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– Advancements in Resistance Welding and Tube Customization
Shijiazhuang Faith Machinery Co.,Ltd is proud to highlight the latest enhancements to its ERW Tube Mill Machine offering, aimed at manufacturers of carbon steel, alloy steel, and stainless steel tubes. In response to industry demands for precision tubing in automotive, mechanical, and structural applications, our machines focus on accurate welding, dimensional control, and flexible product options.
Electric resistance welding (ERW) relies on the principle of Joule heating, where a high‑frequency electrical current passes between the steel strip edges, generating heat that raises the metal to forging temperature. In the ERW Tube Mill Machine, strip material is fed from a pay‑off stand through tension‑leveling units and guiding rolls into the forming section. Multiple roll stands progressively bend the strip into a round profile, leaving a narrow seam where the edges meet.
An induction welding head applies current at frequencies typically ranging from 300 kHz to 1 MHz, depending on material thickness and strip width. The edges are pressed together by welding rolls immediately after heating, producing a solid‑state bond without filler metal. This process yields a clean internal surface and minimal heat‑affected zone. The welding power supply is water‑cooled and mounted on vibration‑damped supports to ensure stable output and extend component longevity.
After the initial weld, the tube passes through aging rolls that stabilize the seam while it remains malleable. Sizing stands equipped with calibration rolls then refine outer diameter and circularity. Laser micrometers positioned before and after the sizing section measure tube geometry in real time, feeding data back to an automatic gauge control (AGC) system. The AGC adjusts roll gap positions to correct dimensional deviations caused by strip thickness variation or thermal shrinkage.
For applications requiring extremely tight tolerances—such as hydraulic cylinders or automotive chassis components—additional stretch‑forming units can be integrated downstream. These units apply controlled axial tension to the tube, reducing ovality and springback effects. The result is a product that meets or exceeds requirements of standards such as ASTM A513, EN 10305, or JIS G3445.
To accommodate a wide array of product specifications, the ERW Tube Mill Machine features a modular design that supports multiple coil widths, wall thickness ranges from 1.5 mm up to 12 mm, and diameters from 15 mm to 168 mm. Operators can select single‑pass or multi‑pass forming configurations, depending on required forming precision and production speed. For larger diameters, additional forming stands guide the strip more gently to prevent edge deformation.
Accessory modules expand the machine’s capabilities:
Scarfing Units: Automatically trim weld beads for a smooth internal finish.
Hydrostatic Testing Stations: Verify weld integrity under high pressure.
Cold Expansion Presses: Enhance mechanical properties around the weld by applying localized plastic deformation.
End‑Forming and Chamfering Tools: Prepare tube ends for downstream welding or assembly.
Each accessory is controlled via the main PLC and synchronized to the line speed, ensuring uninterrupted production and precise integration of post‑weld processes.
The ERW Tube Mill Machine employs a centralized control architecture with distributed I/O and an Ethernet backbone. Operators interact through a color touchscreen HMI, where they can call up production recipes, monitor real‑time metrics (welding current, voltage, line speed, coil tension), and review alarm histories. All process data are recorded in a structured database, enabling traceability and facilitating quality audits.
Predictive maintenance features include vibration sensors on gearbox housings and temperature probes on induction transformers. An edge‑computing module analyzes these signals to identify anomalies indicative of bearing wear or insulation degradation. When thresholds are crossed, maintenance alerts are generated, accompanied by recommended spare‑parts lists and procedures. This approach minimizes unplanned downtime and maximizes equipment availability.
ERW tubes produced on Shijiazhuang Faith’s machines serve a broad range of sectors:
Automotive: Steering components, exhaust systems, and shock absorber tubes requiring precise geometry and consistent wall thickness.
Mechanical Engineering: Hydraulic and pneumatic cylinders, conveyor rollers, and scaffolding structures demanding surface finish and weld integrity.
Furniture and Appliances: Decorative and structural tubing where visual appearance and dimensional accuracy are important.
Construction: Scaffolding, handrail assemblies, and general structural tubes used in building frameworks.
By offering flexible machine configurations and comprehensive quality control, Shijiazhuang Faith Machinery Co.,Ltd enables manufacturers to respond swiftly to market changes—whether launching new product lines or scaling existing ones.
Looking ahead, the ERW Tube Mill Machine platform will incorporate enhanced digital services, including cloud‑based analytics for long‑term trend analysis and AI‑driven process optimization. Further integration of energy‑recovery systems in drive trains and induction power supplies will improve the sustainability profile of tube production.
Shijiazhuang Faith Machinery Co.,Ltd provides end‑to‑end support, from feasibility studies and plant layout design to installation, commissioning, and training. Spare parts kits and service contracts are tailored to individual customer needs, ensuring that each ERW line operates at optimal performance throughout its lifespan. Our commitment to transparent communication, reliable machine performance, and responsive technical assistance underpins long‑term partnerships with tube manufacturers around the world.
