ERW Pipe Machines are the core equipment of welded pipe production lines. Their proper operation is essential for improving production efficiency, increasing economic benefits, and ensuring product quality. Therefore, adjusting the welded pipe unit and accurately diagnosing and resolving faults are of utmost importance. This chapter outlines the key aspects of adjustment.

Adjustment Process for ERW Tube Machine Units

Adjustment refers to the debugging during roll pass installation. Once the pipe blank runs smoothly within the unit and produces qualified products, the adjustment task is considered complete. Adjustments during production fall under fault handling. The key steps are as follows:

1. Preparation

Preparation involves checking the quality of Rolls and Equipment condition:

Roll Quality Inspection: Focus on verifying roll pass shapes using templates to ensure compliance with design specifications. Rolls not meeting requirements should be excluded. Additionally, attention should be given to bottom diameter dimensions, critical for synchronized operation. Paired rolls must have identical sizes and shapes.

Equipment Condition Check: Summarized as “horizontal shafts must be level, vertical shafts upright, rolls securely positioned, slides flexible without wobbling, and adjustments smooth without jamming.” Fixed parts must be secure, and movable parts flexible. Non-compliant equipment must be repaired.

2. Roll Pass Alignment

Roll pass alignment is the first step of adjustment:

Use a 0.5mm diameter steel wire from the forming machine’s feeding roll to the straightening roll in the sizing section to determine the rolling line’s center.

Secure the steel wire slightly above the bottom diameter of the horizontal rolls (by at least 2mm) to prevent contact with roll pass surfaces and ensure accurate alignment. This wire serves as the central reference for alignment.

3. Horizontal Roll Alignment

There are two methods for aligning horizontal rolls:

Method 1: Use fixed shims of varying thickness based on roll pass thickness. However, if component machining accuracy is insufficient, cumulative errors may occur, affecting alignment.

Method 2: Adjust the roll position on the shaft using locknuts, ensuring each roll pass center aligns with the centerline. Use a specialized template for verification. Insert the template into the roll pass and lift it gently. If the steel wire fits smoothly into the template’s center groove, the alignment is correct; otherwise, adjust axially. This method is straightforward and effective.