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Two ways of welding of high frequency straight seam welded pipe unit
When it comes to high-frequency straight seam welding of pipes, there are two primary methods used 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. This method allows for excellent current penetration, maximizing the two effects of high-frequency currents due to the close contact between the copper electrodes and the steel plate. While this approach offers higher welding efficiency and lower power consumption, it is typically employed in high-speed, low-precision pipe production. Contact welding remains a popular choice when dealing with particularly thick steel pipes.
However, contact welding does come with its own set of challenges. First, the copper electrodes wear down quickly due to their constant contact with the steel plate. Second, the stability of the current can be affected by the flatness of the steel plate's surface and the straightness of its edges, leading to inconsistent welding results. Additionally, this method often produces higher internal and external burrs, making it less suitable for high-precision and thin-walled pipe welding.
On the other hand, induction welding uses an induction coil wrapped around the steel pipe, either as a single turn or multiple turns. Multiple turns tend to produce better results, though installing and producing these coils can be more complex. Efficiency increases when the coil is closer to the pipe’s surface, but this also raises the risk of discharge between the coil and the pipe. A recommended gap is between 5 to 8 millimeters to maintain optimal performance.
With induction welding, since the coil doesn’t touch the steel plate, there’s no wear on the equipment, and the current remains more stable, ensuring a smoother welding process. Induction welding is usually preferred when working with precision pipes.
When it comes to maintaining and debugging a welded pipe unit, safety is paramount. Operators should always adhere to safety regulations and avoid touching any molds while the machine is running. Hands should never be placed in the direction of the pipe to prevent accidents.
Before operating the unit, operators should inspect all lubrication points to ensure they are adequately oiled. If not, lubricating oil should be added to guarantee smooth operation. During regular use, high-temperature resistant synthetic composite aluminum-based grease should be applied to key components to protect against wear and tear. Proper maintenance not only extends the lifespan of the equipment but also enhances its operational efficiency, ensuring consistent and reliable performance over time.