined housing base:
(1) When adjust diameter, according to specification and pipe type, select suitable roller;
(2) Examine outside diameter of steel pipe to confirm if fit for the standard;
(3) According to the length, adjust the perpendicular level of notch of steel pipe;
6、Welding
Influence extrusion welding, formed by a couple of extrusion wheel、supporting frame、commissure planar frame. Planar can be perpendicularly and horizontal moved so as to easily adjusted. Only after diameter defined part being adjusted OK, welding part can be adjusted.
(1) Choose magnetism stick according to pipe diameter and positioned between influence fold and pressure wheel;
page3-1
(2) Define ID of influence fold according to the outside diameter of pipe;(usually, 5mm larger than outside diameter of pipe)
(3) Connect influence fold to high frequency water cool device, examine the water in and out condition;
(4) Equipped with 60m3 water pool. Water temperature should be as same as the room temperature.
7、Saw cutting
Automatically staff gauge following device controlled by computer:
(1) Micro-computer automatically following testing the speed. Drive by DC motor to achieve high precision;
(2) Can define the length of steel pipe in 4m-7m and control the number automatically;
(3) Modularize the controlling device, easily to be removed and controlled.
8、Materials discharge base:
Equipped with driving device.
三、Attention
1、 Before startup host-housing, startup air-compress house first;
2、 Open cool down water pump of high frequency influence welding machine to confirm the in and out water condition;
3、 Before startup cutting saw, open the circling water pump of emulsification liquid, confirm the position of magnetism pole and welding ring;
4、 Raise cut immediately as soon as the machine stop, then turn the switch to “OFF”, and turn the knob of high voltage to the least position;
5、 Turn off filament first, and then turn off all the cool down device 15 minutes later.
Specification of 300Kw high frequency influence welding machine
1、 Power input: 3P、 380V、 50Hz
2、 Power out put: 200Kw
3、 Control way: Micro-computer control
4、 Rectifier of high voltage: 40A
5、 Transformer of high voltage: 3P、 380V、400KVA
6、 Radio tube: FD-911S×2
7、 Transformer of radio tube:12V-AC
8、 Anode water pump of radio tube: polyethylene boost up tube
9、 Capacitor: CCG82-1500P-20KV
10、 Protect system:
a、Ⅰclass software protect and Ⅱclass hardware protect;
b、Water-press control relay.
11、 We’ll arrange technicians to fix
12、 Cool down device:
a、 60m3 cool down water pool be bought by the buyer
b、 Outside cool down circling water be equipped by the buyer
Note: Guarantee time: one year (Radio tube for 2 months, besides factitiously break)
