Views: 0 Author: Site Editor Publish Time: 2025-08-28 Origin: Site
Keep roundness on-spec, maximize uptime, and pass audits—this guide distills field-proven practices for running and maintaining TSD’s TDW96Y-2000/1422×12200 calibration press on large-diameter LSAW pipe lines.
The Pipe Calibration Machine is designed to correct out-of-round pipe by applying external force with a 3-beam, 4-column down-stroke hydraulic frame. Pipes are fed axially by transport rolls and rotated 360° by turning rolls to locate the high spot (align the major axis at the “12 o’clock” position) before each press stroke; sections are calibrated sequentially until the whole pipe is within tolerance.
Acceptance targets:
Before calibration: roundness tolerance ≤ ±5% D.
After calibration: roundness tolerance ≤ ±0.75% D.
Rated forming force: 20,000 kN.
Pipe diameter range: Φ508–Φ1422 mm.
Wall thickness: 8–32 mm.
Pipe length: 8,000–12,200 mm.
Hydraulic system max. pressure: 28 MPa.
Controls: Mitsubishi Q-series PLC over CC-Link bus, manual step-by-step mode for every movement.
For thick-wall material (e.g., X70 at 30 mm), reduce axial feed per stroke and calibrate shorter segments to protect tools and hit tolerance.
Regular calibration & preventive maintenance keep accuracy stable, extend component life, and reduce unplanned downtime.
Daily checks, cleaning, and lubrication prevent small issues from turning into costly repairs.
Never overload: stay within force/pressure and the machine’s diameter-length-thickness envelope.
Log everything: calibration, inspections, alarms, parts changes—your audit trail and planning backbone.
Train operators on alignment, step-by-step manual moves, lockout/tagout, and emergency stops.
Check oil level/temperature and look for leaks; visually inspect cylinders, lines, tool seat, and T-slots.
Spin transport and turning rolls; confirm smooth rotation and no abnormal noise/vibration.
Clear PLC/console alarms; verify sensors and limit switches status.
Use turning rolls to rotate the pipe and set the ellipse major axis to 12 o’clock.
Feed the target section into the tools with transport rolls; press per the program.
Watch pressure/position trends; stop to investigate oscillations or drifts.
Record any deviations and corrective actions in the shift log.
Respect 20,000 kN force and 28 MPa system limits; never push beyond the qualified pipe range (Φ508–Φ1422 mm, 8–32 mm wall, 8–12.2 m length).
For heavy-wall or high-strength grades, shorten axial feed per stroke and calibrate in more, shorter sections; schedule high-load work across shifts to reduce thermal/hydraulic stress.
When to calibrate (metrology), not to be confused with production “calibration” runs):
Establish a 6–12-month calibration cycle for pressure chain (gauges/transducers), displacement/position, and tool geometry; tighten intervals for harsh environments or heavy utilization.
Verify the 28 MPa pressure reading against a traceable standard; re-enter PLC thresholds after adjustments.
Run a roundness capability check on representative pipe sizes to confirm ≤ ±0.75% D post-calibration.
Suggested record fields: machine ID, date, item (pressure/position/geometry), method & instrument, result, action, approver.
| Task | Frequency | Notes |
|---|---|---|
| Wipe tool surfaces, guide faces; clear scale/dust | Each shift | Prevents imprint defects and sensor fouling |
| Clean control panels, filters, cabinet inlets | Weekly | Avoids overheating and sticky buttons |
| Lubricate sliding/guide interfaces | Weekly | Wipe excess grease to reduce dust pickup |
| Check leaks, hose wear, cylinder seals | Weekly | Replace seals proactively where seepage is detected |
| Inspect transport/turning rolls & bearings | Monthly | Listen for noise; check play and torque |
| Hydraulic oil analysis (particle count/acid #) | Quarterly | Change oil & filters per results |
| Verify PLC I/O, CC-Link health, grounding | Quarterly | Stable comms prevent nuisance trips |
Keep one full set of cylinder seals and one set of filter elements on hand (“two in use, one spare”) to shorten MTTR.
Capture calibration, PM, faults/alarms, parts replacements—and tie them to pipe lots where practical.
Review logs monthly to spot trends (e.g., repeated pressure drift or roundness rework) and adjust PM/calibration intervals.
Keep supplier certificates and software disclosures (PLC program, access) on file for audits.
Process skills: 360° rotation to locate the high spot, axial feed control, short-segment strategy for thick walls.
Controls: step-by-step manual mode for each movement; safe recovery from alarms.
Safety: lockout/tagout, guarding, spill response; correct PPE for hydraulic and handling tasks.
Store the machine and precision gauges in a dry, ventilated area away from direct heat; protect reference tools in sealed cases.
Avoid impacts during moves; protect machined faces with soft covers.
How often should we calibrate the gauges and position system?
Start with 6–12 months depending on load and environment. Shorten the interval if you see pressure drift or after hydraulic component changes; verify capability against the ±0.75% D roundness target.
Can we run very thick-wall pipes at full stroke length?
Not recommended. For X70 at 30 mm wall, limit per-stroke axial length (e.g., ~700 mm) and increase the number of segments to protect tooling and hit spec.
What control hardware does the press use?
Mitsubishi Q-series PLC with CC-Link bus; manual mode supports stepwise control of inlet/outlet, turning, and the full calibration sequence.
