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An automatic ERW tube mill factory represents a significant step towards integrated manufacturing, where the goal is to minimize manual intervention and maximize throughput consistency. Shijiazhuang Faith Machinery Co., Ltd designs production lines that embody this principle, focusing on the seamless connection of individual operations from raw material to finished pipe. Automation begins at the material handling stage, featuring motorized mandrels for coil loading and automatic strip threading guides.
The core of the automation lies in the synchronization of all moving parts. The forming rolls, welding head, and flying saw are all electronically locked to a common speed reference to maintain process stability. Advanced lines incorporate an automatic strip accumulator between the decoiler and the forming mill. This device stores a sufficient length of strip, allowing the main production line to continue running at a constant speed while a new coil is being prepared and welded at the entry point. This eliminates the need for periodic line stoppages, significantly boosting overall equipment effectiveness.
The welding process itself is often managed by closed-loop control systems. These systems monitor parameters such as weld power and pressure, making micro-adjustments in real-time to compensate for variations in material properties or line speed. Similarly, the flying cut-off saw is precisely synchronized with the linear movement of the pipe, ensuring clean, square cuts without interrupting the forward motion of the production line.
For quality assurance, automated non-destructive testing equipment, such as ultrasonic or eddy current flaw detectors, can be integrated inline to continuously inspect the weld seam. The data from these systems can be logged for traceability. The culmination of this automation is a production environment that not only achieves high output speeds, up to 120 meters per minute for certain sizes, but also maintains a high level of dimensional consistency and weld integrity with reduced operational labor.
