ERW64 High Frequency Straight Seam Welded Pipe Production Line

① Technical Plan

1. Main technical feature of the production line
   The ERW64 high frequency straight seam welded pipe production line is designed for producing high-quality steel pipes with stable welding performance and excellent dimensional accuracy. This line can manufacture round, square, and rectangular pipes that are widely applied in construction, machinery, transportation, energy, and other industries.With advanced forming technology, high frequency welding, and a robust mechanical structure, the production line ensures high output efficiency, reliable operation, and long service life.
2. Raw material:Belt steel roll made of Common Carbon Steel Q195/Q235/16Mn and high strength steel（conform to GB700-88 or GB1591-88）

1. Size of forming pipediameter：Φ12.7—Φ64mm（±0.1mm）
   thickness：0.5—3.0mm（±0.1mm）（square pipe、shaped pipe δ≤2.5mm）

	Round tube	Square tube	Rectangular tube
Pipe diameter range	Φ12.7－64mm	10×10－50×50mm	20×10－40×60mm
Wall thickness range	0.5－3.0mm	0.5－2.5mm	0.5－2.5mm

1.  Forming style of square tube : squeeze round tubes ; corner upward
2. Production style : continuously
3. Running direction of the line : left / right(according to the space of the     workshop)
4. Center height of the equipment operation : +850 mm
5. Welding style : High-frequency induction welding      Power for high-frequency : 150 kW
6. Speed of forming tube : 30-120 m/min
7. Total Power supplied for the line :350KW

1. Process flow

1. Strip coil→pay off reel→cut&butt weld→horizontal type accumulator→leveling→forming→weld&planning scar→cooling→shaping→speed meter→straighter
   →cut size→pack
    
    
    
             

1. Main Equipment Introduction

1. Decoiler 
2. Used for loading strip steel coils to ensure that the strip steel enters the loop smoothly.

1. Shear butt welder 
    
   This is an automated device that connects the ends of two rolls of strip steel. The shearing process is automated, the cutting feed is cut and the welding is done manually;It can save part of the labor, improve the quality of the joint, and greatly shorten the joint time

1. Accumulator  
   Store belt steel ,and ensure uninterrupted supply of raw material.

Structure style	Split bed, single motor drive
Equipment arrangement list	Forming stage:→7 Roller for straightening→1 Horizontal→1 Vertical→2 Horizontal→2 Vertical→3 Horizontal→3 Vertical→4 Horizontal→4 Vertical→5 Horizontal→5 Vertical→6 Vertical→6Vertical→7 Horizontal→7Vertical→8Vertical
	Welding stage:Direction guidance→Extruding(2 roller) →Scarring→Scarring→zinc painting→Polishing→Cooling
	Setting the diameter stage :1 Vertical→1 Horizontal →2 Vertical→2 Horizontal→3 Vertical→3 Horizontal →4 Vertical→4 Horizontal→5 Vertical→5 Horizontal →6Vertical→6Horizontal→Straightening
Drive style	Supplied 160KW /1500 rpm,direct-current-motor,passing to the worm wheel branch drive box through  ZLY224 Speed reducer , then passing to every horizontal roller by universal spindle .
Horizontal roller equipment	Gantry type integral frame, 45 steel forging,horizontally moving frame for roll changing.
	Size of the spindle	Φ65mm ,42CrMo changing quality treatment,surface high-frequency.
Vertical roller equipment	Separate installation of base slide and roller shaft， Screw adjustment roller spacing， The nut matched with the screw rod is made of copper.
	Size of the spindle	Φ40mm,42CrMo changing quality treatment,surface high-frequency
Branch drive box	Driven by spiral bevel gear , modulus M 8 , 20CrMoTi carburizing and quenching treatment,
Guiding device	The effective working part of the device can move both vertically and horizontally , rotate at 360 degrees. The welding-opening-angle can be adjusted back and forth.
Extruding device	3 roller extrusion
Planing device	2 - planer chip removing,cam can be lifted quickly and fine adjustment
Cooling device	Combination of immersion and irrigation
Straightening device	。 Turkey type , Single side 2-roller, can move both vertically and horizontally , rotate at 360 degrees.
Bearing	HRB original
Dimension size	Subject to the foundation drawing

1. Computerized cold Flying Saw 
2. cut pipe by fixed-length.

1. Run out table

1. Mould 

1. Design and manufacture to the customer’s request of the specification and model
2. Material of forming and sizing:Cr12,（HRC）58-62°
3. material of extrusion roller；H13,（HRC）48-52° 

1. Solid-state high-frequency welding machine: Brand: Tianyixing/Bohong 

Rectifier Cabinet
The rectifier cabinet uses high-power thyristor components for rectification and incorporates several harmonic absorption and LC resonant filtering components. This reduces output voltage ripple and improves ripple factor. The overall output ripple factor can reach 1%, ensuring weld quality while also preventing harmonic interference with the power grid.
Inverter Output Cabinet
(1) Provides the AC power required for steel pipe welding. The inverter section consists of a MOSFET single-phase inverter bridge. The inverter bridge uses a building block approach to achieve power stacking. Each bridge board is designed as a drawer-type structure composed of slides, which is convenient for installation and maintenance.
(2) The output power of a single-layer module is 50kW/100kW, and modules of the same power are interchangeable.
The air-water cooler is equipped with an electric load matching device, which can easily adjust the load of the equipment (current and frequency adjustment).
(1) Fully enclosed circulation cooling prevents foreign matter from entering and causing pipe blockage.
(2) Soft water circulation prevents scale from forming and causing overheating and damage to water-cooled components, water-cooled capacitors, water-cooled reactors, quenching transformers, induction coils, etc.
(3) Automatic temperature control implements constant temperature control of the cooling temperature of the circulating cooling water, and the water temperature can be controlled to ≤40℃.
(4) No water tank or cooling tower is required, which is low in cost and occupies a small area. It can be placed and moved with the equipment.
(5) Automatic digital display temperature control, energy saving, and simple operation.
(6) The cooler uses copper tubes, the shell is made of galvanized sheet, and the water tank is made of stainless steel.
(7) High heat exchange efficiency, only one heat exchange is required to exchange heat to the air.
(8) The soft water consumption is extremely low, and only soft water (such as distilled water) needs to be added once. In winter, antifreeze can be added in appropriate amounts.