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Two ways of welding of high frequency straight seam welded pipe unit
There are two primary methods for welding in high-frequency straight seam welded pipe units: contact welding and induction welding. Contact welding involves using a pair of copper electrodes that make direct contact with both sides of the steel pipe being welded. This method allows for excellent current penetration and maximizes the dual effects of high-frequency currents due to the electrodes' direct connection with the steel plate. As a result, contact welding offers high efficiency but also consumes more energy. It’s commonly employed in high-speed production of lower-precision pipes, especially when working with thicker materials. However, this method has notable drawbacks.
One issue with contact welding is the rapid wear of copper electrodes due to their constant contact with the steel plates. Additionally, variations in the flatness of the steel plate surfaces and edge straightness can lead to unstable current flow, resulting in higher internal and external burrs. Consequently, contact welding isn’t typically recommended for applications requiring high precision or thin-walled pipes.
In contrast, induction welding employs one or more induction coils wrapped around the exterior of the welded steel pipe. Multi-turn coils tend to perform better than single-turn ones, though they are more complex to produce and install. The efficiency of induction welding increases as the coil gets closer to the pipe's surface, but maintaining a safe distance—typically around 5 to 8 millimeters—is crucial to prevent electrical discharge between the coil and the pipe. Induction welding avoids the wear issues associated with contact welding since the coil does not physically touch the steel plate. Furthermore, the current remains stable, ensuring consistent performance during welding operations. For these reasons, induction welding is often the preferred choice when manufacturing precision pipes.
When operating or maintaining a welded pipe unit, certain precautions should always be taken. First and foremost, operators must adhere strictly to safety guidelines, avoiding any contact with molds while the machine is running and keeping hands clear of moving parts. Improper handling can lead to accidents or equipment malfunctions.
Before starting up the unit, operators should inspect all lubrication points to ensure proper lubrication. If necessary, additional lubricants should be added to guarantee smooth operation. Over time, high temperatures can degrade standard lubricants, leading to potential damage. Therefore, it’s advisable to use high-temperature resistant synthetic composite aluminum-based greases, which provide enhanced protection against thermal degradation and prolong the lifespan of the equipment.
Regular maintenance checks are equally important to identify and address minor issues before they escalate into major problems. Cleaning debris from critical components, checking belt tension, and verifying coolant levels are just a few examples of routine tasks that help maintain optimal performance. By following these practices, operators can ensure their welded pipe units operate efficiently and reliably over the long term.