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Shijiazhuang Faith Machinery Co., Ltd has established itself as a prominent manufacturer of ERW carbon steel tube mills in China's industrial machinery sector. Our manufacturing philosophy centers on precision engineering, robust construction, and operational efficiency, ensuring that each tube mill meets the diverse requirements of global customers while maintaining competitive positioning in the international market.
The design and construction of our ERW carbon steel tube mills incorporate several critical engineering considerations. The structural framework utilizes high-grade steel plates with optimized ribbing patterns to ensure minimal vibration transmission and maximum stability during operation. Each component undergoes rigorous stress analysis and finite element modeling to guarantee structural integrity under continuous operational loads. The manufacturing process employs CNC machining centers that maintain dimensional accuracy within 0.01mm tolerance levels, ensuring perfect alignment of all critical components.
Our tube mills feature advanced forming technology that progressively shapes carbon steel strips through a series of precisely engineered roll stands. The forming section typically consists of 12-24 stands, each containing custom-designed rolls that gradually transform flat material into circular cross-sections. The roll design incorporates specific parameters including forming angle, roll gap, and pressure distribution to prevent material stretching or compression during the forming process. All rolls undergo heat treatment to achieve surface hardness of HRC 58-62, ensuring extended service life when processing carbon steel materials.
The welding system represents the core technological component of our ERW mills. We employ high-frequency welding technology operating at frequencies between 100-400 kHz, with power output ranging from 60-1000 kW based on production requirements. The system maintains precise control over critical welding parameters including vee length, squeeze pressure, and heat input. Copper alloy contacts ensure efficient power transmission while water cooling systems maintain optimal operating temperatures. The welding process undergoes continuous monitoring through infrared temperature sensors and power monitoring systems that automatically adjust parameters to maintain consistent weld quality.
Post-weld processing includes immediate heat treatment through normalizing systems that refine the weld zone microstructure. Our mills incorporate temperature control systems that maintain the heat-affected zone within specified temperature ranges between 900-950°C, followed by controlled cooling to achieve desired mechanical properties. Sizing sections employ multi-stand arrangements with micro-adjustment capabilities that calibrate the pipe to exact dimensional specifications. Each sizing stand can be independently adjusted during operation to compensate for tooling wear or material variations.
The cutting system utilizes synchronized flying cutters that maintain length accuracy within ±0.5mm. The cutting mechanism incorporates hydraulic damping systems that minimize vibration during the cutting process, ensuring clean cut edges without deformation. Drive systems employ AC vector motors with precision encoders that maintain speed synchronization within 0.1% deviation across all sections of the mill.
Control systems integrate all operational functions through industrial PLC platforms with touchscreen interfaces. The control system provides real-time monitoring of over 200 operational parameters including motor loads, welding statistics, temperature profiles, and production metrics. Recipe management allows storage of parameters for different product specifications, enabling quick changeover between production runs. Data logging capabilities record all production parameters for quality traceability and process optimization.
Our quality assurance protocol includes multiple inspection stages throughout the manufacturing process. Component inspection utilizes coordinate measuring machines for dimensional verification, while material certification ensures all materials meet specified standards. Assembly processes incorporate laser alignment systems that ensure perfect component positioning. Final testing includes run-in trials with actual production materials to verify performance and quality before shipment.
We provide comprehensive technical support including installation supervision, operator training, and maintenance guidance. Our training programs cover operational procedures, maintenance schedules, and troubleshooting techniques. Documentation includes detailed operation manuals, maintenance guides, and parts catalogs to support our customers throughout the equipment lifecycle.
