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Shijiazhuang Faith Machinery Co., Ltd designs and manufactures ERW tube mill machines that represent the culmination of extensive engineering expertise in tubular product manufacturing. These sophisticated systems integrate multiple technological disciplines to transform raw steel coil into precision-engineered tubular products through electric resistance welding technology.
The fundamental operational principle begins with coil loading and strip preparation systems. Heavy-duty decoilers equipped with expandable mandrels handle coil weights up to 20,000 kilograms, while automatic edge trimming units ensure clean, parallel strip edges essential for quality welding. The entry section incorporates precision leveling equipment that removes coil memory and crossbow through a series of independently adjustable rolls, creating optimal flatness before forming.
The forming section employs a progressive roll forming approach where contoured tooling gradually shapes the flat strip into a cylindrical form. This multi-stage process typically involves 12 to 24 forming stands, each contributing to the gradual transformation while minimizing stress on the material. The carefully calculated forming sequence ensures uniform material distribution and prevents edge stretching or compression. Anti-backlash adjustment mechanisms allow micron-level control of roll gaps, ensuring consistent forming accuracy throughout production runs.
Welding represents the core technological process where high-frequency electrical current (typically 100-400 kHz) generates localized heat through either contact or induction methods. The system maintains critical parameters including optimal vee length, squeeze pressure, and power input to create a homogeneous weld without filler material. Copper alloy electrodes with precise cooling systems maintain stable electrical characteristics, while automatic positioning systems ensure consistent electrode alignment throughout production.
Post-weld processing includes immediate scarfing operations that remove internal and external weld flash, followed by sizing stations that calibrate the pipe to exact dimensional specifications. Cooling systems control the metallurgical transformation after welding, employing either air or water cooling methods depending on material specifications. Straightening units ensure longitudinal uniformity through multi-roll arrangements that eliminate any curvature or twist.
The cutting system employs synchronized flying cutters that maintain squareness and length accuracy within tight tolerances. Modern control systems integrate all these operations through programmable logic controllers that monitor and adjust parameters in real-time. Touchscreen interfaces provide operators with comprehensive production data and system diagnostics, while recipe management allows quick changeover between different product specifications.
These machines serve diverse industrial applications including furniture manufacturing, automotive components, construction materials, and fluid transportation systems. The versatility of ERW technology enables production of various diameters (10-508 mm) and wall thicknesses (0.4-16 mm) from different material grades, making it suitable for both standard and specialized applications.
