How to place the impedance in the high frequency welded pipe equipment?
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- Release time:2023-06-04 11:30
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【概要描述】When describing the placement plan of the resistor in the high frequency welded pipe equipment, two positioning standards are used, one is based on the contour of the resistor, and the other is based on the magnetic rod contour inside the resistor. There are certain differences between the two benchmarks.
How to place the impedance in the high frequency welded pipe equipment?
【概要描述】When describing the placement plan of the resistor in the high frequency welded pipe equipment, two positioning standards are used, one is based on the contour of the resistor, and the other is based on the magnetic rod contour inside the resistor. There are certain differences between the two benchmarks.
- Sort:Information
- Auth:
- Source:
- Release time:2023-06-04 11:30
- Pvs:
When describing the placement plan of the resistor in the high frequency welded pipe equipment, two positioning standards are used, one is based on the contour of the resistor, and the other is based on the magnetic rod contour inside the resistor. There are certain differences between the two benchmarks.
In the induction welding process of high frequency welded pipe equipment, the induced current of the welded pipe blank is mainly distributed near the inner and outer perimeter edges of the fusion surface of the pipe blank. The current density in other areas of the billet is lower.
A large number of experiments have shown that under the precondition of placing a magnetic rod (impedance), the current density is higher in the interval from the middle line of the squeeze roller to the front end of the induction coil; in the induction coil area, the current density decreases rapidly, behind the induction coil At the end position, the current density is reduced to 3% of the highest value. After removing the magnetic rod (resistor) in the tube blank, the current density on the side of the tube blank is greatly reduced, and the average current density in front of the induction coil is reduced by about 47%.
Placing a magnetic rod in the tube blank can make the induced current in the tube blank concentrate on the fusion surface, increase the current density on the edge of the tube blank on the fusion surface, and thereby improve the induction welding efficiency and save the power of high frequency welded pipe equipment. If the magnetic bar is not used or the magnetic bar fails, higher output power of the second-hand high frequency welded pipe equipment must be consumed to maintain manufacturing.
It should be noted that if the magnet bar is packaged inside the resistor, there should be a certain distance between the front end of the resistor and the front end of the magnet bar. Some references take the front of the resistor as the placement standard, and align the front end of the resistor with the center of the squeeze roller line, so that the front of the magnet bar may be located behind the squeeze roller line, which will reduce the efficiency of welding. The magnetic rod in the impedance device is the key part that affects the distribution of induced electricity. When placing the impedance device, the contour of the magnetic rod should be the standard.
Practical experience believes that the length of the magnetic rod should be 3.5 times the width of the induction coil, but this kind of insight is less versatile. When clarifying the length of the magnet bar, it should be based on the distribution of the induced current in the radial direction of the welded pipe. In the induction welding process of high frequency welded pipe equipment, the amount of induced current is mainly distributed from the centerline of the squeeze roller to the rear end of the induction solenoid coil. Aligning the front of the magnet bar with the two ends of the axis of the extrusion forming roller, and overlapping the development of the back end of the magnet bar and the back end of the induction coil, can make most of the induced current in the tube blank be concentrated on the fusion surface of the welded pipe by the effect of the magnet bar . The minimum length of the magnet bar can be determined based on the front and rear development parts of the induction electromagnetic coil.
Specific description of the placement of impedance devices in high frequency welded pipe equipment:
When placing the impedance device, the contour of the magnetic rod inside the impedance device should be used as the placement standard. In the axial direction of the welded pipe, the front of the magnetic bar must be aligned with both ends of the center line of the squeeze roller. If the front end of the magnetic bar is located behind the center line of the squeeze roller, the high efficiency of induction welding will be reduced. The length of the magnet bar should not be less than the distance between the center line of the squeeze roller and the rear end of the induction solenoid coil.
In the vertical direction of the cross section of the welded pipe, the resistance of the resistance close to the fusion surface of the welded pipe can improve the high efficiency of induction welding. The cross-sectional area of the magnetic rod inside the impedance is more than 50% of the inner wall section of the welded pipe to meet the manufacturing regulations. Optimizing the magnetic rod group into a hollow structure has less impact on the efficiency of induction welding.
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3. Work Hardening: Stainless steel has a tendency to work harden, which can make machining and forming operations more difficult.
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Overall, the selection of stainless steel electrolytic tubes depends on the specific requirements of the application, balancing their benefits with their drawbacks.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
Advantages of Stainless Steel Electrolytic Tubes:
1. Corrosion Resistance: Stainless steel electrolytic tubes have excellent resistance to corrosion, which makes them ideal for use in harsh environments, including acid and alkaline conditions.
2. Durability: They are highly durable and can withstand high temperatures and pressures, making them long-lasting and reliable.
3. Hygienic Properties: Stainless steel is easy to clean and maintain, making it suitable for applications that require strict hygiene standards, such as in the food and pharmaceutical industries.
4. Strength: These tubes have high mechanical strength and can endure significant amounts of stress without deforming.
5. Recyclability: Stainless steel is recyclable, which makes these tubes environmentally friendly.
6. Aesthetic Appeal: They have a shiny and attractive appearance, which is beneficial for applications where aesthetics are important.
Disadvantages of Stainless Steel Electrolytic Tubes:
1. Cost: Stainless steel electrolytic tubes are generally more expensive than tubes made from other materials.
2. Weight: They can be heavier compared to alternative materials like aluminum or plastic, which may be a disadvantage in some applications.
3. Work Hardening: Stainless steel has a tendency to work harden, which can make machining and forming operations more difficult.
4. Thermal Conductivity: Stainless steel has relatively low thermal conductivity compared to other metals like copper, which can be a limitation in certain applications requiring efficient heat transfer.
Overall, the selection of stainless steel electrolytic tubes depends on the specific requirements of the application, balancing their benefits with their drawbacks.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
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For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
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1.Loading Automated Loading: High-end laser tube cutting machines often feature automated loading systems that can handle multiple tubes at once, which increases efficiency.
Manual Loading: Some systems require manual loading, particularly in smaller or less automated setups.
2.Positioning Alignment: The tube is aligned and secured in place to ensure precise cutting. This can be achieved through mechanical clamps or automated systems that adjust the position based on pre-programmed parameters.
Initial Calibration: The machine checks the initial position of the tube using sensors and adjusts accordingly. This step ensures the accuracy of the cuts.
3.Cutting Laser Generation: The laser source generates a high-intensity beam focused on the tube.
Movement System: CNC (Computer Numerical Control) systems guide the laser along the programmed path to cut the tube according to the desired specifications.
Cooling: Cooling systems protect the laser and the workpiece from overheating during the cutting process.
4.Quality Monitoring Real-time Monitoring: Advanced machines use cameras and sensors to monitor the cutting process in real time, checking for defects and ensuring quality.
Feedback Loop: Errors detected are communicated back to the control system, which can make real-time adjustments to the cutting parameters.
5.Sorting and Unloading Automated Sorting: After cutting, sections of the tube are sorted automatically based on their size, shape, or another criterion.
Unloading: The finished pieces are then unloaded, either manually or using an automated system, and prepared for the next stage of processing or delivery.
6.Post-processing (if necessary)
Deburring: Some cut tubes might require deburring to remove sharp edges.
Cleaning: The workpieces could require cleaning to remove any residual material or dirt.
7. Inspection Dimensional Inspection: Quality control checks the dimensions of the cut pieces to ensure they match the required specifications.
Surface Inspection: The surface quality is also inspected to ensure there are no defects or damages that might affect the product's functionality or appearance.
8. Packaging and Shipping Packaging: The finished tubes are packaged to prevent damage during transportation.
Shipping: The packaged tubes are then prepared for shipping to the customer or for further processing.
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For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
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Idle Time: Machines may consume energy even when not actively cutting, depending on the design and standby modes.
5.Maintenance and Consumables
Lens and Mirrors: Regular maintenance and replacement of optical components are necessary, adding to operational costs.
Assist Gases: Gases like oxygen, nitrogen, or compressed air are used in the cutting process and add to operating expenses.
6.Labor Costs
Operational Efficiency: Skilled operators can optimize machine performance, reducing waste and downtime.
Automation: Automated systems may reduce labor costs but require initial investment and maintenance.
7.Capital Depreciation
Machine Depreciation: Over the machine’s lifespan, depreciation costs contribute to overall operating costs. Higher initial investment means higher depreciation.
These calculations can be adjusted based on actual usage, efficiency, and local energy prices.
ConclusionThe energy consumption and operating costs of a laser tube cutting machine depend on multiple factors, including the type of laser, machine efficiency, material being cut, operational time, and maintenance requirements. By optimizing each of these factors, it’s possible to manage and reduce the overall operating costs effectively.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
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Utilization Rate: How often and for how long the machine is operated directly impacts total energy consumption.
Idle Time: Machines may consume energy even when not actively cutting, depending on the design and standby modes.
5.Maintenance and Consumables
Lens and Mirrors: Regular maintenance and replacement of optical components are necessary, adding to operational costs.
Assist Gases: Gases like oxygen, nitrogen, or compressed air are used in the cutting process and add to operating expenses.
6.Labor Costs
Operational Efficiency: Skilled operators can optimize machine performance, reducing waste and downtime.
Automation: Automated systems may reduce labor costs but require initial investment and maintenance.
7.Capital Depreciation
Machine Depreciation: Over the machine’s lifespan, depreciation costs contribute to overall operating costs. Higher initial investment means higher depreciation.
These calculations can be adjusted based on actual usage, efficiency, and local energy prices.
ConclusionThe energy consumption and operating costs of a laser tube cutting machine depend on multiple factors, including the type of laser, machine efficiency, material being cut, operational time, and maintenance requirements. By optimizing each of these factors, it’s possible to manage and reduce the overall operating costs effectively.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
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2.Beam Delivery System: This system directs the laser beam from the laser source to the cutting head. It usually consists of mirrors and lenses ensuring the beam remains focused and consistent in power and quality.
3.Cutting Head:Includes a focusing lens, a nozzle, and sometimes a height sensor. The focusing lens concentrates the laser beam to a fine point for precise cutting. The nozzle directs assist gases (like oxygen or nitrogen) towards the cutting point, helping to clear molten material and enhance cutting quality.
4.Assist Gas System: Supplies gases (usually oxygen, nitrogen, or compressed air) required for the cutting process. Different gases are used based on the material being cut to achieve optimal cutting quality and speed.
5.Chuck and Rotary Axis: Holds and rotates the tube to position it accurately under the laser beam. These chucks can be adjusted to accommodate different tube sizes and shapes, ensuring secure and precise handling.
6.CNC Control System: The brain of the operation, this computer numerical control system runs the software that guides the laser cutting process. It handles the movement of the cutting head, the rotation of the chuck, and the application of assist gases per the programmed design.
7.Material Handling System: Includes loading and unloading mechanisms that manage the tubes before and after cutting. Automated systems can greatly enhance productivity by reducing manual intervention.
8.Cooling System: Maintains the temperature of the laser source and other critical components to ensure they operate efficiently and avoid overheating.
9.Exhaust and Filtration System: Removes fumes and particulates generated during the cutting process, ensuring a clean working environment and protecting sensitive components from contamination.
10.Safety Features: Includes protective barriers, interlock switches, and emergency stop buttons to ensure operator safety during machine operation.
Each of these components must function optimally and in harmony to achieve precise and efficient tube cutting with minimal wastage and high-quality outputs.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
1.Laser Source:This is the core component that generates the laser beam used for cutting. It can be of different types, such as CO2, fiber, or Nd:YAG lasers, each providing varying power levels and suitable for different materials and thicknesses.
2.Beam Delivery System: This system directs the laser beam from the laser source to the cutting head. It usually consists of mirrors and lenses ensuring the beam remains focused and consistent in power and quality.
3.Cutting Head:Includes a focusing lens, a nozzle, and sometimes a height sensor. The focusing lens concentrates the laser beam to a fine point for precise cutting. The nozzle directs assist gases (like oxygen or nitrogen) towards the cutting point, helping to clear molten material and enhance cutting quality.
4.Assist Gas System: Supplies gases (usually oxygen, nitrogen, or compressed air) required for the cutting process. Different gases are used based on the material being cut to achieve optimal cutting quality and speed.
5.Chuck and Rotary Axis: Holds and rotates the tube to position it accurately under the laser beam. These chucks can be adjusted to accommodate different tube sizes and shapes, ensuring secure and precise handling.
6.CNC Control System: The brain of the operation, this computer numerical control system runs the software that guides the laser cutting process. It handles the movement of the cutting head, the rotation of the chuck, and the application of assist gases per the programmed design.
7.Material Handling System: Includes loading and unloading mechanisms that manage the tubes before and after cutting. Automated systems can greatly enhance productivity by reducing manual intervention.
8.Cooling System: Maintains the temperature of the laser source and other critical components to ensure they operate efficiently and avoid overheating.
9.Exhaust and Filtration System: Removes fumes and particulates generated during the cutting process, ensuring a clean working environment and protecting sensitive components from contamination.
10.Safety Features: Includes protective barriers, interlock switches, and emergency stop buttons to ensure operator safety during machine operation.
Each of these components must function optimally and in harmony to achieve precise and efficient tube cutting with minimal wastage and high-quality outputs.
For more information, please pay attention to the website of Jinyujie Mechanical and Electrical Used Pipe Mill Supplier:www.usedpipemill.com
JinYuJie-Used Pipe Mills Supplier(Please click the link→) :second-hand pipe mill
Wechat: 13392281699
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