Overview
Steel gas tube cold roll forming machines are used to produce steel tubes and pipes for gas transmission from steel coil strips. This equipment forms steel strips into round, square or rectangular hollow sections by progressively bending and welding through a series of rollers.
Key features of steel gas tube cold roll forming machines:
| Parameter | Details |
|---|---|
| Forming Method | Cold roll forming |
| Materials | Low carbon steel, stainless steel |
| Tube Types | Round, square, rectangular, other custom shapes |
| Tube Sizes | 12 – 200 mm diameter (round)<br>20 – 250 mm (square and rectangular) |
| Wall Thickness | 0.5 – 3 mm |
| Tube Length | 6-12 m |
| Speed | 10 – 40 m/min |
| Drives | Servo motor, hydraulic |
| Automation | PLC control system |
Applications of Steel Gas Tube Cold Roll Forming Machine
Steel gas tubes from cold roll forming find application in:
| Application | Details |
|---|---|
| Natural Gas Transmission | For long distance overground gas pipelines |
| LPG Gas Transmission | Transmission lines for liquefied petroleum gas |
| CNG Gas Transmission | Piping networks for compressed natural gas |
| Industrial Gas Pipelines | To transport other gases like oxygen, nitrogen, hydrogen etc. |
| Structural and Mechanical Systems | As mechanical components, structures |
Types of Steel Gas Tube Cold Roll Forming Machines
There are three main types of cold roll forming machines for steel gas tubes:
| Machine Type | Description |
|---|---|
| Round Tube | Produces round hollow tube sections |
| Square and Rectangular Tube | Forms square and rectangular tube profiles |
| Custom and Special Shapes | For non-standard tube cross-sections |
Round Tube Cold Roll Forming Machine
- Uses a coil strip which is gradually rolled and welded into a round tube
- Diameter size range of 12 – 200 mm
- Output speed up to 40 m/min
- Used for gas pipelines, automotive parts, structural sections
Square and Rectangular Tube Cold Roll Forming Machine
- Forms steel strips into square and rectangular tubing
- Size range of 20 – 250 mm
- Used for specialized mechanical structures and gas piping
Custom Shape Cold Roll Forming Machine
- Produces non-standard tube cross-sections
- Shapes like oval, triangular, trapezoidal etc. sections
- Used where special tube profiles are required
Specifications of Steel Gas Tube Cold Roll Forming Machine
The following table outlines typical technical specifications of steel gas tube cold roll forming machines:
| Specifications | Details |
|---|---|
| Tube Sizes | Round: 12 – 200 mm diameter <br> Square: 20 – 250 mm <br> Rectangular: 50 x 30 mm to 250 x 150 mm |
| Wall Thickness | 0.5 – 3 mm |
| Strip Width | Up to 1250 mm |
| Tube Length | 6 – 12 m (up to 18 m optional) |
| Forming Speed | 10 – 40 m/min |
| Machine Power | 5.5 – 30 kW |
| Voltage | 380V, 3-phase, 50 Hz |
| Machine Weight | 8000 – 32000 kg |
| Machine Size | 10 – 25 m long x 2 – 3 m wide x 2 – 2.5 m high |
Steel Gas Tube Cold Roll Forming Machine Design
The main design aspects and components of steel gas tube cold roll forming machines are:
- Uncoiler – Feeds strip coil into machine
- Straightening rollers – Correct coil curvature
- Forming stations – Progressive bending rollers in 5-16 stations
- Welding assembly – High frequency contact welding
- Tube cutting unit – Cuts formed tube into lengths
- PLC control – Automated forming parameters and speed
- Conveyor system – Transfers formed tubes outside
Other features:
- Heavy duty structural frame and gearbox transmission
- Roller materials – alloy steel, wear-resistant
- Safety covers, light curtains, sensors
- Options for degreasing, cleaning, testing
Standard codes and standards like ASME B31.8, API 5L, ASTM A500 must be followed for gas tube design.
Working Principle of Steel Gas Tube Cold Roll Forming
The working stages in steel gas tube cold roll forming machine:
1. Feeding – Coil strip enters machine through powered uncoiler
2. Straightening – Rollers correct strip curvature
3. Pre-bending – Initial bend profile imparted
4. Progressive forming – Strip passes through bending stages
5. Welding – Edges welded by contact pads
6. Cutting – Formed tube cut to length by saws
7. Discharge – Conveyor transfers tube outside
8. Degreasing and testing – Cleaning and inspection
Installation of Steel Gas Tube Cold Roll Forming Machine
- Install on flat leveled concrete floor
- Anchor forming machine to ground
- Allow working space around for coil loading, tube offloading
- Install electric supply lines and control panel
- Connect hydraulic, pneumatic lines if used
- Integrate safety barriers, controls
- Test run empty to confirm alignments
Operation and Maintenance of Steel Gas Tube Cold Roll Forming Machine
Operation
- Ensure adequate strip lubrication
- Set forming parameters on control panel
- Monitor tube dimensions during production
- Inspect welding seam quality
- Allow cooling time between production cycles
Maintenance
- Lubricate roller bearings and sliding parts
- Check roller and gear wear periodically
- Inspect electrical contacts and welder pads
- Verify hydraulic system performance
- Replace damaged forming rollers
- Keep machine area clean to avoid debris
Choosing a Steel Gas Tube Cold Roll Forming Machine Supplier
Consider the following when selecting a steel gas tube cold roll forming machine supplier:
| Parameter | Details |
|---|---|
| Technology | Look for latest designs, high-end components |
| Experience | Number of years supplying such machines |
| Production Range | Diverse roll forming capabilities |
| Customization | Ability to customize for specialized needs |
| Quality | ISO certified manufacturing, quality control |
| Services | Installation support, operator training, after-sales service |
| Pricing | Competitive pricing for machine supply, spares, service |
| Lead Times | Ability to deliver equipment on scheduled time |
Cost of Steel Gas Tube Cold Roll Forming Machines
The price of steel gas tube cold roll forming machines depends on:
- Type of machine (round, square, custom tube)
- Production speed and automation level
- Size range of tubes to be produced
- Additional pre/post-processing like degreasing, testing
- Shipping and installation charges
Typical price range:
| Machine Type | Price Range |
|---|---|
| Small Round Tube | $50,000 – $150,000 |
| Medium Round and Square Tube | $150,000 – $350,000 |
| Large Round and Square Tube | $350,000 – $600,000 |
| Custom Tube | $200,000 – $800,000 |
Pros and Cons of Steel Gas Tube Cold Roll Forming
Advantages
- High production speeds and output
- Consistent quality and dimensional accuracy
- Low material waste
- Automated process requiring less labor
- Ability to form complex and custom shapes
- Lower costs than alternatives like extrusion
- Safer than hot forming processes
Limitations
- Higher initial machine investment
- Limited to certain tube sizes and wall thicknesses
- Relatively inflexible once set up
- Welding quality important to performance
- Significant floor space required for equipment
FAQs
What materials can be roll formed into gas tubes?
Steel is the most common material for gas tube cold roll forming. Low carbon steel, stainless steel, galvanized steel strips are generally used.
What shapes can be produced by steel tube cold roll forming?
Round, square, rectangular and custom non-standard hollow sections can be produced. Oval, trapezoid, triangular shapes are also possible.
What are the advantages of cold roll forming vs hot rolling for gas tubes?
Cold roll forming has benefits like closer size tolerance, better surface, no scale, safer process compared to hot rolling. But hot rolling allows larger sizes and wall thicknesses.
How to maintain quality of gas tube welding in cold roll forming?
Correct weld pad pressure, alignment and electrical conductivity parameters must be maintained. Roller wear, strip cleanliness also affect weld quality.
What safety aspects need consideration for gas tube roll forming machines?
Safety guards for moving parts, emergency stops, strip and tube sensors should be installed. Proper machine grounding, isolation from electrical hazards is required.
How to calculate power requirement for a gas tube cold roll forming machine?
Power depends on strip width, thickness, yield strength, tube size, production speed and number of forming stations. Typically 0.5-2 kW per roller is installed.
Conclusion
Steel gas tube cold roll forming machines offer an efficient automated process to produce round, square and custom hollow section tubes for gas transmission pipelines and structural applications. With high production speeds, precision tolerances and good surface finish, these machines provide quality tubes at relatively low costs. By selecting a capable supplier and ensuring proper machine installation, operation and maintenance, manufacturers can benefit from roll formed steel gas tubes.