一、主要技術規格Main Tech Parameters
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原材料(鋼帶)材質 Steel strip material |
熱軋或冷軋,低碳鋼，低合金鋼，鍍鋅鋼帶 Hot rolled or cold rolled, low carbon steel, low ally steel, galvanized steel. |
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成品要求 Finished Products requirements |
圓管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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機列要求 Machine column requirements |
機列形式：分體式 Form: Split |
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布置方式：根據客戶的需求 arrangement form: according to the customer's requirements |
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機組生產速度 Unit production speed |
0～100m/min (特定條件下無法達到最高速度The maximum speed can not be reached under certain conditions |
二、工藝流程 Working Flow
開卷→剪切對焊→螺旋活套→校平→軋制成型→高頻焊接→刮刀→冷卻 →定徑→矯直→鋸切料→下料臺
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、焊管線主要構成規格 Mainly Composed Specifications Of Pipe Line
1、開卷機 Uncoiler
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結構形式 type |
雙頭氣動式開卷機Double Side pneumatic Mechanical Un-coiler |
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適用鋼帶內徑 Shrinking and expanding range of I.D |
鋼卷內徑漲縮范圍φ470-φ520mm（根據客戶需求） Φ470-Φ520(according to the customer’s request) |
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鋼帶外徑 steel strip O.D |
≤φ1800mm |
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鋼帶寬度 Steel strip width |
40～120mm |
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鋼帶卷重 Steel strip coil weight |
單邊One side≤1.5噸Ton |
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制動形式 Brake from |
氣動、強弱制動Pneumatic brake |
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轉動形式 rotation form |
人工推動平臺±180°Manual push platform±180° |
2、液壓剪切手工對焊機或自動焊Hydraulic shear And Manual Butt Welder or Automatic welding
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作用Function |
切除鋼帶頭尾的缺陷部分以及帶卷中間的缺陷部分 在對焊前切頭切尾，使對焊接頭平直對正，利于對焊 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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結構形式 Structure form |
液壓剪+手動焊接+手動對縫 或 液壓剪+自動焊接+自動對縫 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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最大剪切寬度 Maximum steel strip width |
130mm |
3、盤式螺旋活套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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活套直徑 Diameter |
Ф3.5米meter |
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鋼帶寬度 Steel strip width |
40～120mm |
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鋼帶厚度 Steel strip thickness |
≦2.0mm |
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充料速度 Feeding speed |
≥200m/min |
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送料電機功率 Feeding motor power |
7.5KW |
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活套主體功率 Accumulator unit motor power |
11KW |
4、成型定徑機組Forming And Sizing Machine
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進料裝置 Feeding device |
導向立輥 Guide vertical roll |
矯平輥后兩對導向立輥，通過手動調節對中開合調整 After leveling roll two pairs of vertical guide rollers, regulation of the opening and closing by manual adjustment |
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矯平輥 Leveling roller |
采用7輥矯平裝置，使鋼帶平穩進入成型機組，矯平輥為無動力輥，下輥固定，上輥通過首輪絲桿上下調整 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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成型機架 Forming bracket |
成型原理 principle |
本機組采用底線水平輥式成型原理，軋輥采用雙半徑孔型 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 |
圓管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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成型機架規格 Forming bracket specifications |
輥架 Roller bracket |
數量 quantity |
輥架軸徑 Shaft diameter of roller bracket |
輥軸材料 Material of roller bracket |
軸熱處理 Heat treatment |
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水平輥架 Horizontal Roller bracket |
7 |
Φ50mm |
42Crmo |
調質高頻淬火 HF quenching |
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立輥架 Vertical Roller bracket |
7 |
Φ35mm |
42Crmo |
調質高頻淬火 HF quenching |
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成型機架機構要求 Forming bracket institutions requirements |
在每個開口成型水平機架上輥方軸承頂部都設由過載保護裝置，當遇到過載時該墊有緩沖，以保護水平輥和傳動裝置 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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水平輥架為龍門式結構，其中：開口成型4機架；閉口成型3機架。水平輥模具采用隔套直接固定，保證機組精度 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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立輥架為滑槽式結構，其中：雙立輥導向，手動調節同時開合和對中；立輥滑塊為分體式，用螺釘調節松緊； 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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換輥方式：側拉式 Roller changing way: Side pull |
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機架潤滑：水平輥架后端排架使用油槍油脂潤滑，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、焊接設備(機械部分) Welding Unit
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焊縫導向機架 Weld guide bracket |
（1套）導向輥由上下兩個輥子組成，中間裝有導向刀片，焊縫角度通過螺桿調節 (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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焊接擠壓輥機架 Welding extrusion roller bracket |
（1套）2輥式，壓輥加壓將熔融的金屬擠壓并焊合在一起 (1 set) Two roller, roller pressure squeezing molten metal and welded together |
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側擠壓輥軸裝輥直徑 Roller diameter of The lateral extrusion roller |
Φ35mm |
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外毛刺去除裝置 Outer burr removal device |
（1架）裝有可交替使用的前后刀具座，手輪調整刀具的高度和橫向位置并加裝有快速進退刀裝置 (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，高度可調；可保證焊縫切削光滑平整 Hard wood supports, height is adjustable; can ensure the seam cutting is smooth |
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磨光輥機架 Polishing roller bracket |
（1架）立輥式，手動調節開合和對中 （1 set）Vertical roller, manually adjust the opening and closing |
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冷卻裝置型式 Form of cooling device |
噴淋和溢池聯合式 Spray pool and overflow pool |
6、定徑機架Sizing Bracket
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定徑要求 Sizing requirement |
圓管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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定徑機架規格 Sizing bracket specifications |
輥架 Roller bracket |
數量 quantity |
輥架軸徑 Shaft diameter of roller bracket |
輥軸材料 Material of roller bracket |
軸熱處理 Heat treatment |
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水平輥架 Horizontal Roller bracket |
6 |
Φ50mm |
42Crmo |
調質高頻淬火 HF quenching |
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立輥架 Vertical Roller bracket |
6 |
Φ35mm |
42Crmo |
調質高頻淬火 HF quenching |
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水平輥模具采用隔套直接固定，保證機組精度 Horizontal roller mold adopt spacer fixed directly, ensure its accuracy |
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定徑機架機構要求 Sizing bracket institutions requirements |
換輥方式：側拉式 Roller changing way: Side pull |
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上輥調整：左右單獨調整 Adjustment of Upper roller: left or right to adjust alone |
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立輥架為滑槽式結構，雙立輥導向，手動調節同時開合和對中；雙立輥導向，手動調節同時開合和對中；立輥滑塊為分體式，用螺釘調節松緊 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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矯直裝置(土耳其頭) Straightener(Turkey head) |
作用 Function |
矯直鋼管平直度,引導鋼管正確進入飛鋸，也可對方矩管進行整徑 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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結構 structure |
四輥土耳其頭，分別上下、左右調整和旋轉調整 Four-roll Turkey head, up and down, left and right adjustment and rotation adjustment respectively |
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數量 quantity |
兩架單面土耳其頭 Two Single-sided Turkey head |
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7、電腦飛鋸機Computer Control Flying Saw
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型式Type |
微機定尺飛鋸 computer length flying saw |
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用途 Usage |
確定鋼管定長切斷位置，并能快速起動使切斷設備與作業線速度同步 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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維持切斷設備與作業線速度同步，切斷機構動作切斷鋼管 Maintaining cutting device synchronized with the production line, cutting off steel body movements and steel pipe |
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快速復位 Fast reset |
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控制方法 Control way |
微機控制電機通過減速箱傳動齒輪齒條驅動移動組件 Microcomputer control motor drives mobile component through gear box gear rack |
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切割方式 Cutting way |
熱摩擦鋸切 Friction heat of mental sawing |
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鋸車最大運行速度 Maximum running speed of saw car |
100m/min |
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鋸切管徑 Pipe diameter |
圓管round pipeФ12.7-Ф38.1mm，方管Square tube: 10*10 –30*30mm |
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鋸切管壁厚 Pipe thickness |
≤2.0mm |
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切割精度 Cutting precision |
±3mm |
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定尺長度 Specified length |
4～10m |
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鋸片規格 Saw blade |
Φ400×35×3 |
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鋸片轉速 Saw blade rotation speed |
3000rpm |
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鋸切電機 Cutting motor |
7.5KW（AC） |
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跟蹤電機 Tracking motor |
11KW（DC） |
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氣動系統 Pneumatic system |
0.4～0.7Mpa |
8、后輥道架Run Out Table
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支架結構形式 Support structure |
采用型鋼焊接結構 Using steel welded structure |
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輥道架標高Roller rack elevation |
與管件軋制、飛鋸下料中心標高一致 In line with pipe rolling and flying saw cutting center elevation |
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托輥形式、材料 Idler roller form and material |
托輥為平輥，材料：45＃鋼淬火鍍硬鉻，使用壽命長，不劃傷鋼管 Idler roller is flat roller Material:45# steel quenching hard chrome plated, long service life, don't scratch steel pipe |
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托輥運轉動力 Operation power of idler roller |
采用3KW電機拖動，可滿足不同生產速度的需求 Adopt 3kw motor, can meet the needs of different production speed |
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翻料方向 Turning direction |
管件前進方向 |
四、傳動系統 Transmission system
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傳動原理 Principle |
整個機組成型機和定徑機聯動傳動，各系統的主電機通過減速箱、齒輪箱(螺旋傘齒輪傳動)、萬向傳動軸拖動水平輥；立輥為無動力輥。螺旋傘齒輪材質采用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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主機機組電機 The host unit motor |
110KW |
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齒輪箱潤滑 Gearbox Lubrication |
稀有浸泡潤滑；箱體外有油位顯示 Rare immersion lubrication; There is oil level outside the enclosure |
五、水管分布 Water pipe Distribution
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結構 Structure |
整機預留冷卻液總接入口， 每段軋輥中間安裝可調金屬冷卻管噴淋頭 Reserve the engine cooling fluid total access, installing adjustable metal cooling spray headin the middle of each roller |
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冷卻液流量 Coolant flow rate |
≥15噸/小時ton/hour |
六、焊管線主要外購件 Mainly Purchased Components of pipe line.
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主電機 Main motor |
國產品牌 Domestic brands |
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減速機 Reducer |
國產名牌Domestic brands |
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飛鋸電源 Flying saw power |
進口品牌Imported brands |
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汽缸、氣動元件 Cylinder, pneumatic components |
國產品牌Domestic brands |
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成型、定徑機組軸承 Bearing of forming and sizing bearing unit |
國產品牌（哈、洛、瓦）Domestic brands |
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主要電器元件 Main electric components |
進口品牌Imported brands |
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固態高頻 Solid state high frequency |
200KW節能一體機固態高頻，單拖，風水冷，空調，調整支架 200KW energy-saving all-in-one machine solid state high frequency, single drag, air and water cooling, air conditioning, adjustment bracket |
江陰市銀江機械有主導產品有：開卷機、剪切機、螺旋活套、焊管成形設備等，是一家集研發，設計，生產，銷售為一體的專業制造廠家。
