HG50 高精度焊管生产线技术参数

HG50 HIGH PRECISION WELDED PIPE PRODUCTION LINE

TECHNICAL PROPOSAL

HG50 高频直缝精密焊管生产线主要用于生产圆管 φ17.2～φ60.3mm，壁厚 1.5

～3.5mm，方管 15×15--50×50mm,厚度 1.5-3.0mm 的电焊钢管。该生产线各单机在消
化吸收国内外同类设备的基础上,结合我国国情,创新设计。操作维修方便,设计水平
和制造质量在全国处领先地位,在结构和精度上达到近几年引进机组水平。本机组加
工质量和装配精度较高，采取合理的轧辊孔型，可以生产精度比较高的电焊钢管.
HG50 High-Frequency Welded Pipe Production Line is designed to produce welded pipes of Ф17.2～

60.3mm in diameter and 1.5～3.5mm in wall thickness ,square tube:15×15--50×50mm with thickness 1.5-

3.0mm and other deformed pipes of the corresponding size. Adopting roll pass design, the production line

can manufacture welded steel pipes with good quality machining and high precision assembling.

1. 主要技术参数 Main Parameters and Specifications：

1) 材料规格：Material Specifications：
应符合 YB189-64 标准（焊管坯）的要求
 Conforming to the YB189-64 standard
材质 Material 低碳钢、低合金钢
Low carbon steel and low alloy constructional steel
材料机械性能 Mechanical properties σb≤640Mpa，σs≤415MPa
带钢宽度 strip width 54～200mm
带钢厚度 strip thickness 1.5～3.5mm
带钢卷内径 I.D of Coils Φ580～φ630mm
带钢卷外径 O.D of Coils φ1300～φ2000mm
带钢卷卷重 Coil Weight ≤3.0T

2) 焊管产品主要规格：Welded Pipe Specification

成品钢管直径 Round Pipe Diameter Φ17.2～φ60.3mm
成品圆管壁厚 Round pipe thickness 1.5-3.5mm
成品方管尺寸 square tube size 15×15--50×50mm
成品方管厚度 square tube thickness 1.5-3.0mm
成品钢管长度 Finish pipe length 6-8m
定尺精度 Cut accuracy ±3mm
成型速度 Forming speed 50-100m/min

3) 电力，水和空气供应 Power, Water & Air Supply

电能 Power Power Volume of the Line 总功率 Approx.400KW
Power Source 电源 480V/60Hz/3phases
Circulation Cooling Water Flow 流量 20T/h～30 T/h
循环冷却水 Pool Volume 蓄水量 30m3
Compressed Air Flow 流量 5m3/min
压缩空气 Pressure 压力 5～11kg/ cm2

4) 车间要求：workshop require:
厂房高（从天车轨道上面到地面距离）应大于 5m，跨度 8m，长度 60m。
8m wide, 60m long, at least 5m high from Ceiling Rails to Ground.

2. 生产工艺：Product process:
带钢卷料→开卷→剪切对焊→活套储料→成型、高频焊接、水冷、焊缝抛光、定径、粗矫直→锯切
定尺→检查收集→打包→入库。
Coil Loading → Uncoiling →Cutting and Welding →cage Accumulator → Forming, HF welding,

Deburring, Cooling, Sizing, Straightening →cutting saw → Packing → Storage

3. 设备组成及单机主要参数 Main parameters of each unit.

3.1 双锥手动开卷机 double cone Uncoiler

用于支撑带卷，为生产线提供原料。该机主要由底座、立轴、回转支撑、气动刹车装置系统，为涨
缩型悬臂式。液压涨缩，气动制动。
The uncoiler is of the structure of one cone. It contains two main parts: main body and the fixed base.
The main body is equipped with pneumatic system to satisfy the needs of expanding, contracting and
braking of the mandrels. hydraulic expanding and Pneumatic driving

钢卷外径 coil out diameter Φ1300-2000mm

钢卷内径 coil inner diameter Φ580-630mm
带钢宽度 strip width 54-200mm
带钢厚度 strip thickness 1.5-3.5mm
带钢重量 strip weight Max3.0T
涨缩形式 expand type 手动涨缩 manual expansion
制动 break 气动制动 Pneumatic drive
芯轴材质 mandrel material 40Cr,调质处理，硬度 HB220-260

3.2 自动剪切机 Automatic shear welder

用于带钢头尾不规则部分的剪切和对焊，以保证焊管机组的连续生产。
 Shear &welder is used to cut the irregular ends of the strips and then connect the strips by welding.
剪切宽度 shear width 54-200mm
焊接厚度 shear thickness 1.5-3.5mm
剪切方式 shear type Automatic shear 自动剪切
焊接形式 welding type Automatic welding 自动焊接
气压 Pneumatic pressure 0.5MPa
工作周期 Working Cycle Max.300 seconds

3.3 盘式活套 Horizontal accumulator

1. This machine is used between the shearing butt welding machine of the welded pipe production line

and the mainframe (forming sizing machine). Its function is to run out of the previous strip, and the next

strip is prepared from The continuous production of the main machine (forming sizing machine) is
ensured within a time and sufficient strip steel is stored.

2. This machine is mainly composed of feeding guide roller frame, clamp feeding device, looper body

assembly, discharging device and electrical control device.

3. Clamp feeding device: It is mainly composed of a frame, a motor, a brake, a universal drive shaft of

a reducer, a pinch roller, and a guide roller pneumatic system. It can feed the steel belt into the looper.

When the feeding needs to stop, the brake It can stop the motor and the clamp feeding roller from

rotating, and the electric motor's rotation speed and feeding speed can be adjusted by the electric control

device.

4. Accumulator body assembly: It is mainly composed of motor, machine base, inner circumferential

roller, center discharge roller, outer ring roller and pressure roller, etc. It can store the strip steel sent by

the clip feeding device and can be from the center The discharge roller is withdrawn.

5. Discharging device: It consists of a bracket, a guide roller group, an upper and lower lead-out roller,

and a speed measuring device. It can horizontally introduce the steel belt stored in the looper body into

the forming unit and make the device.

Thickness 1.5-3.5mm Width 54--200mm

Storage material more

Advantage Feeding speed Max 200m/min
No strike to strip steel surface

Carry motor power 15KW Accumulator motor power 18.5KW

Accumulator
4 meter
diameter

3.4 喂入导向装置 feeding guide unit

将平直的钢带顺利导入成型装置。
Guide the steel strip into the forming device smoothly.
矫平辊硬度 Leveling roll hardness HRC58-62
矫平辊材质 leveling roll material Gcr15
矫平辊结构 Leveling roll structure up2 down 3 上 2 下 3
较平辊数量 leveling roll No. 5

3.5 成型机 Forming machine:

 带钢进入成型机架，在成型机架部分形成圆形。
The steel strip goes into the forming stand then in the forming part into a round shape.

水平辊调整方式，手动调整，
Horizontal roll up and down adjust way，manual adjust
特点
水平辊下轴活动的,固定端配有补偿垫
leveling roll lower shaft is active,leveling shaft fix side with compensate pad
水平辊架数量 Horizontal stand quantity 7
水平辊轴直径 Horizontal shaft diameter 65mm
水平辊轴材质 Horizontal shaft material 40Cr
技术参数
成型速度 forming speed 50-100m/min
成型电机 motor DC 90Kw
Technical
水平机架材质 leveling stand material steel plate welding 钢板焊接
parameters
立辊架数量 vertical stand quantity 7
立辊轴直径 vertical shaft diameter 40mm
立辊轴材质 vertical shaft material 40Cr

3.6 焊缝导向，挤压辊和焊接刮疤：Weld seam guide and squeeze roll stand, welding bead cutter:
挤压辊是为了挤压加热到焊接温度的管子的边缘，通过挤压辊施加一定的压力来达到焊接的
目的。焊缝刮疤刀用于焊缝刮疤，去除外毛刺。它由两种刀具组成，交替使用。如果一个被损坏了，
另一个将会替换使用。刮疤刀可以调整，并通过凸轮快速换刀。在刀架下有两个支撑辊，以承受刮
擦的透支。刮疤后有一个水平机架用来磨光。
Squeeze roller is to squeeze the edge of the tube which has been heated to welding temperature, by
squeezing rolls giving a certain pressure to achieve welding purpose. Weld bead cutter is used to scrap
weld seam and remove external burr. It is made up of two cutters for using alternately. If one is damaged,
the other one will take the place to scrap. Scrapers can be adjusted and have the quick lift function by cam.
There are two supporting roller underneath knife rest, in order to bear the overdraft of scraping. and after
the bead cutter with one horizontal stand for polish.

刮刀数量 Scrap knife 2 sets

挤压辊轴数量 Squeezing roll shaft No. 2
挤压辊轴直径 squeeze roll diameter 50mm
挤压辊轴材质 squeeze roll diameter 40Cr

3.7 冷却水槽：Water cooling unit:

材质：钢板焊接 material: steel plate welding
 3.8 定径机 sizing machine
圆管经过定径部分形成要求的直径和形状.
The round pipe after sizing part into the require diameter and shape

水平辊架数量 Horizontal stand quantity 5

水平辊轴直径 Horizontal shaft diameter 65mm
水平辊轴材质 Horizontal shaft material 40Cr
水平机架材质 leveling stand material steel plate welding 钢板焊接
立辊架数量 vertical stand quantity 5
立辊轴直径 vertical shaft diameter 40mm
立辊轴材质 vertical shaft material 40Cr
定径电机 sizing motor DC 110KW
土耳其头 Turkey head 2 sets

3.9 齿轮箱 Gear box:

 齿轮箱数量 Gear box quantity 12
齿轮箱箱体材质 Gear box boday material steel plate welding 钢板焊接
齿轮材质 Gear material 20CrMnTi
齿轮硬度 Gear hardness HRC 58-62
齿轮轴材质 Gear shaft material 40 Cr
齿轮轴硬度 Gear shaft hardness HRC40-45
减速箱数量 Reducer box quantity 1

3.10 Cold saw 冷切锯

 The cold saw machine is the key equipment in the production pipe, and it used to precisely cut all

kinds of frame tube automatically. Concerning to using high accurate STD control system and

machinery system, this unit has the good precisely dimension advantage, and the machinery transfer best

advantage, so the quickly ability and accurate processing, without Burr is this unit advantage.

Round pipe:φ17.2-φ60.3mm
Thickness: 1.5-3.5mm
Pipe size
Square pipe:15x15-50x50mm
Thickness:1.5-3.0mm
Material Q235.
Speed Max. 100m/min
Pipe end burr No burr(less than 0.2mm)
Cutting Length 4-12m
Precision ±1.5mm
Drive motor 15kw servo motor (yaskawa)
Feeding motor 4.4kw servo motor (yaskawa)

Cutting motor 11KW variable frequency

3.11 200kw 固态高频 200kw solid high frequency welder

 1) 固态高频设计参数 Design parameters of solid state high frequency welder

额定输出功率 Rated output power 200KW

总效率 Total efficiency η ＞85%
共振形式: Resonance form 复合共振 Compound resonance
输出形式: Tank output form 无焊接变压器输出 No welding transformer output.
涟漪系数 Ripple Coefficient ＜1%
焊接方式: Welding mode 感应焊接、接触焊接 Induction welding, Contact welding
配电容量 Power distribution capacity 461KVA
输入电压 Input voltage 380V/50Hz，3 phase 4 wire system
额定输入电流 Rated input current I=700A
 2) 循环水冷却系统 Cooling system
出水温度 Output water temperature ≤41℃，温度范围 temperature range：4℃
冷却水流量 Cooling water flow 15m3/h
工作水压 Working water pressure: 0.35Mpa
水质要求 Water quality requirements： 蒸馏水 Distilled water

3.13 辊道 run-out table

用于输送储存锯切后的钢管，并打钢管送到打包机。辊道为“V”型轧道，翻料结构为电动翻料。
It is used to transport and store the sawed steel pipe, and to drive the steel pipe to the packing line. The
roller table is a "V" type roller table, and the turning structure is electric turning.

3.13 模具 ：roller
成型辊材质 Forming roller Material Cr12
焊接辊材质 welding roller material H13
热处理硬度 Heat treatment hardness HRC58~62
4. PRICE (EX-Works Price)
No. Name Qty Unit Price (USD)
1 双锥手动开卷机 double cone uncoiler 1 set 6,000
2 自动剪切对焊机 automatic shear welder 1 set 8,500
3 盘式活套 horizontal accumulator 1 set 30,700
4 喂入导向装置 feeding guide unit 1 set
5 成型机 forming machine 1 set
焊缝导向，挤压辊和焊接刮疤：
6 Weld seam guide stand and the squeeze roll stand, 1 set
70,000
welding bead cutter:
7 冷却水槽：Water cooling unit: 1 set
8 定径机 sizing machine 1 set
9 齿轮箱 gear box 1 set
10 Cold saw 冷锯 1 set 60,000
200kw 固态高频 200kw solid high frequency welder 1 set
11 30,800
拖动系统 Drive system 2 sets
12 下料辊道 runout table 12m set 5,200

IN TOTAL 211,200 USD

Note: The price of rollers shall be calculated by weight, Unit price is 6,250 USD/Tons

5. 售后服务和质保期 Warranty
设备到达需方后，派技术服务人员在现场进行调试、保养服务，提供设备试运行、调试、操作及
维护的指导，负责对需方的设备操作和维护人员进行技术培训。在用户遵守使用规则、正常操作设
备情况下，自设备到货之日起 12 个月内，如确因质量不良影响使用、发生零件损坏导致设备无法
正常工作，制造厂将无偿的给予修理或更换。
When the production line is delivered to the demander, our commissioning engineers will be
responsible for guiding the demander fulfill the installation, commissioning, operation and maintenance
of the line and training the demander’s workers how to operate and maintain the line.Under the premises
that the demander’s workers comply with operation principles and the line is running in correct
conditions, if the line is really unable to run normally due to product quality problem or broken
components within 12 months after the delivery of the line is finished, the producer of the line will fix
the line or change the broken components without the demander paying anything.
 设备调试期一个月，买方需支付卖方调试人员每人每天 100 美金，（一般调试人员为 3 人）
负责签证，往返机票的费用，并提供调试人员在其当地的食宿，交通等费用。因为客户原因，导致
调试期延长，超过一个月的部分，买方需付调试人员每人每天 120 美金。
The buyer should pay for the engineer USD 100.00 one person one day(during one month),and supply the
visa cost, round air tickets, local cost such as the food, hotel and others.
Due to the buyer responsibility, delay the debugging time, the delay time, buyer should pay for the
engineer USD 120.00 one person one day.
6. 提供的技术文件 Technical Document Provided
1）机组使用说明书(交货前一个月提供) 1份
Instruction Manual of Pipe Mill (provided at the time of a month before delivery time)
2）出厂检验合格证(交货时提供) 1份
Inspection Certificate (provided at the delivery time)
3）装运清单(交货时提供) 1份
Loading Order (Provided at the delivery time)
4）平面布置图 (交货前一个月提供) 1份
Layout Drawing (provided at the time of a month before delivery time)
5）地基图 (交货前一个月提供) 1份
Ground Base Drawing (provided at the time of a month before delivery time)
6）电气原理图 1份
Electrical Principle Diagram
7）各单机总装配图 1份
Overall Assembly Drawing of every unit of the line
8）易损件的零件图 1份
Part Diagram of Vulnerable Parts

7. 生产周期 Manufacture period

预付款到账后 3 个月
3 month after got the advance payment

8. 付款方式 payment terms

30% TT as advance payment
70% TT pay off before delivery.