Design, Software Development, and Prototype Manufacturing of a Spiral Welded, Mold-Free Variable Diameter Pipe Production Line
An automation system has been developed that will enable the production of spiral welded pipes with homogeneous, non-porous welded seams, high strength and diameters that are not available in the market. This system is designed to produce pipes of different sizes and wall thicknesses with high precision. Thanks to computer-controlled automation, the same welding quality is achieved at every point, while 20% less raw material consumption is achieved. While high-strength products are obtained with techniques such as TIG or gas arc welding, semi-finished product consumption is reduced with laser cutting technology. This solution for intermediate diameters that are needed in the industry but not available in the standards also offers an innovative approach in terms of energy efficiency and occupational safety.
The production of spiral welded pipes with critical diameters is not possible with current systems, and these diameters are laboriously obtained by machining methods. It is difficult to achieve homogeneous welding quality in conventional methods, and distortion and residual stresses occur due to the uneven distribution of welding heat. Additionally, manual production techniques lead to long manufacturing times and high labor costs. These methods are inefficient in terms of both raw materials and energy and cannot meet the quality standards in the industry.