Ф219～Ф820前摆式螺旋焊管生产线
技术参数
Technical Specification of Φ219-Φ820 SSAW PML
1. 螺旋焊管生产线原料及产品参数raw material and workshop area:
1.1 原料参数raw material：
钢卷外径coil O.D.： | Φ1200-Φ1800 mm |
钢卷内径coil I.D.： | Φ500-Φ760 mm |
钢卷宽度coil width： | 450-1250 mm |
钢卷重量coil weight： | MAX20 t |
1.2 产品参数pipe parameter：
钢管直径pipe dia.： | Φ219-Φ820 mm |
钢管壁厚pipe wall thick： | 5-12 mm |
螺旋角spiral angle： | 40°～80° |
钢管长度pipe length： | 12 m |
钢管螺距pipe thread： | Max 1450 mm |
钢管材质 | Q235；Q345B |
1.3. 机组基本参数unit basic parameter：
机组形式unit form： | 前摆式中心定位 front-swing, center positioning |
成型方式forming way： | 三辊弯板成型、外控辊式定径 Three-roll bend forming, outside control roll sizing |
成型方向forming direction： | 右旋成型 right spiral forming |
成型角范围forming angle： | 40°～80° |
下管方式pipe discharging： | 摆动托辊卸管 swinging carrier roll discharge pipe |
焊接速度welding speed： | 0.8-2.1 m/min |
装机容量installed capacity： | ～280KW |
年产量annual output： | ～20,000 ton |
1.4设备清单及重量equipment list:
N/N | 设备名称 Equipment Description | 台数 Qty. | 备注 Remark |
1 | 开卷机 uncoielr | 1 |
|
2 | 夹送矫平机 pinching& leveling machine | 1 |
|
3 | 手动立辊 manual vertical roll | 1 |
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4 | 电动立辊electric vertical roll | 2 |
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5 | 切割对焊cutting& butt-welding | 1 |
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6 | 园盘剪 rotary shear | 1 |
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7 | 递送机 delivery machine | 1 |
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8 | 预弯导板pre-bend guide board | 1 |
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9 | 成型机forming unit | 1 |
|
10 | 前桥front bridge | 1 |
|
11 | 内焊装置 inside welding device | 1 |
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12 | 外焊装置outside welding device | 1 |
|
13 | 后桥 rear bridge | 1 |
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14 | 飞切机 flying cutter | 1 |
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15 | 埋设件 buried parts | 1 |
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16 | 主机液压系统 host hydraulic system | 1 |
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17 | 主机电控系统 host electric system | 1 |
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18 | 内/外焊焊机 inside/outside welder DC-1500 | 2 | 美国林肯公司 American LINCOLN |
19 | 对焊小车butt-welding car | 1 |
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20 | 等离子切割机plasma cutter | 1 |
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21 | 焊剂供给回收装置 weld flux supply& recycling device | 2 |
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22 | 焊剂烘干磁选处理装置 weld flux dry and separating device | 1 |
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23 | 空压机 air compressor | 1 |
|
2. 螺旋焊管生产线工艺流程process flow：
开卷→夹送矫平→立辊→切割、对焊→立辊→圆盘剪→立辊→递送机→预弯导板→成型→内焊→外焊→飞切→拨出
Uncoiling→ pinching& leveling→vertical roll→ cutting& butt welding→ vertical roll→ rotary shear→ verticalroll→ main drive→ pre-bend guide board→ forming unit→ inside welding→ outsidewelding→ flying cutting off→ kick-off
3. 前摆式螺旋焊管生产线主要设备简介introduction of main equipment：
3.1开卷机uncoiler
支撑辊直径：Ф280，材质42CrMo，表淬,HRC52-56
Supportingroll: dia. φ280, material 42CrMo, surface quenchingHRC52-56
传动电机：11KW，
Transmissionmotor: 11KW
锥头移动油缸：Ф100/Ф70x780 2件
Cone-headmoving cylinder: Ф100/Ф70x780, two pieces
锥头提升油缸：Ф150/Ф85x800 2件
Cone-headlifting cylinder: Ф150/Ф85x800, two pieces
铲刀油缸：Ф150/Ф85x800 2件
Oilcylinder of shovel knife: Ф150/Ф85x800, two pieces
3.2夹送矫平机pinching&leveling machine：
夹送辊: 直径φ230mm ，材质42CrMo，热处理淬火HRC52-56。
Dia. of pinching roll φ230, material42CrMo, heat treatment quenching HRC52-56
矫平辊：直径φ230mm ，材质42CrMo，热处理淬火HRC52-56。
Dia. of leveling roll φ230, material42CrMo, heat treatment quenching HRC52-56
夹送电机： 18.5kw
Pinching motor: 18.5KW
压下电机：3 KW
Screw-downmotor: 3KW
气缸：IQG-F80B75-MP4
Pneumatic cylinder: IQG-F80B75-MP4
夹送压下油缸：φ140xφ80/165
Pinching screw-down cylinder: φ140xφ80/165
3.3切割对焊cutting&butt welding：
小车移动油缸：φ80/φ45X500
Trolley moving cylinder: φ80/φ45X500
压板压紧油缸：φ125/φ90X90
Compacting cylinder of pressing board:φ125/φ90X90
切割方式：半自动等离子
Cutting way: semi-auto plasmacutting
焊接方式：半自动埋弧焊
Welding way: semi-auto sub-mergedarc welding
等离子切割机：LGK-200
Plasma cutter: LGK-200
3.4电动立辊electricvertical roll：
立辊材质为42CrMo,热处理淬火HRC52-56
Material of vertical roll is 42CrMo, heat treatment quenching HRC52-56
电机功率:2.2kw
Motorpower of electric vertical roll: 2.2KW
3.5圆盘剪rotaryshear
设备组成：由两牌坊组成，剪刃装于两牌坊上，被动剪切。
Consistsof two supports, on which shear blade is installed, passive shear type
剪刃直径为φ320，材质为6CrW2Si。热处理淬火硬度HRC54-58。
Dia.of shear blade φ320, material 6CrW2Si, heat treatment quenching hardnessHRC57-60
3.6板面清扫装置platecleaning device
传动电机： 1.1kW
Transmission motor: 1.1KW
清扫带宽度：160mm；
Cleaningstrip width: 160mm
3.7递送机maindrive
递送辊径：φ354 mm ，材质42CrMo，热处理淬火硬度HRC52-56
Dia.of delivery roll φ354,material 42CrMo, heat treatment hardness HRC52-56,
电机：30kw 980r/min
Electric motor: 30kw 980r/min
调速方式：交流变频调速
Speed adjusting way: AC VF speedadjsuting
递送速度：0.6-2.5m/min
Delivering speed: 0.6-2.5m/min
3.8预弯及导板pre-bendingguideboard：
预弯辊材质42CrMo，热处理淬火硬度HRC52-56。
Material of pre-bending roll is 42CrMo,heat treatment quenching hardness HRC52-56
3.9成型机forming unit：
成型辊材质为GCr15，热处理淬火硬度HRC52-56
Material of forming roll is GCr15, heattreatment quenching hardness HRC52-56
1号辊移动电机：XWD1.1-3-1/29 1台
1# roll moving motor: XWD1.1-3-1/29 1set
2号辊压下电机：XWD3-5-1/87 2台
2# roll screw-down motor: XWD3-5-1/87 2sets
3号辊移动电机：XWD1.1-4-1/29 1台
3# roll moving motor: XWD1.1-4-1/29 1set
横梁升降电机：XWD2.2-4-1/11 1台
Beam lifting motor: XWD2.2-4-1/11 1set
3.10前桥front bridge：
前桥摆动油缸：φ140/φ100×600
Front bridge swinging cylinder: φ140/φ100×600
摆动角度：40°～80°
Swinging angle: 40°～80°
3.11后桥rearbridge:
微调角度： ±1°
Trimming angle: ±1°
后桥摆动油缸：φ100/50×400。
Swinging cylinder of rear bridge:φ100/50×400
拨管油缸： φ100/50×210。
Pipe kick-off cylinder: φ100/50×210
3.12主机埋设件：是主机设备的轨道。
Host buried parts: rail of hostmachine
3.13飞切小车flying cutter
切割方式：等离子切割
Cutting way: plasma cutting
等离子切割机型号：LGK200
Modelof plasma cutter: LGK200
气缸型号：IQG63X100-MT4-A
Model of pneumatic cylinder:IQG63X100-MT4-A
3.14内焊装置insidewelding device：
焊接电源：DC-1500
Weldingpower source: DC-1500
焊接速度：0.8-2.1m/min
Weldingspeed: 0.8-2.1m/min
减速机：0.55 KW
Speedreducer: 0.55 KW
力矩电机130LY54 功率0.055KW 转速400r/mm
Torquemotor: 130LY54, power: 0.055KW, rotating speed: 400r/mm
3.15外焊装置outside weldingdevice
焊接电源： DC-1500/AC1200
Welding power source: DC-1500/AC1200
焊接速度： 0.8-2.1m/min
Welding speed: 0.8-2.1m/min
减速机： 0.55 KW
Speedreducer: 0.55 KW
力矩电机 130LY54 功率 0.055KW 转速400r/mm
Torque motor: 130LY54, power:0.055KW, rotating speed: 400r/mm
3.16螺旋焊管生产线主机液压系统host hydraulicsystem：
液压泵站系统是各类液压装置以液压为动力核心的工作系统，根据工作要求向装置中各动作执行元件（如液压缸、马达等）提供可控制方向、压力及流量的压力介质，通过管路传输，装置便可实现各种设定的动作和工作循环。
Key work system of each hydraulic device, thehydraulic pump station offers pressure medium available to control direction,pressure and rate of flow to actuator such as hydraulic cylinder and motor. Thedevice can achieve set action and work cycle through pipeline transmission.
3.16.1液压泵组布置型式Arrangement of pumpstation
泵组卧式布置：电机泵组卧式安装在油箱盖板上，主要适用于小排量或小排量变量泵等自吸收性能好的液压系统。
Horizontal arrangement: motor pump group is horizontallyinstalled on cover plate of oil tank, which mainly suits hydraulic system of goodself-absorption like small displacement or small displacement variable pump
3.16.2液压系统的工作介质和温度条件Work medium andtemperature：
1）工作介质：推荐采用抗磨液压油，YB-N46
Work medium: recommend to use the anti-abrade hydraulicoil, YB-N46
2）介质温度：正常工作温度范围0-60℃，当温度低于0℃或高于60℃时，必须事先进行加热或冷却至正常工作温度。
Medium temperature:normal temperature: 0-60℃,when the temperature below 0℃or exceed 60℃,must heat or cool till the normal temperature.
3.16.3液压泵站系统的元件的选用hydraulic component
液压元件采用引进德国力士乐技术生产线所生产元件。
Adoptthe product produced by introducing Rexroth technology.
3.16.4液压泵站系统的冷却方式Cooling ofhydraulic pump station
强迫冷却：采用水冷却器进行强制冷却。
Forcecooling: water cooling
3.16.5液压系统的电气控制Electric control ofhydraulic system
1）控制方式：电气控制系统通过接线盒与液压泵站系统实现连线控制
Control way: tocontrol the hydraulic pump station by junction box.
2）电源电压、频率、电磁线圈和其他接线装置的控制电源
电源电压、频率为380V、50Hz，电磁阀的线圈控制电压为直流DC24V
Voltage:380V, frequency: 50Hz, coil control power of the electromagnetic valve is DC24V
3.17螺旋焊管生产线主机电控系统host electricsystem：
1）主机电气系统使用于操作和控制整个大口径螺旋焊管生产机组的各单机设备。属非标设计电气控制系统。控制范围：开卷机～后桥
Thisnon-standard electrical control system is used for operation& control ofindividual equipment of spiral welded pipe mill, ranging from uncoiler to pipekickoff of rear bridge.
2）电控系统由PLC自动控制系统、直流调速控制系统、交流调速控制系统、数字显示系统组成。系统设计和元件选用符合IS9001和CCC标准。
Consist of PLC auto-control system, DC speedgovernor, AC speed governor and digitalized display system, of which design andspare parts are in line with IS9001 and CCC standard
3）在需调速机械的系统设计中均设有速度参量自动均衡调节、手动连续可调功能。
Have speedauto-balance governing, manually continuous adjustment;
4）电气系统设有板速自动显示系统。
Equippingwith plate speed auto-checking and displaying system
5）电气系统设有钢管定尺控制及自动切管系统。
Equippingwith sizing control and auto-cutoff system for steel pipe
6）22KW以上电动机(无调速系统)设有降压启动,55KW(无调速系统)设有软启动。
Motor exceeding 22KW (no speed regulator) equipswith step-down starting, 55KW motor (no speed regulator) equips with softstart;
7）系统配备的交流变频装置设置有输入电抗器，以降低对电源网侧的污染。
AC frequency converter and DC speed regulatorequipping with input reactor to reduce pollution to electricity supply.
8）电气系统应用Profibus工业现场总线技术。主控系统选用德国SIEMENS公司S7—300系列PLC（CPU315—2DP）；总线端子模块和现场模块亦选用德国SIEMENS公司ET200系列。防护等级：现场元件采用IP44，控制柜及操作台采用IP20。
Profibus technology is used, Germany SIEMENS S7-300 serialPLC (CPU315—2DP) as main control, submodule at bus terminal and module at siteadopts SIEMENS ET200 serial. Protection level of element at site is IP44, asfor control cabinet and operation panel is IP20
9）交流调速装置采用西门子公司M440系列变频调速器；直流调速装置采用英国欧陆590P系列调速器。
AC speed regulator is SIEMENS M440 serial VF speed regulator,DC speed regulator is Eurotherm 590P serial.
10）电气系统的控制功能设计为能与机组工艺、单机设备、液压系统紧密结合，并能随之变化进行控制。
Control function of electric control system is designed totightly linked with unit process, individual equipment and hydraulic system,and can control as per variation.
11）电气设备基本控制功能basiccontrol function：
a．设备工作方式选择
tochoose work mode
b．机组设备起停车和紧急停车控制
Unitstart/ stop and emergency stop control
c．生产顺序控制和连锁控制
productionprocedure control and linkage control
d．液压系统等辅助设施控制
Controlof assistant equipment such as hydraulic system
e．系统故障及报警systemfault and alarm function
f．就地通讯接口（与机电成套设备）
local communication interface (tomatch with complete set of mechanical and electric equipment )
