ZNHG-40 Intelligent welded pipe control system
智能焊管控制系统采用一站式数字化集中控制架构，通过高性能工业总线与数据采集模块，实现对整条生产线的统一调度与实时监控。该系统能够与焊接电源、光亮退火、定径矫直等关键设备进行连机通讯和数据交互，支持参数自动调用、工艺实时监测以及多工序的联动控制。通过开放式的数据接口，用户可实现生产状态可视化、工艺数据追溯及远程运维管理，有效提升焊接精度、生产效率与设备协同稳定性，为焊管生产线的数字化升级提供核心支撑。
智能焊管控制系统的优势
Product Introduction: Intelligent Welded Pipe Control System
Overview
The Intelligent Welded Pipe Control System provides centralized, digitalized control for modern welded pipe production lines. It connects seamlessly with welding power supplies, bright annealing equipment, sizing mills, cutting units, and other key devices, ensuring stable operation and consistent product quality.
Key Features
Integrated Digital Control
Unified system architecture enables communication, data exchange, and coordinated control with all major equipment.Multi-Station HMIs
Main HMI at the welding station and an additional HMI at the cutting station for convenient local parameter adjustments and full-line control.Main HMI Functions
Equipped with touchscreen display, gas flow regulator, production speed and welding current controls, start/stop buttons, arc ignition, and emergency stop switch.Real-Time Monitoring
Operators can monitor and control forming mills, welding power sources, robotic welding arms, annealing systems, sizing mills, and cutting tables.Touchscreen Data Display
Displays critical production parameters including motor speed, line speed, welding current/voltage, gas flow, cutting length, annealing temperature, and system faults.Welding Gas Flow Control
Integrated flowmeter with test-gas function ensures precise gas regulation and consistent shielding conditions.Access Control
Secure login with employee ID and password prevents unauthorized operation.Data Logging & Reporting
Built-in storage and printing functions allow operators to generate production reports covering specifications, current, output, and gas consumption.
Benefits
Higher Efficiency – Centralized digital control reduces downtime and improves workflow coordination.
Improved Quality – Real-time monitoring and precise parameter adjustment ensure stable welding results.
Enhanced Safety – Access control and emergency functions protect both operators and equipment.
Data Traceability – Automatic reporting supports process analysis, optimization, and compliance.
Intelligent Welded Pipe Control System: Login, Access, and Real-Time Monitoring
System Login and Access Management
The intelligent welded pipe system features a multi-level login mechanism with two roles: Administrator and Operator. Each role has specific permissions and operational scope, ensuring safe and regulated production processes.
Once logged in, the system automatically associates historical production data with the employee’s account. This enables comprehensive traceability and precise data management, providing a reliable basis for production analysis and quality control.
Main Page Parameter Display
The main interface is designed for simplicity and clarity, consolidating all key production parameters in a single view. Operators can monitor real-time production status and quickly adjust settings, enhancing operational efficiency and ease of use.
ZNHG-40 Intelligent Welded Pipe Control System Features
Equipment Configuration
Production line equipment can be flexibly configured according to different welded pipe processes.
Activated devices perform automatic self-checks before the production line starts, ensuring proper equipment status.
Activated devices automatically start in coordination when the line begins operation, simplifying setup.
During production, devices share information, trigger coordinated alarms, and support automatic stoppage.
Intelligent Line Start
Pressing the start button initiates the full production line automatically, eliminating the need for manual start-up of individual devices. Intelligent start effectively prevents:
Failed arc ignition, which would result in un-welded workpieces;
Mismatched welding current and speed causing weld penetration issues;
Complex manual adjustments that could introduce weld defects.
The production start process involves two steps: pre-start preparations and full line start. Intelligent start ensures smooth operation, reduces human error, and improves product quality and yield.
Intelligent Line Stop
For non-fault stops (e.g., shift changes), conventional methods often rely on visual judgment to stop the line, which may misalign weld overlap positions. Intelligent stop calculates the exact weld length and stop position when the stop button is pressed. Once the optimal position is reached, the system stops all equipment automatically. Upon restart, welding overlaps remain correctly positioned after the cut (with configurable allowance), ensuring production continuity and weld quality.
Automatic Water Pump Control
Lubrication and grinding water pumps can start and stop automatically, with the option for manual control for flexible operation.
Welding Control and Parameter Acquisition
The system monitors and collects welding current, voltage, and shielding gas flow in real time, maintaining a stable and reliable welding process.
Bright Annealing Parameter Acquisition
Parameters such as annealing temperature, power, and operational status are displayed on the main HMI. These values are stored in the production process database for traceability. If the line is welding while the bright annealing unit is off, the system triggers an alarm.
Wireless Remote Control
An industrial-grade wireless remote enables manual jog control for moving the line forward or backward during setup and maintenance.
Welding Gas Flow Alarm
Shielding gas flow is a key factor affecting weld quality. The system allows users to set flow thresholds. If gas flow exceeds the set range, an audible alarm alerts the operator to ensure consistent weld quality.
Equipment Fault Alarm and Recording
The system provides comprehensive protection, including over-temperature, over-current, water or gas shortage, missed welds, and auxiliary equipment faults. Alarms are categorized as:
Level 1: Immediate stop of the entire production line;
Level 2: Audible alert with fault details displayed on the main HMI.
All alarms are logged with timestamp and type for easy tracking. The system includes visual and audible indicators for efficient on-site response.
Energy Consumption Monitoring
The system calculates energy consumption per production line, allowing precise cost calculation per ton of steel pipe and supporting refined production management. Note: Consumption excludes annealing gas.
Line Group Control Interface
The system provides a data interface for integration with group control platforms (GCP), offering a comprehensive and accurate data platform. Production line data is transmitted via Ethernet to a central server, where customers can view data and set parameters, which are then sent back to the production line. Full-process production, from planning to quality control, can be managed digitally via GCP, reducing management costs and improving efficiency.
On-Site Printing
Supports on-site report printing, allowing multiple production lines to connect to one or more network printers. Reports can be printed at the production floor or office area.
Electrical Control System Requirements
All electrical components are installed in dedicated control cabinets with cooling fans;
High-voltage and low-voltage circuits are separated and labeled; grounding complies with standards;
All control wiring is shielded to prevent interference;
Signal cables and components use modular connectors with labels for easy replacement and maintenance;
Control components are high-quality branded products; non-standard or unbranded components are not used;
Control and power lines are routed via overhead galvanized trays, preventing corrosion, mechanical damage, or accidental contact;
Tray design separates high and low voltage lines; low-voltage cables are shielded to ensure equipment stability.
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