ERW Tube Mill Machine
◎What Is ERW Tube Mill Machine?
ERW seamless pipe, full name Electric Resistance Welding, is a steel pipe made by heating and melting the edge of the tube blank through the skin effect and proximity effect generated by the high-frequency current of the ERW Tube Mill Machine, and pressure welding under the action of the extrusion roller of the erw pipe machine.
ERW Tube Mill Machine adopts hot-rolled steel plate and then welded by high-frequency current. The weld is stress-eliminated by medium-frequency heat treatment, and the internal burrs are removed by an annular knife. Generally speaking, the cross section of erw steel tube is circular, the coating is mostly uncoated black tube, the connection method is welding, and it is suitable for high-pressure fluid transportation.
ERW seamless pipe is mainly divided into two forms: ERW AC welded steel pipe and ERW DC welded steel pipe. ERW straight seam welded pipe is divided into low frequency welding, medium frequency welding, ultra-medium frequency welding and high frequency welding according to the frequency. High frequency welding is mainly used for the production of thin-walled steel pipes or ordinary thick-walled steel pipes, and high frequency welding is divided into contact welding and induction welding.
◎Technical Specification Of ERW Tube Mill Machine
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Raw Material |
Applicable materials include hot-rolled or cold-rolled strip coils such as carbon steel and low alloy steel. |
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Strip Width |
78-240mm |
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Strip Thickness |
1.0-4.0mm |
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Pipe Making Range |
Round Tube Diameter |
Φ25-Φ76mm |
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Round Tube Wall Thickness |
1.0-3.5mm |
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Square Tube Size Range |
20x20-60x60mm 20x40-40x80mm |
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Square Tube Wall Thickness |
0.8-3.0mm |
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Welding Method |
High frequency induction welding, high frequency power 300Kw |
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Pipe Mill Speed |
Max 10-80m/min |
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◎Working Processing Of ERW Pipe Mill Machine
Steel Strip
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Decoiler
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End Cutting
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Butting Welding
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Horizontal Accumulator
Flattening
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Roll Forming
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Electric Resistance Welding
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Removing Burrs
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Water Cooling
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Sizing
↓
Cutting
↓
Bundling
◎ERW Pipe Mill Machine Main Component Details
Hydraulic Decoiler And Shearing And Butt Welding
The hydraulic decoiler device of the ERW tube making machine is used to help the welded tube production line achieve stable unwinding, accurate feeding and continuous feeding of steel coils. The unwinding device of the ERW tube mill machine provides a stable and reliable raw material supply for continuous production through mechanical tension, precise centering and intelligent coordination.
ERW Tube Mill Machine adopts Shearing & Butt Welding as the core technology to realize continuous feeding of strip steel, which is mainly used to shear, align and weld the head and tail of the front and rear rolls of strip steel to ensure uninterrupted production.
Tube Mill Horizontal Accumulator Unit
ERW Tube Mill Horizontal Accumulator Unit is used for strip storage and stable feeding, solving the problem of mismatched production rhythm between the front and rear processes of the pipe mill machine.
The core function of the Horizontal Accumulator Unit is to achieve flexible buffer storage of strip steel through a spiral structure, ensuring that the pipe mill unit can continue to operate during intermittent operations such as strip steel docking and coil changing, thereby improving overall efficiency.
ERW Pipe Mill Machine Roll Forming
The roll forming part in the ERW Tube Mill Machine is used to continuously roll the steel strip into a tube and weld it into a tube. Then, the skin effect and proximity effect of high-frequency current are used to highly concentrate the current on the weld surface of the tube edge, so that the tube edge is quickly heated to the welding temperature, and the welding is completed under the pressure of the extrusion roller. After cooling, sizing and rough straightening, it becomes a steel pipe of the required specifications.
The ERW Pipe Mill Machine adopts the bottom line horizontal method for forming, and the roller adopts a double radius hole type. The main machine consists of a forming section, a welding section, and a sizing section.
High Frequency Welding For ERW Tube
The high-frequency welding (HFW) device in the ERW (resistance welding) pipe making machine achieves rapid heating and solid-state welding of the strip edge through the skin effect and proximity effect generated by high-frequency current.
After the strip is formed into an open tube, the high-frequency current heats the edge to a molten state by induction or contact. The extrusion roller applies pressure to squeeze out the slag and achieve metal lattice bonding to form a forged weld without cast structure.
Removing Burrs Device
The ERW (resistance welding) tube mill uses a removing burrs device to remove burrs formed on the inner and outer surfaces of the tube during welding, ensuring that the weld is smooth and accurate in size, and meets the industrial standard requirements for the surface quality of welded pipes.
Generally speaking, the removing burrs device of the ERW Tube Mill Machine uses an online scraper + closed-loop control to ensure a smooth weld and meet the requirements of a high-pressure environment.
ERW Tube Mill Machine Sizing System
The sizing system in the ERW pipe making machine is used to cut the continuously produced steel pipes to the required length. The saw carriage is synchronized with the high-speed main machine through speed measurement and calculation, and then the pipes are cut to the required length. Due to the use of fast and high-precision control systems and high-precision mechanical systems, it has the characteristics of stable operation, easy operation, accurate sizing, good synchronization performance, reliable mechanical transmission, and low failure rate.
◎Feature Of KINGREAL ROLL FORMER ERW Tube Mill Machine
1/High-precision pipe making process
ERW tube mill machine realizes ultra-precision processing through five-dimensional closed-loop control system, the deviation of welded tube outer diameter is ≤0.02mm, the deviation of ellipticity is ≤0.02mm, and straightness is <0.8mm/m. ERW tube mill machine adopts high-frequency inductive welding combined with on-line normalizing process, which makes the organization of weld seam consistent with the base material, and the strength of weld seam reaches more than 95% of the base material; the detection rate of defects increases by 40% through ultrasonic flaw detection and real-time monitoring. Real-time monitoring, defect detection rate increased by 40%.
2/Roller quick change system
KINGREAL ROLL FORMER Tube Mill Making Machine adopts dovetail groove positioning + hydraulic locking structure, which reduces the time of changing rollers to 10 minutes, and the production recovery time is only 20 minutes. Equipped with RFID chips, the rolls can automatically recognize the specifications and retrieve the preset parameters, which reduces the error of manual calibration.
3/ERW Tube Making Machine is easy to operate.
ERW Tube Making Machine supports Siemens S7-1500 series controllers, integrates 12 functional modules for welding, forming and cutting, and the operator interface supports Chinese/English/Spanish switching, which reduces the training period to 3 days.
4/ERW Tube Making Machine produces different shapes of products.
ERW Tube Making Machine can produce different shapes and sizes of tubes by replacing the rolls in the tube mill with high frequency ERW tube production line. A single ERW pipe mill production line can produce Φ8-630mm round pipe and 10×10-500×500mm square tube with wall thickness covering 0.5-20mm, and the material is compatible with carbon steel, low alloy steel and magnesium alloy.
◎Application Of ERW Pipe Mill Machine
☆Chemical Industry: ERW Pipe Mill Machine plays a key role in the chemical industry, used to produce stainless steel pipes and accessories for conveying chemicals, acid and alkali solutions, high-pressure gases, etc. Stainless steel pipes have excellent corrosion resistance and can meet the special requirements of chemical substances to ensure the safe delivery of media.
☆Oil and Gas Industry: The oil and gas industry requires a large number of stainless steel piping systems for conveying, storing and processing energy resources such as crude oil and natural gas. ERW Pipe Mill Machine can produce high-strength, pressure-resistant stainless steel pipes that meet relevant standards and specifications to meet the needs of the oil and gas industry.
☆Food and Beverage Industry: ERW Pipe Mill Machine plays an important role in the food and beverage industry. The food and beverage industry has very high requirements for hygiene. Stainless steel pipes have smooth inner surfaces and are non-toxic and odorless, which can ensure the quality and safety of food and beverages.
☆Pharmaceutical Industry: The pharmaceutical industry has strict requirements on the cleanliness of the piping system and the safety of the materials. ERW Pipe Mill Machine can produce high-precision, seamless stainless steel pipes for conveying drugs, manufacturing medical equipment, etc. Stainless steel pipes are corrosion-resistant, easy to clean and sterile, which are very suitable for applications in the pharmaceutical industry.
◎About KINGREAL ROLL FORMER
KINGREAL ROLL FORMER is a professional roll forming machine manufacturer in China, specializing in the design and quality manufacturing of roll forming machine equipment for more than 20 years. ERW pipe making machine is one of KINGREAL ROLL FORMER most popular products. We can provide customized design solutions according to the actual production needs of erw tube mill, and provide after-sales installation and operation guidance services for erw tube mill machine customers.
Welcome to contact us!
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