Steel Pipe Cutting and Shrinking Machine
Xuhui (Shandong) Intelligent Equipment Co., Ltd.
Xuhui (Shandong) Intelligent Equipment Co., Ltd. is an enterprise that integrates the research and development, production, and sales of CNC steel bar equipment. The company has introduced advanced concepts in steel bar processing. Relying on its team of technical experts and modern steel bar processing equipment, it provides standardized construction solutions for building steel bars to a wide range of customers. It delivers excellent, efficient, and cost-effective products for steel bar construction processes, helping customers achieve greater profits.
Xuhui (Shandong) Intelligent Equipment Co., Ltd., as a professional equipment manufacturer focusing on CNC steel bar processing, has developed diverse competitive advantages through in-depth technological research and systematic management.
Technological innovation is supported by professional teams.
The company has built a strong technical talent team dedicated to the research, development, and optimization of CNC steel bar equipment. The team has introduced advanced steel bar processing concepts and accumulated expertise in areas such as automatic control and precision mechanical design, enabling it to respond quickly to the industry’s technological upgrade needs. Its management team, with many years of experience in the heavy machinery field, has a deep understanding of construction equipment application scenarios and is able to translate practical industry experience into product optimization.
The quality control system is supported by authoritative certifications.
The company has passed ISO9001 Quality Management, ISO14001 Environmental Management, and ISO45001 Occupational Health and Safety certifications, and has established a comprehensive quality control system covering the entire process from raw material procurement to finished product delivery. During production, real-time data monitoring and self-check mechanisms are implemented. When abnormalities such as clamping deviations occur, the machine automatically issues an alarm and shuts down, effectively reducing the defect rate.
Product Introduction
Steel Pipe Cutting and Shrinking Machine
The steel pipe cutting and tapering machine of Xuhui (Shandong) Intelligent Equipment Co., Ltd. is a highly efficient device that integrates automated metal cutting and forming. Its core advantage lies in end-to-end automation. Driven by servo motors and controlled by a PLC system, it seamlessly connects steel pipe feeding, plasma hole cutting, medium-frequency heating for tip tapering, and unloading, with the entire process requiring only one operator.
The equipment adopts the cold extrusion process (some models combine hot rotary forging technology), allowing diameter reduction of carbon steel, stainless steel, and other pipes without heating or with rapid heating. After forming, the pipe diameter error is controlled within ±1 mm, and the surface remains smooth and scratch-free. Its hole-cutting system supports dual-gun plasma cutting, capable of multi-row punching at equal or unequal intervals, with hole position accuracy of ±0.1 mm to meet different grouting hole layout requirements.
In addition, the equipment is equipped with an intelligent mold-changing system, enabling quick switching between processing molds of different cross-sections such as square tubes and rectangular tubes. Compared with manual processing, efficiency is increased by 5 to 8 times, while oxygen and other consumables costs are reduced by about 70%. The device has passed ISO quality, environmental, and occupational health and safety certifications, ensuring strong stability.
Product Advantages
Benefits of Product
The steel pipe cutting and tapering machine of Xuhui (Shandong) Intelligent Equipment Co., Ltd. is a highly efficient automated device specially designed for engineering applications. Through technological innovation and engineering practice verification, this equipment has become a benchmark product for steel pipe processing in tunnel construction, delivering efficient, precise, and cost-effective integrated solutions.
Fully integrated automation
The equipment is driven by servo motors and controlled by a PLC system, achieving automated integration of steel pipe feeding, plasma hole cutting, medium-frequency heating and tapering, and unloading. The entire process requires only one operator. Once parameters are preset via the touch screen, the equipment automatically completes multi-process linkage, significantly reducing manual intervention and lowering labor intensity.
High-precision processing capability
The hot rotary forging process ensures smooth, scratch-free surfaces after forming. The dual-gun plasma cutting system supports multi-row punching at equal or unequal intervals, meeting the layout requirements of different grouting holes.
Ultimate efficiency enhancement
Daily production capacity can reach 3,000 to 5,000 pieces, which is 5 to 8 times more efficient than manual processing and significantly shortens the processing cycle. The intelligent mold-changing system allows rapid switching between molds of different cross-sections, such as square and rectangular tubes, further improving production flexibility.
Process and cost optimization
By adopting medium-frequency induction heating technology, energy consumption is reduced by more than 30% compared with traditional flame heating, while avoiding material oxidation. The cold extrusion process achieves plastic deformation at room temperature and is suitable for thin-walled pipes. Plasma cutting technology replaces traditional oxygen-acetylene cutting, saving about 70% in gas costs. The closed lubrication system extends the mold’s service life and reduces maintenance frequency.
Intelligence and safety
Equipped with advanced safety protection functions, the system can automatically detect operational errors and shut down to prevent equipment damage. It supports storage of up to 100 groups of punching files, allowing easy recall of different project parameters. The fully enclosed protective shell reduces noise and splash risks. The conveying frame adopts an integrated welded structure, ensuring high operational stability.
Engineering adaptability and reliability
The equipment has passed ISO three-system certification and can operate stably in environments ranging from -20℃ to 40℃. It has been successfully applied in major projects, achieving an average daily processing capacity of over 4,000 steel pipes with a finished product rate of 99.8%.
Product Features
The steel pipe cutting and tapering machine of Xuhui (Shandong) Intelligent Equipment Co., Ltd., as a core piece of equipment in the field of tunnel engineering, has become a benchmark product for advanced tunnel support construction through technological innovation and engineering verification. Its core features can be summarized as high precision, high efficiency, and high reliability, providing customers with an integrated solution from equipment to process.
The equipment adopts a servo motor drive + PLC control system, achieving full-process linkage of steel pipe feeding, plasma hole cutting, medium-frequency heating tip reduction, and unloading. After presetting parameters through the touch screen, the equipment can automatically complete multi-stage processing. The entire process only requires one operator for monitoring, reducing human input by more than 70% compared with traditional manual processing.
The machine body is welded with 25 mm thickened steel plates and undergoes aging treatment to eliminate stress, ensuring long-term operational stability. The fully enclosed protective housing reduces noise to below 75 dB, meeting the ISO 3744 noise standard. Equipped with an infrared light curtain sensor and an emergency stop interlock device, it stops within 0.1 seconds when an abnormal approach is detected. The hydraulic system is equipped with an overload protection valve to prevent mold damage.
It has passed ISO 9001 quality management system certification and CE EU safety certification. Key components (such as servo motors and PLCs) are sourced from international brands like Delta and Siemens, improving reliability by 50%.
Positioning System
Quick Mold Change
Continuous Operation
Heating Technology
Mold Design
Structural Optimization
Intelligent Control
Safety Protection
Remote Operation and Maintenance
Environmental Compatibility
Mobility Convenience
Qualification Certification
Product Type
Common types
Product Maintenance
Full-Cycle Maintenance Plan
The steel pipe cutting and tapering machine of Xuhui (Shandong) Intelligent Equipment Co., Ltd. requires systematic maintenance and upkeep to ensure long-term stable operation. Proper maintenance can reduce the comprehensive failure rate of the equipment by more than 70%, extend the service life of key components by 30% to 50%, and effectively guarantee the continuity and cost-efficiency of tunnel construction. It is recommended that, based on the actual operating conditions of the equipment, the manufacturer’s technicians conduct a comprehensive inspection every six months to ensure that the equipment is always in optimal operating condition.
I. Daily Basic Maintenance
- Cleaning Operations
Use compressed air or a brush every day to clean metal debris and oil stains from the surface and interior of the equipment, focusing on the taper die, plasma cutting gun head, and transmission guide rails to prevent impurities from affecting accuracy.
Wipe the touch screen and operation panel to prevent liquids or dust from entering electronic components.
- Lubrication Management
Apply high-temperature-resistant grease to moving parts such as the feeding lead screw, slider, and bearing at least once a day.
Check the oil level of the hydraulic system to ensure it is within the marked range, and promptly address any leakage.
- Function Check
Before starting, make sure that the emergency stop button, infrared light curtain, and other safety devices are sensitive and effective. Run the machine without load for 3 to 5 minutes and listen for abnormal noises.
Check the installation tightness of the cutting tool and the mold, and confirm whether the cutting/tapering effect meets process requirements.
II. Periodic In-Depth Maintenance
(1) Weekly Maintenance
- Mechanical System
Clean oxide scale from the surface of the medium-frequency heating coil, check for damage to the coil’s insulation layer, and test insulation resistance with a megohmmeter to ensure it is ≥5 MΩ.
Adjust the tension of the drive belt/chain. Replace it if wear exceeds 5% of the original length.
- Electrical System
Check whether the contacts of the contactor are eroded, remove metal particles inside the arc extinguishing cover, and tighten the power line connector.
Test the accuracy of the PLC controller’s input and output signals, and back up the program to prevent data loss.
(2) Monthly Maintenance
- Hydraulic System
Replace the hydraulic oil filter element and use a dedicated oil filter to filter the hydraulic oil. (It is recommended to test the oil quality every three months. When contamination exceeds NAS 1638 Grade 9, oil replacement is mandatory.)
Test the pressure stability of the hydraulic pump to ensure working pressure fluctuations are ≤±0.5 MPa.
- Cutting System
Calibrate the verticality of the plasma cutting gun head, check electrode and nozzle wear, and replace the electrode when wear exceeds 20% of its original length.
Clean the cooling water tank, replenish with deionized water or special coolant, and ensure the water temperature is ≤40℃.
(3) Quarterly Maintenance
- Precision Calibration
Use a micrometer to measure taper error of the tapering die and adjust it to within ±0.5°. Calibrate the feeding positioning accuracy of the laser rangefinder to ±0.05 mm.
Check the spacing of plasma cutting holes. If the error exceeds ±0.1 mm, recalibrate the coordinate system.
- Equipment Lubrication
Change the oil in the transmission gearbox of the medium-frequency heating furnace using GL-5 grade heavy-duty gear oil. Perform the first oil change after 500 hours of operation, and then every 2,000 hours thereafter.
(4) Annual Maintenance
- Comprehensive Overhaul
Disassemble and clean the tapering oil cylinder, and replace sealing parts. Check the inter-turn insulation of the medium-frequency induction coil and carry out vacuum impregnation if necessary.
Calibrate the accuracy of temperature sensors, pressure transmitters, and other instruments to ensure measurement error is ≤±1%.
- Performance Testing
Simulate full-load operation for 2 hours and monitor equipment temperature rise (motor housing ≤70℃, hydraulic oil ≤60℃).
Conduct capacity tests to verify whether daily processing capacity meets design specifications.
III. Maintenance in Special Scenarios
- Extreme Environment Response
When operating in environments below -20℃, preheat the hydraulic oil to above 15℃ in advance and replace it with low-temperature grease.
In high-temperature and humid environments, increase the frequency of using the dehumidifier in the electrical cabinet and check the desiccant condition once a week.
- Long-Term Shutdown Handling
Drain the cooling water tank, apply anti-rust oil to the equipment surface and exposed metal parts, and cover with dust-proof cloth.
Power on and run for 30 minutes every half month to prevent electronic components from becoming damp or damaged.
IV. Maintenance Records and Spare Parts Management
- Establish an Archive
Record in detail the time, content, replaced spare parts, and fault handling of each maintenance session, and create an “Equipment Maintenance Log.”
Regularly analyze maintenance data to predict the lifespan of vulnerable parts (e.g., mold lifespan of ~100,000 cycles, electrode lifespan of ~80 hours), and stock spare parts in advance.
- Compliant Operation
Maintenance personnel must hold relevant qualifications such as electrician or welder certificates. For high-voltage circuits or special equipment, lockout-tagout procedures must be strictly followed.
Hazardous waste such as used oil and discarded batteries must be handed over to qualified environmental protection companies for disposal.
Product Usage Precautions
Matters Need Attention
The steel pipe cutting and tapering machine of Xuhui (Shandong) Intelligent Equipment Co., Ltd. undertakes key processing tasks in tunnel engineering. By following the above usage norms, the comprehensive failure rate of the equipment can be reduced by more than 70%, and the service life of key components can be extended by 30% to 50%, effectively ensuring the continuity and cost-efficiency of tunnel advanced support construction. Operators must always adhere to the principle of "safety first, prevention foremost" and incorporate standardized operations throughout the entire life cycle of the equipment.
System Check Before Operation
- Environment and Material Preparation
- Ensure that the temperature and humidity in the workshop are within the range of -20℃ to 40℃, with humidity not exceeding 85%RH, to prevent electrical components from becoming damp.
- Clear away any debris around the equipment, keep the operation area dry and clean, and pay special attention to removing cutting debris and oil stains.
- Check the pipe parameters. For cold-drawn steel pipes, the heating temperature should be reduced to below 800℃ to avoid work hardening.
- Equipment Status Verification
- Check the tightness of the taper die and cutting gun head installation. Use a feeler gauge to confirm that the die clearance is ≤0.1mm to ensure there is no loosening or wear.
- Test safety devices such as infrared light curtains and emergency stop buttons, ensuring a response time of no more than 0.1 seconds. Shielding safety signals is strictly prohibited.
- Calibrate the temperature sensor and pressure transmitter to ensure accurate parameter display.
Operation Process Norms
- Parameter Settings and Material Processing
- Preset parameters can be accessed through the touch screen. When making adjustments, the administrator password must be entered. Unauthorized modification of core parameters is prohibited.
- Pipes must be cleaned of burrs and oil stains in advance. Cold-drawn steel pipes should undergo phosphating treatment to reduce mold wear.
- When heating, ensure that the coaxiality between the medium-frequency coil and the pipe material is ≤0.2mm to prevent local overheating and material oxidation.
- Dynamic Monitoring and Safety Protection
- Operators must wear heat-resistant gloves, goggles, earplugs, and other protective equipment. Loose clothing and jewelry are prohibited.
- Monitor the hydraulic oil temperature (35–55℃) and motor current (≤110% of the rated value) in real time. If any abnormality is detected, stop the machine immediately for inspection.
- During the tapering process, it is strictly forbidden to touch the mold or the cutting area. When the equipment is in operation, personnel must maintain a safety distance of at least 1.5 meters.
- Multi-Batch Processing Control
- After every 50 pipes are processed, randomly inspect the taper diameter (tolerance ±0.5mm) and hole spacing (±0.1mm) using a micrometer. Recalibrate if deviations exceed the standard.
- When switching molds, strictly follow the 3-minute rapid mold change procedure. After replacement, conduct three no-load test runs to confirm accuracy.
Long-Term Shutdown and Restart
- Shutdown Protection Measures
- For short-term shutdowns (≤1 week), power on and run for 30 minutes every two days for dehumidification. For long-term shutdowns (more than one month), drain the cooling water tank, apply anti-rust oil to the equipment and exposed metal parts, and cover them with dust-proof cloth.
- Before turning off the main power supply, return the device to its initial position and lock the mold to prevent accidental movement.
- Restart Verification Process
- Before restarting, check the grounding resistance (≤4Ω) and insulation resistance (≥5MΩ), and replace expired desiccant.
- Conduct five no-load trial runs to test feeding accuracy (±0.05mm) and cutting verticality (≤0.5°). Production may only begin once the standards are met.
Personnel Qualifications and Compliance Requirements
- Operation and Maintenance Qualifications
- Operators must be trained by the manufacturer and obtain an "Equipment Operation Qualification Certificate." Maintenance personnel must hold special operation certificates for electricians or hydraulic workers.
- Conduct safety operation refresher training once a year, with emphasis on emergency shutdown and fault prediction capabilities.
- Compliance Management
- Strictly abide by the "Regulations on Safety Supervision of Special Equipment," regularly undergo inspections by local quality inspection departments, and ensure the validity of CE certification and ISO9001 compliance.
- Hazardous wastes such as waste oil and used batteries must be handed over to qualified environmental protection companies for disposal. Arbitrary disposal is strictly prohibited.
How To Cooperate With Us
FAQ
Q: What specifications of pipes can this equipment process? What engineering scenarios is it applicable to?
A: Our equipment is mainly suitable for carbon steel and stainless steel pipes with diameters ranging from 32 to 50mm. For special requirements, it can be customized for diameters up to 108mm, making it perfectly suited for processing small conduits in scenarios such as advanced tunnel support and subway construction. The processed pipes fully comply with national technical standards.
Q: How much can efficiency be improved compared with manual processing? How many people are needed to operate it?
A: The equipment adopts a fully automated design, with a daily production capacity of 3,000 to 5,000 pieces—5 to 8 times higher than manual processing! Traditional manual labor can process up to 20 pieces per hour, while our equipment can process 6 pieces per minute. The entire process only requires one person to monitor and operate, directly replacing 5 to 8 workers and significantly reducing labor costs.
Q: How about processing accuracy? Can it meet the strict requirements of grouting holes?
A: Absolutely! Hole spacing and taper angles can both be precisely controlled. The double-gun plasma cutting system supports both equal and unequal distance punching. After forming, the pipe surface is smooth and free of scratches, fully meeting the sealing and load-bearing requirements of tunnel grouting holes, while avoiding the dimensional inconsistencies often caused by manual processing.
Q: Are the costs of consumables and energy consumption high? How much can be saved compared to traditional methods?
A: This is one of the key advantages of our equipment! By replacing traditional oxygen and acetylene with plasma cutting, gas consumable costs are reduced by 70%. Medium-frequency induction heating technology lowers energy consumption by more than 30% compared with flame heating. Based on processing 4,000 pieces per day, electricity usage is only about 5.5 kWh per day. The material cost savings compared with manual processing are equivalent to half a month of equipment depreciation.
Q: Can ordinary workers quickly learn to operate it? Is mold changing troublesome?
A: Very easy! The equipment is equipped with a PLC touch screen and preset with 100 sets of processing parameters. Workers can operate independently after just one hour of training. The mold replacement system is designed for quick changes—it takes only 3 minutes to switch from round tubes to square tubes without professional tools. Even non-technical personnel can easily complete the task.
Q: Can the equipment work stably in damp and dusty tunnel environments?
A: Yes! The equipment has passed ISO three-system certification. Its body is welded with 25mm thickened steel plates, and the protection level is suitable for harsh environments with temperatures ranging from -20℃ to 40℃ and humidity ≤85%. The fully enclosed shell is dust- and moisture-proof. The cooling system and electrical cabinet have special protection, ensuring long-term stable operation even in damp and dusty tunnel conditions.
Q: Is daily maintenance complicated? Is it convenient to replace vulnerable parts?
A: Daily maintenance is very simple! Just clean mold debris and check grease levels daily, and calibrate the cutting gun head once a week. Key vulnerable parts such as plasma electrodes and molds are standardized in design, with service lives of 80 hours and 100,000 uses respectively. Replacement does not require disassembling the machine. A sufficient inventory of spare parts is always available, and they are delivered to construction sites on time after orders are placed.
Q: Is there any guarantee for after-sales service?
A: We offer a one-year warranty for the entire machine and provide lifetime remote guidance services, ensuring peace of mind.
Xuhui (Shandong) Intelligent Equipment Co., Ltd. is one of the most professional steel pipe cutting and shrinking machine manufacturers and suppliers in China. Please feel free to wholesale high quality machines made in China here and get quotation from our factory. Contact us for customized service.
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