一、主要技术规格Main Tech Parameters
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原材料(钢带)材质 Steel strip material |
热轧或冷轧,低碳钢，低合金钢，镀锌钢带 Hot rolled or cold rolled, low carbon steel, low ally steel, galvanized steel. |
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成品要求 Finished Products requirements |
圆管round pipeФ12.7-Ф38.1mm， thickness 壁厚：0.4-2.0mm 方管Square tube: 10*10 –30*30mm thickness 壁厚：0.4-1.5mm 矩形管Rectangle tube:within same bandwidth of tube/pipe |
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机列要求 Machine column requirements |
机列形式：分体式 Form: Split |
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布置方式：根据客户的需求 arrangement form: according to the customer's requirements |
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机组生产速度 Unit production speed |
0～100m/min (特定条件下无法达到最高速度The maximum speed can not be reached under certain conditions |
二、工艺流程 Working Flow
开卷→剪切对焊→螺旋活套→校平→轧制成型→高频焊接→刮刀→冷却 →定径→矫直→锯切料→下料台
hanging material→feeding→un-coiler→shear and butt welder→horizontal spiral accumulator→forming→high frequency welding→scraper→cooling →sizing→straightener→computer control saw→lay out table
三、焊管线主要构成规格 Mainly Composed Specifications Of Pipe Line
1、开卷机 Uncoiler
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结构形式 type |
双头气动式开卷机Double Side pneumatic Mechanical Un-coiler |
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适用钢带内径 Shrinking and expanding range of I.D |
钢卷内径涨缩范围φ470-φ520mm（根据客户需求） Φ470-Φ520(according to the customer’s request) |
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钢带外径 steel strip O.D |
≤φ1800mm |
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钢带宽度 Steel strip width |
40～120mm |
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钢带卷重 Steel strip coil weight |
单边One side≤1.5吨Ton |
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制动形式 Brake from |
气动、强弱制动Pneumatic brake |
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转动形式 rotation form |
人工推动平台±180°Manual push platform±180° |
2、液压剪切手工对焊机或自动焊Hydraulic shear And Manual Butt Welder or Automatic welding
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作用Function |
切除钢带头尾的缺陷部分以及带卷中间的缺陷部分 在对焊前切头切尾，使对焊接头平直对正，利于对焊 Removal of the defective portion of the strip head and tail and coil center, Cutting head and tail before butt welding, make the butt-welded head straight on to be good for welding |
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结构形式 Structure form |
液压剪+手动焊接+手动对缝 或 液压剪+自动焊接+自动对缝 Hydraulic shearing and manual alignment and manual welding Or Hydraulic shearing and automatic alignment and automatic welding |
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剪切厚度 Applicable steel strip thickness |
≦2.0mm |
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最大剪切宽度 Maximum steel strip width |
130mm |
3、盘式螺旋活套Horizontal Spiral Accumulator
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活套原理 Principle |
由外套引入，中心出料 Introduced by the outer accumulator, center discharge |
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活套直径 Diameter |
Ф3.5米meter |
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钢带宽度 Steel strip width |
40～120mm |
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钢带厚度 Steel strip thickness |
≦2.0mm |
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充料速度 Feeding speed |
≥200m/min |
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送料电机功率 Feeding motor power |
7.5KW |
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活套主体功率 Accumulator unit motor power |
11KW |
4、成型定径机组Forming And Sizing Machine
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进料装置 Feeding device |
导向立辊 Guide vertical roll |
矫平辊后两对导向立辊，通过手动调节对中开合调整 After leveling roll two pairs of vertical guide rollers, regulation of the opening and closing by manual adjustment |
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矫平辊 Leveling roller |
采用7辊矫平装置，使钢带平稳进入成型机组，矫平辊为无动力辊，下辊固定，上辊通过首轮丝杆上下调整 Adopt 7-roller leveling device, so that a smooth strip into the forming units, leveling roll is a non-powered roller, lower roller is fixed, upper roller can be adjusted through the first round screw up and down |
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成型机架 Forming bracket |
成型原理 principle |
本机组采用底线水平辊式成型原理，轧辊采用双半径孔型 This unit uses the baseline level roll-forming principle, Roller adopts double radius of groove |
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成型要求 forming requirements |
圆管round pipeФ12.7-Ф38.1mm， thickness 壁厚：0.4-2.0mm 方管Square tube: 10*10 –30*30mm thickness 壁厚：0.4-1.5mm 矩形管Rectangle tube:within same bandwidth of tube/pipe |
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成型机架规格 Forming bracket specifications |
辊架 Roller bracket |
数量 quantity |
辊架轴径 Shaft diameter of roller bracket |
辊轴材料 Material of roller bracket |
轴热处理 Heat treatment |
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水平辊架 Horizontal Roller bracket |
7 |
Φ50mm |
42Crmo |
调质高频淬火 HF quenching |
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立辊架 Vertical Roller bracket |
7 |
Φ35mm |
42Crmo |
调质高频淬火 HF quenching |
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成型机架机构要求 Forming bracket institutions requirements |
在每个开口成型水平机架上辊方轴承顶部都设由过载保护装置，当遇到过载时该垫有缓冲，以保护水平辊和传动装置 On each opening forming horizontal rack roller bearings are located at the top side by the overload protection device, the pad has a buffer when faced with overload, in order to protect the horizontal roller and transmission device |
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水平辊架为龙门式结构，其中：开口成型4机架；闭口成型3机架。水平辊模具采用隔套直接固定，保证机组精度 Horizontal roller bracket is gantry structure, including: open molding 4 brackets; Silent molding 3 brackets. Horizontal roller mold adopt spacer fixed directly, ensure its accuracy |
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立辊架为滑槽式结构，其中：双立辊导向，手动调节同时开合和对中；立辊滑块为分体式，用螺钉调节松紧； Vertical roller is sliding-type structure, including: double vertical roller Guide,manually adjust the opening and closing at the same time vertical roll slider is the split, with screw to adjust tightness |
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换辊方式：侧拉式 Roller changing way: Side pull |
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机架润滑：水平辊架后端排架使用油枪油脂润滑，配加油嘴 Bracket Lubrication: horizontal roller bracket back-end bent use grease lubrication oil gun, with refueling nozzle |
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5、焊接设备(机械部分) Welding Unit
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焊缝导向机架 Weld guide bracket |
（1套）导向辊由上下两个辊子组成，中间装有导向刀片，焊缝角度通过螺杆调节 (1 set)Guide roller is composed of upper and lower rollers, the middle is equipped with guide blade, weld angle adjusted through the screw |
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焊接挤压辊机架 Welding extrusion roller bracket |
（1套）2辊式，压辊加压将熔融的金属挤压并焊合在一起 (1 set) Two roller, roller pressure squeezing molten metal and welded together |
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侧挤压辊轴装辊直径 Roller diameter of The lateral extrusion roller |
Φ35mm |
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外毛刺去除装置 Outer burr removal device |
（1架）装有可交替使用的前后刀具座，手轮调整刀具的高度和横向位置并加装有快速进退刀装置 (1 set) Before and after the tool holder can be used interchangeably, the hand wheel adjust the cutting tool height and horizontal position and equipped with a fast cutting device |
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下支承部分 lower support part |
硬木板支承，高度可调；可保证焊缝切削光滑平整 Hard wood supports, height is adjustable; can ensure the seam cutting is smooth |
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磨光辊机架 Polishing roller bracket |
（1架）立辊式，手动调节开合和对中 （1 set）Vertical roller, manually adjust the opening and closing |
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冷却装置型式 Form of cooling device |
喷淋和溢池联合式 Spray pool and overflow pool |
6、定径机架Sizing Bracket
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定径要求 Sizing requirement |
圆管round pipeФ12.7-Ф38.1mm， thickness 壁厚：0.4-2.0mm 方管Square tube: 10*10 –30*30mm thickness 壁厚：0.4-1.5mm 矩形管Rectangle tube:within same bandwidth of tube/pipe |
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定径机架规格 Sizing bracket specifications |
辊架 Roller bracket |
数量 quantity |
辊架轴径 Shaft diameter of roller bracket |
辊轴材料 Material of roller bracket |
轴热处理 Heat treatment |
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水平辊架 Horizontal Roller bracket |
6 |
Φ50mm |
42Crmo |
调质高频淬火 HF quenching |
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立辊架 Vertical Roller bracket |
6 |
Φ35mm |
42Crmo |
调质高频淬火 HF quenching |
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水平辊模具采用隔套直接固定，保证机组精度 Horizontal roller mold adopt spacer fixed directly, ensure its accuracy |
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定径机架机构要求 Sizing bracket institutions requirements |
换辊方式：侧拉式 Roller changing way: Side pull |
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上辊调整：左右单独调整 Adjustment of Upper roller: left or right to adjust alone |
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立辊架为滑槽式结构，双立辊导向，手动调节同时开合和对中；双立辊导向，手动调节同时开合和对中；立辊滑块为分体式，用螺钉调节松紧 Vertical roller is sliding-type structure, including: double vertical roller Guide,manually adjust the opening and closing at the same time,vertical roll slider is the split, with screw to adjust tightness |
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矫直装置(土耳其头) Straightener(Turkey head) |
作用 Function |
矫直钢管平直度,引导钢管正确进入飞锯，也可对方矩管进行整径 Straightening steel pipe straightness, lead the steel pipe right into flying saw, can also be rectangular tubes for the whole size |
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结构 structure |
四辊土耳其头，分别上下、左右调整和旋转调整 Four-roll Turkey head, up and down, left and right adjustment and rotation adjustment respectively |
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数量 quantity |
两架单面土耳其头 Two Single-sided Turkey head |
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7、电脑飞锯机Computer Control Flying Saw
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型式Type |
微机定尺飞锯 computer length flying saw |
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用途 Usage |
确定钢管定长切断位置，并能快速起动使切断设备与作业线速度同步 Determine steel pipe fixed length cutting position, and can quickly start to make the cutting device synchronized with the production line |
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维持切断设备与作业线速度同步，切断机构动作切断钢管 Maintaining cutting device synchronized with the production line, cutting off steel body movements and steel pipe |
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快速复位 Fast reset |
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控制方法 Control way |
微机控制电机通过减速箱传动齿轮齿条驱动移动组件 Microcomputer control motor drives mobile component through gear box gear rack |
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切割方式 Cutting way |
热摩擦锯切 Friction heat of mental sawing |
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锯车最大运行速度 Maximum running speed of saw car |
100m/min |
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锯切管径 Pipe diameter |
圆管round pipeФ12.7-Ф38.1mm，方管Square tube: 10*10 –30*30mm |
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锯切管壁厚 Pipe thickness |
≤2.0mm |
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切割精度 Cutting precision |
±3mm |
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定尺长度 Specified length |
4～10m |
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锯片规格 Saw blade |
Φ400×35×3 |
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锯片转速 Saw blade rotation speed |
3000rpm |
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锯切电机 Cutting motor |
7.5KW（AC） |
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跟踪电机 Tracking motor |
11KW（DC） |
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气动系统 Pneumatic system |
0.4～0.7Mpa |
8、后辊道架Run Out Table
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支架结构形式 Support structure |
采用型钢焊接结构 Using steel welded structure |
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辊道架标高Roller rack elevation |
与管件轧制、飞锯下料中心标高一致 In line with pipe rolling and flying saw cutting center elevation |
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托辊形式、材料 Idler roller form and material |
托辊为平辊，材料：45＃钢淬火镀硬铬，使用寿命长，不划伤钢管 Idler roller is flat roller Material:45# steel quenching hard chrome plated, long service life, don't scratch steel pipe |
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托辊运转动力 Operation power of idler roller |
采用3KW电机拖动，可满足不同生产速度的需求 Adopt 3kw motor, can meet the needs of different production speed |
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翻料方向 Turning direction |
管件前进方向 |
四、传动系统 Transmission system
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传动原理 Principle |
整个机组成型机和定径机联动传动，各系统的主电机通过减速箱、齿轮箱(螺旋伞齿轮传动)、万向传动轴拖动水平辊；立辊为无动力辊。螺旋伞齿轮材质采用20CrMnTi Forming and sizing machines of the entire unit Transmission linkage, the main motors of each system drag horizontal roller through reducer, gear box (spiral bevel gear), universal transmission shaft; vertical roller is unpowered roller. Spiral bevel gear material used 20CrMnTi |
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主机机组电机 The host unit motor |
110KW |
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齿轮箱润滑 Gearbox Lubrication |
稀有浸泡润滑；箱体外有油位显示 Rare immersion lubrication; There is oil level outside the enclosure |
五、水管分布 Water pipe Distribution
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结构 Structure |
整机预留冷却液总接入口， 每段轧辊中间安装可调金属冷却管喷淋头 Reserve the engine cooling fluid total access, installing adjustable metal cooling spray headin the middle of each roller |
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冷却液流量 Coolant flow rate |
≥15吨/小时ton/hour |
六、焊管线主要外购件 Mainly Purchased Components of pipe line.
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主电机 Main motor |
国产品牌 Domestic brands |
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减速机 Reducer |
国产名牌Domestic brands |
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飞锯电源 Flying saw power |
进口品牌Imported brands |
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汽缸、气动元件 Cylinder, pneumatic components |
国产品牌Domestic brands |
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成型、定径机组轴承 Bearing of forming and sizing bearing unit |
国产品牌（哈、洛、瓦）Domestic brands |
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主要电器元件 Main electric components |
进口品牌Imported brands |
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固态高频 Solid state high frequency |
200KW节能一体机固态高频，单拖，风水冷，空调，调整支架 200KW energy-saving all-in-one machine solid state high frequency, single drag, air and water cooling, air conditioning, adjustment bracket |
Our main products are: open-book machine, shearing machine, spiral looper, precision welded pipe forming equipment, is a research and development, design, production, sales as one of professional manufacturers.
