FFX 튜브 밀

How Does A FFX（Flexible Forming and Sizing Work?

튜브 밀은 일련의 기계적 공정을 통해 평평한 강철 스트립 또는 코일을 용접된 강철 튜브로 변환하여 작동합니다. 첫 번째 단계는 평평한 강철 스트립을 풀어서 밀에 공급하는 것입니다. 그런 다음 스트립을 일련의 롤러로 안내하여 점진적으로 원통형 모양으로 만듭니다. 스트립이 이러한 롤러를 통과하면서 가장자리가 합쳐져 ​​용접할 준비가 됩니다. 이 공정의 다음 핵심 단계는 용접입니다. 튜브 가장자리는 고주파 또는 레이저 용접 기술을 사용하여 용접하는데, 이는 열을 사용하여 가장자리를 강력하고 연속적인 이음매로 융합합니다. 용접 후 튜브는 롤러 세트와 냉각 장치를 통과하여 모양을 유지하고 안정적인 온도로 냉각되도록 합니다. 냉각 후 튜브를 곧게 펴서 성형 및 용접 공정으로 인한 왜곡을 제거합니다.

그런 다음 튜브는 가장자리 다듬기, 특정 길이로 자르기, 때로는 기계적 특성을 향상시키기 위한 열처리와 같은 다양한 마무리 단계를 거칩니다. 튜브는 의도된 응용 분야에 따라 코팅되거나 연마될 수도 있습니다. 이 프로세스 전반에 걸쳐 튜브 밀에는 공급 속도, 장력 및 용접 조건과 같은 주요 매개변수를 모니터링하는 제어 시스템이 장착되어 일관되고 정확한 튜브 생산을 보장합니다. 그 결과 강도, 크기 및 표면 마감에 대한 필수 사양을 충족하는 고품질의 내구성 있는 용접 튜브가 만들어집니다. 튜브 밀은 건설, 자동차 및 에너지를 포함한 다양한 산업에서 구조, 배관 및 기타 응용 분야를 위한 튜브를 생산하는 데 사용됩니다.

Working Principle

The core principle of the FFX forming process lies in the unique design of the opening section, which enables the equipment to produce welded pipes with various diameters and cross-sectional shapes without the need for frequent mold changes. The steel strip is gradually bent into a tubular shape using precise rollers and tooling, and high-frequency induction welding is applied to join the edges of the strip, forming a long pipe. After the forming, the pipe goes through a sizing section to ensure dimensional accuracy and surface smoothness.

Steel Strip Feeding: The unwinder feeds the steel coil into the production line, where the steel strip is unrolled and adjusted before entering the forming section.

Forming: The steel strip is progressively bent into a circular shape by a series of forming rollers. In the opening section, the shared mold design allows for quick adaptation to different pipe diameters without mold changes.

Welding: As the steel strip is formed into a tube, the edges are welded together using high-frequency induction welding, ensuring a strong, high-quality seam.

Sizing and Straightening: After welding, the pipe passes through sizing rollers, which adjust the pipe's diameter and straighten it to meet precise specifications.

Cutting : The finished pipe is then cut to a preset length using a servo-controlled flying saw, ensuring accurate lengths.

Discharge: The cut pipes are transferred to a stacking area or packaging section via conveyor belts, ready for further processing or delivery.

Advantages of FFX Forming

Mold Savings: The shared mold design in the opening section enables quick adaptation to different pipe diameters and cross-sectional shapes without frequently changing molds, reducing mold costs.

Flexibility in Production: The equipment can be quickly adjusted according to production needs, enabling small-batch, multi-spec production to meet changing market demands.

Increased Production Efficiency: The use of high-frequency induction welding and servo-controlled cutting systems ensures the equipment runs efficiently, achieving high-speed production with minimal downtime.

Reduced Downtime: The quick adjustment of molds and production lines minimizes downtime, improving overall productivity.

Real-world Application Cases

• Egyptian Customer - 10-inch FFX Welded Pipe Equipment
  In 2023, we installed a 10-inch FFX welded pipe production line for a large pipe manufacturer in Egypt. This customer previously only produced small pipes, but with the flexibility of the FFX technology to quickly switch molds, they expanded into large structural pipe markets. Within just six months of equipment installation, they secured several large-scale infrastructure project orders, which helped them open up a new market and achieve significant profit growth. They have since placed an order for a second production line.

• U.S. Customer - Multiple 8-inch FFX Units for Octagonal Pipe Production for Solar Panels
  In California, Texas, and other renewable energy markets in the U.S., several customers adopted our 8-inch FFX system to produce octagonal pipes for solar panel mounting structures. The quick switching and size consistency of FFX technology helped customers meet the high-precision, high-strength demands of the solar energy market. Currently, these products are in high demand, and the equipment is running at full capacity. Customers have provided feedback that the equipment is extremely stable, easy to debug, and has a very low failure rate.

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Wide Product Application Areas

• Solar panel supports, wind turbine tower structures

• Building steel structures, scaffolding, curtain wall profiles

• Electrical cable conduits, fire water pipes

• Automotive beams, motorcycle parts

• Furniture frames, supermarket display racks

• Sports fitness equipment, agricultural supports, etc.

  Particularly suitable for the mass production and flexible production of high-precision, high-strength pipes.

Maintenance Recommendations (Customer-Tested Summary)

• Regularly check the servo adjustment system's operating condition to ensure adjustment accuracy

• Inspect the cooling system of the high-frequency welding system weekly, maintaining a clean water cycle

• Keep rollers clean and regularly fine-tune them to prevent accumulated errors

• Replace consumables promptly, and stock spare parts to reduce downtime risks

• Backup PLC programs and parameters quarterly to prevent data loss in case of power outages

• It is recommended that operators undergo professional training to reduce failure rates and setup time

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