Welded pipe production may seem complex, but it is actually a collaborative operation of a series of precision processes. The ZY series high-frequency welded pipe mill transforms steel strips into high-precision pipes through a 12-step standardized process, with each step containing hidden ingenuity. The following breaks down the core principles and key parameters of each link from raw materials to finished products.
Core Equipment: Pneumatic double-reel uncoiler
Working Principle: Fix the coiled steel strip (inner diameter φ508mm, outer diameter ≤φ1200-1800mm, coil weight ≤1.5-5 tons) through a pneumatic expansion reel, and control the uncoiling speed through pneumatic strength braking to avoid slack or tearing of the steel strip.
Key Details: The double-reel design supports manual 180° rotation for station replacement, reducing downtime for coil change by 50%, and is suitable for various raw materials such as hot-rolled/cold-rolled low-carbon steel and galvanized steel.
Two Forms Adapt to Different Needs:
Core Functions:
① Cut off the defective parts at the head, tail and middle of the steel coil to ensure the purity of raw materials;
② Cut the head and tail before welding to make the joint flat and aligned (manual seaming), laying the foundation for welding.
Parameter Highlights: The cutting thickness is 0.4-4.5mm (covering the whole series), the blade is made of T12A high-strength steel, and the 2-3 edge design prolongs the service life. Hydraulic/pneumatic shearing power is suitable for different steel strip thicknesses.
Core Equipment: 7-roller leveling device
Working Principle: The lower roller is fixed, and the upper roller is adjusted in height through a handwheel screw. The unpowered roller group eliminates the rolling stress of the steel strip through multiple passes of rolling, making it enter the forming mill smoothly.
Why 7 Rollers: The multi-roller design can precisely control the deformation, avoiding wrinkling of thin steel strips (0.4mm) and bending of thick steel strips (4.5mm), laying the foundation for subsequent forming accuracy.
Core Principle: Using the baseline horizontal roller forming principle, the rollers adopt a double-radius pass. Through the cooperation of horizontal rollers and vertical rollers, the flat steel strip is gradually rolled into a tubular shape.
Structural Details:
Three Steps to Achieve Seamless Welding:
① Weld Seam Guiding: The upper and lower rollers clamp the pipe blank, and the middle guide blade calibrates the seam angle (adjusted by screws) to ensure edge alignment;
② High-Frequency Heating: Through 100-300kw solid-state high-frequency equipment, the metal at the seam is instantly melted (temperature reaches 1300-1500℃);
③ Extrusion Welding: Two-roller/three-roller extrusion rollers (side roller diameter φ25-50mm) apply pressure to squeeze out molten impurities, making the edges of the pipe blank fuse into one.
Equipment Design: 1 stand with double tool holders (alternately usable), adjusting the height and lateral position of the tool through a handwheel, combined with a pneumatic fast feed and retract device, to efficiently remove external burrs generated during welding.
Detail Guarantee: The hardwood lower support (height adjustable) lifts the pipe blank to avoid shaking of the pipe during cutting and ensure the weld is flat.
Cooling Method: Combined spraying and overflow pool
Core Function: Through the precision rolling of 6 horizontal rollers and 6 vertical rollers, the size of the formed pipe is calibrated to the target value (round pipe φ8-102mm, square pipe 10x10-80x80mm, etc.).
Accuracy Guarantee: The horizontal roller shaft diameter is φ40-90mm (same as the forming roller material), the upper roller is adjusted separately left and right, and the vertical roller is equipped with an up-down adjustment mechanism to ensure the pipe diameter tolerance is ≤±0.1mm.
Two Devices Adapt to Needs:
Core Performance:
Structural Design: Section steel welded bracket, the idler is 45# steel quenched and hard chrome plated (scratch-resistant), driven by a 3-5kw motor, the speed matches the production line, and smoothly conveys the finished pipe to the stacking area.
From uncoiling to run-out, the ZY mill transforms steel strips into high-precision pipes through 12 steps in three stages: "raw material processing → shaping and welding → finishing and cutting". The core advantages lie in:
What you can understand in 3 minutes is not only the process, but also the design logic of "precision, efficiency and reliability" of the ZY mill.
Contact Person: Mr. Darcy
Tel: 008613962217067
Fax: 86-512-58371721