Record the specific requirements and execution standards of the current task order customer in the production task order. These data will be saved with the production process data for the parameters of each steel pipe. Easy implementation of quality traceability. When our production process matures in practical applications, we can save it. In the future, steel pipes of the same specification will be directly transferred out for use on the production line, which is convenient and fast. More reliable production quality. Welding process, every time the welding current changes, a record of the welding process is made. We can record the full monitoring of current changes during our welding process. The production line IoT system requires hardware architecture construction for the IoT platform. After entering the monitoring interface, real-time data from grouped monitoring devices can also be viewed, including important historical data and historical data curves. View historical data, alarms, temperatures, and other important data, as well as historical data curves. You can choose a previous date for data analysis and remote maintenance. The alarm information or event information of the production line can be sent to designated personnel through the network, including "SMS", "email", and "WeChat".
Smart Production Line Control System with IoT Integration
Our Smart Production Line Control System is designed to revolutionize manufacturing efficiency and oversight, particularly within demanding industrial environments. At its core, this system integrates advanced Internet of Things (IoT) modules to provide comprehensive, real-time control and monitoring capabilities across your entire production workflow.
IoT Module Capabilities: Enhanced Connectivity and Control
The embedded IoT module transforms your production line into a connected, intelligent ecosystem, offering unparalleled visibility and operational flexibility:
Centralized Production Task Management: Seamlessly issue and manage production task lists directly through the IoT network. This streamlines scheduling and ensures all operational directives are instantly communicated and executed.
Real-time Production Status Monitoring: Gain instant, real-time insights into the overall production status of your entire line. This allows for proactive decision-making and rapid response to any deviations.
Shift-Specific Performance Tracking: Easily monitor the production status for specific shifts. This granular data helps in evaluating performance, optimizing resource allocation, and identifying areas for improvement during each operational period.
Individual Equipment Status Access: Dive deep into the operational health of each machine by accessing individual device running states. This detailed view supports predictive maintenance and troubleshooting, minimizing downtime.
Proactive Maintenance Alerts: Critical equipment alarms, fault codes, and timestamps are automatically pushed to maintenance personnel. This ensures engineers receive immediate notifications of potential issues, enabling rapid diagnosis and intervention, significantly reducing potential production interruptions.
Forming & Welding Section: Precision Control for Online Solid Solution
Within the Forming & Welding section, our system provides precise control, especially for processes like online solid solution. This critical stage benefits from intelligent oversight and automated parameter management:
Configurable Power and Temperature Settings: After initiating "online solid solution," operators can precisely set the current for both "heating power" and "insulation power." Additionally, the system allows for the accurate input and transmission of DTE module temperature setpoints directly to the shop floor machinery.
Critical Parameter Monitoring: The system continuously monitors important parameters to detect any discrepancies or errors, ensuring the process operates within specified tolerances.
Real-time Status Information & Trend Analysis: It provides comprehensive status information monitoring and the ability to view various temperature curves. This allows for thorough analysis of heating and cooling cycles, ensuring optimal material properties and weld quality.
By integrating robust IoT capabilities with specialized control for critical sections like forming and welding, our Smart Production Line Control System not only enhances operational visibility but also significantly boosts efficiency, reduces downtime, and ensures consistent product quality in advanced manufacturing environments.
Record the specific requirements and execution standards of the current task order customer in the production task order. These data will be saved with the production process data for the parameters of each steel pipe. Easy implementation of quality traceability. When our production process matures in practical applications, we can save it. In the future, steel pipes of the same specification will be directly transferred out for use on the production line, which is convenient and fast. More reliable production quality. Welding process, every time the welding current changes, a record of the welding process is made. We can record the full monitoring of current changes during our welding process. The production line IoT system requires hardware architecture construction for the IoT platform. After entering the monitoring interface, real-time data from grouped monitoring devices can also be viewed, including important historical data and historical data curves. View historical data, alarms, temperatures, and other important data, as well as historical data curves. You can choose a previous date for data analysis and remote maintenance. The alarm information or event information of the production line can be sent to designated personnel through the network, including "SMS", "email", and "WeChat"
The new intelligent control system for high-speed precision welded pipe production line, combined with the latest Internet of Things technology and humanized design, achieves digital control and has the following powerful functions:
• The production line has one click preparation and start stop functions, information can be collected and uploaded, process parameters can be stored and selected, and each process section can be started and stopped synchronously or asynchronously.
• The production line has a comprehensive self-diagnosis function: by pressing the prepare button, the system automatically diagnoses the water and electrical preparation status of the production line. If there is an abnormality and the startup conditions are not met, the alarm light will be on. After troubleshooting, turn on the green light. Can start the production line.
• The position of the welding gun is quickly and accurately adjusted into position using a motor (requiring fine adjustment).
• Double gun argon arc welding+electromagnetic arc control+machine vision weld seam tracking process, improving weld quality and increasing welding speed by more than 20%~40% (depending on the specific pipe material).
• Argon arc welding+electromagnetic arc control+machine vision weld seam tracking process, improving the quality of thick walled pipes' weld seams and avoiding air bubbles.
• The power of the production line is provided by well-known brand variable frequency motors, making the speed more stable, easy to adjust, and improving the quality of finished products.
• Press the start button, the production line will automatically retreat by a certain distance (adjustable), then start forward and automatically start the welding machine to ensure no welding leakage.
• Using laser detection sensors to achieve missed welding and perforation detection alarms and automatic water stop functions, ensuring the dryness of the storage area and timely detection of abnormalities by workers.
• Air pressure detection, water level detection alarm for circulating water tank.
• The grinding control system has the functions of maintaining a constant grinding torque, achieving automatic feeding, and alarming when consumables need to be replaced.
• The coding and spraying of each steel pipe on the production line site, and the corresponding steel pipe parameter data are saved in the system, with traceable quality.
• When the production line is stopped, the welding length can be set to extinguish the arc. Adjustable for 6m and 12m.
• Provide Ethernet networking interface for all parameter data of the production line, facilitating communication connection with the MES system of the intelligent factory of the demander.
Every time the finishing tube is rolled, it must go through the process of solution treatment. Ta ensure that the performance of the steel pipe meets the technical requirements. and to provide guarantee for the post-process processing or use. Bright solution treatment process of ultra-long seamless steel pipe has always been a difficulty in the industry.
Traditional electric furnace equipment is large,covers a large area, has high energy consumption and large gas consumption, so it is difficult for realize bright solution process. After years of hard work and innovative development, the use of current advanced induction heating technology and DSP power supply. Precision control of heating temperature to ensure that the temperature is controlled within t2C,to solve the technical problem of inaccurate induction heating temperature control. The heated steel pipe is cooled by "heat conduction"in a special closed cooling tunnel, which greatly reduces the gas consumption and is more environmentally friendly.
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