composite pipe production line-Anhui Dongchai Machinery|high-speed automated production&energy-efficient manufacturing

Introduction

The composite pipe production line represents a cutting-edge solution for manufacturing high-performance polyethylene composite pipes reinforced with a steel wire mesh skeleton. This advanced production system integrates multiple components, including a high-speed extruder, precision die, vacuum setting table, traction unit, and full-automatic sealing machine, all controlled by a PLC computer. The result is a highly automated, energy-efficient, and stable production process that ensures superior product quality and reduced rejection rates.

Key Highlights of the Production Line

1. Advanced Electrical and Mechanical Components

The main engine of the production line is equipped with international first-line brand electrical appliances, ensuring reliability and precision. The dies and screws are made from 40Cr alloy structural steel, offering exceptional durability. The ceramic heating ring is wrapped with an insulation layer for rapid heating, while the inner and outer walls feature incremental rings to enhance thermal efficiency. The gear box is equipped with a condenser, ensuring stable and fast discharging speeds.

2. Precision Vacuum and Cooling System

The vacuum box is constructed from 304 stainless steel, which is bent and welded as a single unit. All internal parts are laser-cut for accuracy, and the spray port is controlled by an intensive frequency converter. The system maintains constant water temperature for low noise and efficient cooling. The disc-type 304 ball valve allows for electrically adjustable crossbars, ensuring precise control over the production process.

3. Full-Intelligent Automatic Sealing Machine

The full-intelligent automatic sealing machine eliminates the need for on-line guards, enabling automatic tube unloading and achieving a reliable sealing effect. This feature enhances operational safety and reduces labor costs, making the production line more efficient and user-friendly.

Material and Structural Characteristics

The steel wire mesh composite pipe is composed of high-strength steel wire and thermoplastic polyethylene. The steel wire, formed into a mesh through spiral winding, acts as the skeleton reinforcement, significantly improving the pipe's strength. High-performance HDPE modified bonding resin is used to closely connect the steel wire skeleton with the inner and outer HDPE layers, ensuring an excellent composite effect.

Performance Advantages

These pipes overcome the limitations of traditional steel and plastic pipes while retaining their advantages. Key benefits include:

• Corrosion Resistance: The HDPE matrix provides excellent resistance to chemical corrosion.
• Smooth Inner Surface: Reduces friction and ensures efficient fluid or gas flow.
• Thermal Insulation: Maintains stable temperatures, preventing heat loss or gain.
• Wear Resistance: Suitable for high-pressure and abrasive environments.
• Lightweight: Easier to transport and install, reducing construction costs.

Additionally, the strength of the pipe increases with rising temperature, and its degree of reduction is lower compared to pure plastic pipes. The design also prevents rapid cracking, especially in large-diameter pipelines.

Production Technology and Flexibility

The production line utilizes advanced technology to ensure stable and reliable product quality. By adjusting parameters such as steel wire diameter, mesh spacing, plastic layer thickness, and plastic type, the system can tailor the pipe's properties to meet specific requirements for pressure resistance, temperature resistance, and corrosion resistance.

Installation and Maintenance

The steel wire mesh composite pipe is ideal for high-pressure transportation environments, such as conveying liquids and gases. Its lightweight design simplifies installation, reducing construction costs. The electric welding joint connection technology is mature and reliable, minimizing the risk of leaks. The system's durability and low maintenance requirements make it a cost-effective solution for long-term use.

Product Specifications

Model	Pipe Diameter (mm)	Production Speed (m/min)	Power Consumption (kW)	Installed Power (kW)	Dimensions (L x W x H, m)
DCS-160	50-160	2.4	110	385	73 x 4.7 x 3
DCS-315	110-315	2.4	170	545	75 x 5 x 4
DCS-630	315-630	1.2	260	855	76 x 6 x 4
DCS-800	500-800	1.0	360	1150	80 x 6 x 4
DCS-1000	710-1000	0.6	350	1150	86 x 7 x 4
DCS-1200	800-1200	0.6	460	1400	100 x 7 x 4.7

Company Background

Anhui Dongchai Machinery Technology Co., Ltd. (安徽东财机械科技有限公司) is a leading manufacturer specializing in the design and production of advanced machinery for the construction and industrial sectors. With a focus on innovation and quality, the company has established itself as a trusted provider of solutions for polyethylene composite pipe production. Their expertise in integrating cutting-edge technology with practical applications ensures that their products meet the highest industry standards.

Applications and Industry Impact

The composite pipes produced by this line are widely used in various industries, including:

• Drainage and Sewage Systems: Resistant to corrosion and long-lasting, making them ideal for underground applications.
• Industrial Pipelines: Suitable for transporting chemicals, gases, and liquids under high pressure.
• Construction and Infrastructure: Used in water supply, heating, and ventilation systems.
• Oil and Gas: Provides reliable solutions for transporting hydrocarbons in harsh environments.

The versatility of the production line allows it to cater to diverse market needs, from municipal engineering to large-scale industrial projects.

Conclusion

The composite pipe production line is a testament to the advancements in material science and manufacturing technology. Its combination of high-speed production, energy efficiency, and adaptability makes it a competitive choice for industries requiring durable and reliable piping solutions. As the demand for sustainable and high-performance materials grows, this production line is poised to play a pivotal role in shaping the future of pipeline systems.

References

NIST (National Institute of Standards and Technology) has been instrumental in developing standards and guidelines for material testing and measurement, ensuring the reliability of industrial products. For more information, visit https://www.nist.gov/.