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Shijiazhuang Faith Machinery Co.,Ltd offers a full suite of tube mill equipment designed to support manufacturers in producing a wide range of tubes—from structural sections to precision mechanical tubing. By integrating robust mechanical design with flexible configuration options, our tube mill equipment enables reliable, high‐volume production while maintaining dimensional accuracy and weld integrity.
Tube mill equipment typically comprises the following core modules, each engineered for durability and ease of integration:
Payoff/Decoiler Unit
A hydraulic or mechanical mandrel decoiler accommodates strip coils up to 8 tons (for small‐diameter tubing) and up to 25 tons (for larger profiles).
Expandable mandrels ensure a secure grip on the coil core, with minimal friction surfaces to prevent strip marking.
Hydraulic load‐holding brakes control uncoiling tension, reducing strip whip and ensuring smooth feeding.
Tension Leveler
Multi‐bar leveling stands remove residual stresses, coil set, and camber from the flat strip.
Hydraulic crown control adjusts work‐roll pressure across the strip width, ensuring uniform flatness for consistent forming and welding.
Forming Section
A series of forming roll stands (commonly 6–12 stands) progressively bends the strip from flat to a U‐profile, then into a cylindrical shape.
Heavy‐duty roll shafts, supported by precision bearings, resist deflection under load. Rolls are mounted on adjustable stands, allowing quick changeover for different tube diameters and wall thicknesses.
Roll surfaces can be customized (e.g., hardened cast steel or chrome plating) to suit various strip materials—carbon steel, stainless steel, aluminum, or galvannealed steel.
Welding Station
Depending on customer requirements, the tube mill equipment can be configured with either high‐frequency induction welding (HFIW/ERW) or submerged arc welding (SAW).
ERW (Electric Resistance Welding): Uses high‐frequency current to heat strip edges, followed by forging rolls that press edges together to form the seam. Weld power supplies are water‐cooled, with integrated monitoring of current and voltage for consistent seam strength.
SAW (Submerged Arc Welding): Employs granular flux delivered over the seam area, with single or dual‐wire heads. Flux recovery systems capture unused flux for recycling. Weld head settings (current, voltage, travel speed) are adjustable via the central PLC to match strip gauge and grade.
Scarfing and Bead Removal (Optional)
For SAW lines, inline scarfing units remove excess weld bead on the inside and outside surfaces. Bead removal heads are equipped with rotating blades and vacuum extraction to capture waste flux and metal chips.
Sizing and Calibration Stands
Sizing stands consist of multiple rolls that refine tube outer diameter and roundness. Closed‐loop control, based on feedback from laser micrometers, adjusts roll positions to correct ovality and ensure dimensional tolerances (commonly ±0.5% of nominal diameter).
Stretch‐forming units apply axial tension to the tube, reducing springback and improving straightness, particularly important for precision mechanical tubing.
Cutoff and Finishing Units
Hydraulic or flying cutoff saws produce tubes at programmed lengths, with burr‐free finishes. For continuous high‐speed lines, flying cold saws coordinate with line speed, eliminating the need for line stops during cutoff.
End‐forming modules (e.g., chamfering, beveling, cold expansion) prepare tube ends for downstream joining, threading, or flaring operations.
Handling and Coil Systems (for Coil‐Feed Lines)
Finished tubes are transferred to stacking conveyors, bundling stations, or recoilers for coiled tubing applications. Automated coil winders with laser‐guided edge tracking ensure neat coil build for flexible tubing.
Modern tube mill equipment from Shijiazhuang Faith Machinery Co.,Ltd is driven by advanced automation systems that optimize production efficiency and quality consistency:
Centralized PLC Architecture: A programmable logic controller network manages decoiler tension, roll stand positioning, welding power, and cutoff timing. Ethernet communication between modules ensures synchronized operation, minimizing indexing errors.
HMI and Recipe Management: A touchscreen human‐machine interface (HMI) allows operators to recall “recipes” for different tube sizes, wall gauges, and material grades. Each recipe stores parameters such as strip width, forming roll sequence, welding current profile, and cutoff length.
Closed-Loop Dimension Control: Laser micrometers and ultrasonic wall-thickness sensors provide real-time feedback. The PLC adjusts roll gaps and welding parameters on the fly, maintaining tube outer diameter within ±0.5% and wall thickness within ±5%.
Weld Monitoring: Weld seam inspection combines surface cameras (for visual bead quality) and ultrasonic flaw detectors (for volumetric defect detection). Data are logged automatically, and suspect tube segments are marked or diverted to scrap conveyors without stopping the line.
Tension Control: Load cells in the decoiler, leveler, and pull-through sections measure strip tension. Variable‐frequency drives (VFDs) on feed and pull motors adjust speeds to maintain consistent tension, preventing strip flutter or seam misalignment.
Shijiazhuang Faith’s tube mill equipment supports a wide variety of materials and tube specifications:
Carbon Steel Tubing: Tube diameters from 15 mm to 168 mm, wall thicknesses from 0.8 mm to 6 mm. Common in automotive, furniture, and general structural applications.
Stainless Steel Tubing: Diameters from 16 mm to 114 mm, wall gauges from 0.5 mm to 4 mm. Utilized in food processing, pharmaceutical, and chemical industries. Material grades include 304, 316, and duplex alloys.
Aluminum and Galvannealed Steel: For lighter‐weight tubing used in HVAC and refrigeration. Forming rolls and welding power settings are adjusted to accommodate lower strip stiffness and higher conductivity.
Specialty Profiles: Beyond round tubes, the modular forming section can accommodate simple square or rectangular profiles by swapping forming rolls and adjusting mandrel support. Inline seam trimming and edge squaring ensure compatibility with downstream fabrication.
Consistent product quality and traceability are essential in tube production. Shijiazhuang Faith’s tube mill equipment incorporates multiple checkpoints:
Incoming Material Verification: Operators log coil heat numbers and batch certificates into the HMI. The system tracks each coil’s origins and grade, linking this data to final tube production logs.
In-Line Nondestructive Testing (NDT): Ultrasonic flaw detectors scan each tube section post-weld to identify internal voids, inclusions, or lack of fusion. Detected defects trigger automatic tagging and diversion to scrap.
Dimensional Inspections: Periodic manual checks complement the continuous laser micrometer measurements. A sampling plan ensures that at least one tube per meter length is subject to manual caliper inspection, verifying outer diameter, wall thickness, and ovality.
Automated Marking: Inkjet or laser‐etching systems imprint each tube with heat number, size, production date, and batch code. These marks facilitate full traceability throughout the supply chain.
Data Logging and Reporting: All process parameters—strip tension, welding current, temperature profile, dimensional readings—are archived in a central SQL database. Production managers generate reports for quality audits and continuous improvement.
Every tube mill installation has unique spatial constraints and production goals. Shijiazhuang Faith Machinery Co.,Ltd offers flexible layout options:
Straight-Line Configuration: Optimal for facilities with ample floor space. Materials flow in a linear sequence from decoiler to cutoff, allowing easy access for maintenance.
L-Type or U-Type Layouts: Ideal for plants with limited length but wider floor area. Forms a compact footprint while maintaining process sequence.
Modular Skid-Mounted Units: Each major module (decoiler, leveler, forming, welding, sizing, cutoff) is preassembled on a steel skid. This approach accelerates on-site installation and simplifies alignment.
Utility Integration: Electrical, hydraulic, and cooling‐water connections are centralized on a service platform, reducing piping complexity. Compressed air lines are pre-routed to lubrication points, and cable trays provide for easy conduit runs.
Shijiazhuang Faith Machinery Co.,Ltd’s commitment to customer success extends beyond equipment delivery. Our comprehensive support offerings include:
Turnkey Installation: Experienced project managers oversee site preparation, equipment leveling, anchoring, and alignment. On-site commissioning validates machine performance against guaranteed specifications.
Operator and Maintenance Training: A multi-day program covers safe operation, recipe management, routine lubrication, and preventive maintenance. Training materials include operation manuals, maintenance schedules, and troubleshooting guides.
Spare Parts Provisioning: A recommended spare parts list includes critical components—form roll bearings, welding power supply capacitors, shear blades, and hydraulic seals. Customers can opt for a spare parts kit delivered alongside the equipment or stock locally for rapid turnaround.
Remote Diagnostics and Software Updates: Customers may enable a secure remote access link, allowing Faith Machinery’s technical team to review PLC programs, analyze alarm logs, and propose parameter optimization. Periodic software updates ensure compatibility with the latest HMI features and data‐logging protocols.
On-Site Service and Upgrades: For periodic inspections, roll profile adjustments, or equipment overhauls, Faith Machinery dispatches skilled service engineers. Retrofit kits—such as additional forming stands, higher-capacity welding power units, or advanced NDT modules—enable capacity expansion and technology renewal.
By combining rugged mechanical design, advanced automation, and dedicated service, Shijiazhuang Faith Machinery Co.,Ltd’s tube mill equipment empowers manufacturers to produce high‐quality tubes with minimal downtime, consistent dimensions, and full process traceability.
