Condenser Flat Pipe Mill

Shijiazhuang Faith Machinery Co.,Ltd presents its Condenser Flat Pipe Mill, specialized for manufacturing the flattened tubes used in heat exchangers, condensers, and evaporators. These mills convert round or elliptical tubes into uniform flat sections that maximize heat transfer surface area while meeting precise dimensional requirements.

Process Overview
The condenser flat pipe line begins with straight-seam welded round tubes produced on an ERW (electric resistance welding) or HFIW (high-frequency induction welding) mill. After welding and initial sizing, tubes are fed into a flattening section. Hydraulic flattening rolls compress the tube, reducing its height by a controlled amount to achieve a specific flatness ratio. Roll spacing is adjustable to accommodate tube diameters typically ranging from 10 mm to 50 mm and wall thicknesses from 0.5 mm to 2 mm.

Precision Flattening and Profile Control
Flattening stands incorporate crowned roll profiles to ensure even deformation across the tube length. Pneumatically actuated roll pressure controls enable fine adjustments during the run. Tubes pass through successive sets of rolls that gradually achieve the final profile, reducing stress concentration and preventing cracks in the weld seam. Laser gauges positioned before and after the flattening section measure tube height and width, triggering real-time corrections via the PLC.

Cut-to-Length and End Preparation
Following flattening, flying cut-to-length shears produce sections up to 6,000 mm long with length tolerances within ±1 mm. End chamfering units may be integrated to prepare tube ends for brazing or expansion into header plates. Automatic stacking conveyors organize finished pipes into bundles, minimizing manual handling and ensuring consistent packaging for downstream assembly.

Automation and Data Management
The Condenser Flat Pipe Mill is controlled by a distributed PLC system with an HMI touchscreen interface. Operators select product recipes—defining flattened height, cut length, and production speed—and the system recalls stored parameters for decoiler tension, roll pressure, and shear timing. Production data, including flattened profile measurements and cycle counts, are logged in a database for traceability and quality audits.

After-Sales Service
Shijiazhuang Faith provides turnkey installation, commissioning support, and operator training focused on flattening roll maintenance, hydraulic system care, and quality inspection methods. Preventive maintenance schedules cover roll surface inspection, hydraulic filter replacement, and cutting blade sharpening. Remote monitoring options enable service engineers to review machine alarms and recommend parameter optimizations, ensuring consistent flat tube production.