一(yi)、基本情況
江蘇天淮(huai)鋼(gang)管(guan)有(you)(you)限公司(si)(si)φ508mm（20in）PQF連軋(ya)管(guan)機組，是目前全球最大口徑的三輥式連軋(ya)管(guan)機組，2012年5月28日熱負荷(he)試(shi)車成功。該機組由中(zhong)冶京誠工程技術有(you)(you)限公司(si)(si)做工廠設(she)計(ji)，主軋(ya)線設(she)備(bei)由德國梅爾公司(si)(si)、意大利因西設(she)計(ji)制造，設(she)計(ji)能(neng)力為年產(chan)無(wu)縫鋼(gang)管(guan)50萬噸。自投產(chan)半年時間里(li)，生產(chan)Φ377～508mm 規(gui)格鋼(gang)管(guan)共(gong)3.8萬噸，產(chan)品質量(liang)優良。
二、產品規格(ge)和主要品種
1. 產(chan)品規格
外徑：φ245～508mm；
壁厚：6.1～60mm；
長度(du)：6～15m。
2. 主要品種
管線(xian)管、鍋爐用管、氣瓶管、機(ji)械管、液壓支柱管，流體輸(shu)送管、結構管等。
3. 工藝流程
φ508mm PQF連軋管(guan)機組(zu)的工藝布置如圖6-16所示。
工藝流程為：合格管坯→鋸切→冷(leng)定(ding)心(xin)→環形爐(lu)加熱(re)→高壓水(shui)除(chu)磷→穿(chuan)孔(kong)→吹硼砂(sha)→穿(chuan)芯棒→高壓水(shui)除(chu)鱗→F連(lian)軋→脫管→高壓水(shui)除(chu)鱗→定(ding)徑→冷(leng)卻→定(ding)尺鋸切→矯直→吹吸灰→探傷→人工內外表面檢查→噴(pen)標→收集入庫。
三個(ge)變形主機(ji)(ji)(ji)由(you)(you)(you)帶管坯(pi)預旋轉的(de)錐(zhui)形輥(gun)導板式(shi)穿孔機(ji)(ji)(ji)、5機(ji)(ji)(ji)架PQF限動芯棒連軋管機(ji)(ji)(ji)、12架單獨傳動的(de)定(ding)徑機(ji)(ji)(ji)組成，三大主機(ji)(ji)(ji)本體(ti)設(she)備(bei)都由(you)(you)(you)德國MEER公(gong)司設(she)計制(zhi)造(zao)，主機(ji)(ji)(ji)設(she)備(bei)前后臺連線設(she)備(bei)由(you)(you)(you)中冶京誠工(gong)程技術(shu)有(you)限公(gong)司設(she)計，天津賽瑞機(ji)(ji)(ji)器(qi)制(zhi)造(zao)有(you)限公(gong)司制(zhi)造(zao)。φ508PQF機(ji)(ji)(ji)組采用更為完善的(de)先進工(gong)藝(yi)(yi)控制(zhi)系統-CARTA系統、嚴(yan)格的(de)質量(liang)控制(zhi)系統-QAS系統、物料跟蹤系統（MTS）以及在線檢測系統等工(gong)藝(yi)(yi)控制(zhi)技術(shu)，從而確保(bao)了(le)熱(re)軋大口徑無縫鋼管生(sheng)產的(de)工(gong)藝(yi)(yi)先進性及穩(wen)定(ding)性。
四(si)、主(zhu)要工藝設備及性(xing)能特(te)點
1. 環形加(jia)熱爐(lu)
環形爐(lu)由LOI天津公司設計及(ji)制(zhi)(zhi)作，為降低(di)成本，采用高(gao)爐(lu)煤氣(qi)(qi)和(he)(he)天然氣(qi)(qi)混合氣(qi)(qi)作為燃(ran)料。從(cong)裝料到出(chu)料共分7個加熱(re)(re)(re)控制(zhi)(zhi)段(duan)(duan)(duan)，其(qi)中第1～2段(duan)(duan)(duan)為預(yu)熱(re)(re)(re)段(duan)(duan)(duan)，第3～5段(duan)(duan)(duan)為加熱(re)(re)(re)段(duan)(duan)(duan)，第6～7段(duan)(duan)(duan)為均熱(re)(re)(re)段(duan)(duan)(duan)；其(qi)中預(yu)熱(re)(re)(re)2段(duan)(duan)(duan)和(he)(he)加熱(re)(re)(re)段(duan)(duan)(duan)采用高(gao)爐(lu)煤氣(qi)(qi)蓄熱(re)(re)(re)燒(shao)嘴，均熱(re)(re)(re)段(duan)(duan)(duan)用頂置的天然氣(qi)(qi)平焰(yan)燒(shao)嘴均熱(re)(re)(re)，環形爐(lu)采用全自動、先進、可靠的熱(re)(re)(re)工(gong)控制(zhi)(zhi)系統測量和(he)(he)控制(zhi)(zhi)爐(lu)子的熱(re)(re)(re)工(gong)過程，可根據不同(tong)工(gong)況準確匹配爐(lu)子供熱(re)(re)(re)量，保證管(guan)坯按最佳的工(gong)藝曲線加熱(re)(re)(re)和(he)(he)保溫。
環形加熱爐主(zhu)要參數(shu)包括：
中(zhong)徑(jing)：51m；
爐底寬度：5.4m；
最大(da)加熱(re)長(chang)度(du)：5.0m；
最(zui)大坯(pi)重(zhong)：7620kg；
最(zui)大加(jia)熱能力：260t／h；
最(zui)大裝出料節奏：90p/h。
2. 錐形輥穿孔機
該機組采用導板式錐形輥立式穿孔機，在18in PQF機組基礎上，穿孔輥直徑從1500mm增大到1700mm，電機功率從6500kW2臺增加到8200kW×2臺，提高穿孔機的變形能力，減少連軋機的變形負荷；采用導板式主要目的是穿孔機孔型封閉性好、毛管壁厚精度高，減少了導盤傳動系統，減小了牌坊的尺寸，降低了設備投資。
由于本機(ji)(ji)組采用(yong)的(de)管(guan)(guan)坯(pi)直(zhi)徑（Φ310mm、ф380mm、Φ450mm、φ500mm）比18in機(ji)(ji)組管(guan)(guan)坯(pi)直(zhi)徑大(da)(da)，管(guan)(guan)坯(pi)重量(liang)也大(da)(da)，為方(fang)便管(guan)(guan)坯(pi)咬入，防止前(qian)卡事故，在(zai)(zai)前(qian)臺設置(zhi)了管(guan)(guan)坯(pi)預(yu)旋(xuan)轉裝置(zhi)，見圖6-17，大(da)(da)管(guan)(guan)坯(pi)在(zai)(zai)推鋼機(ji)(ji)推入軋輥(gun)前(qian)在(zai)(zai)預(yu)旋(xuan)轉的(de)驅動下旋(xuan)轉起(qi)來，這樣很大(da)(da)程(cheng)度改善了咬入條件，減少了事故，提高了軋輥(gun)壽命。
該(gai)穿孔機(ji)后(hou)臺(tai)一段(duan)有6組(zu)三輥(gun)定(ding)心裝置(zhi)，后(hou)臺(tai)二(er)段(duan)的(de)(de)頂(ding)(ding)(ding)桿(gan)采用在(zai)線小車上下(xia)料、頂(ding)(ding)(ding)頭采用內部(bu)循環水冷(leng)(leng)(leng)加外部(bu)氣(qi)(qi)霧冷(leng)(leng)(leng)卻(que)方(fang)式(shi)，當頂(ding)(ding)(ding)頭穿廢(fei)時隨頂(ding)(ding)(ding)桿(gan)一起(qi)更換，見圖6-18所示。頂(ding)(ding)(ding)桿(gan)上料后(hou)冷(leng)(leng)(leng)卻(que)水可直接循環到(dao)頂(ding)(ding)(ding)頭工作段(duan)的(de)(de)內腔，在(zai)軋(ya)制(zhi)及間(jian)歇(xie)不管頂(ding)(ding)(ding)桿(gan)在(zai)什么位(wei)置(zhi)，都能通(tong)過內部(bu)循環水對(dui)頂(ding)(ding)(ding)頭快速(su)冷(leng)(leng)(leng)卻(que)；在(zai)軋(ya)制(zhi)間(jian)歇(xie)時頂(ding)(ding)(ding)桿(gan)回(hui)退到(dao)基位(wei)后(hou)，進(jin)入有外部(bu)氣(qi)(qi)霧冷(leng)(leng)(leng)卻(que)箱(xiang)對(dui)頂(ding)(ding)(ding)頭進(jin)行外部(bu)冷(leng)(leng)(leng)卻(que)，氣(qi)(qi)霧冷(leng)(leng)(leng)卻(que)箱(xiang)中的(de)(de)15道水環分4組(zu)控(kong)制(zhi)，從圓周方(fang)向分別對(dui)頂(ding)(ding)(ding)頭不同部(bu)位(wei)分別控(kong)制(zhi)時間(jian)控(kong)制(zhi)水量(liang)來冷(leng)(leng)(leng)卻(que)，從而保證了頂(ding)(ding)(ding)頭工作段(duan)良(liang)好的(de)(de)冷(leng)(leng)(leng)卻(que)效果。
在以(yi)前18英寸(cun)PQF機(ji)組基礎上頂(ding)頭(tou)冷卻(que)形式做了很大改進(jin)，見圖(tu)6-19（其(qi)中，圖(tu)6-19為(wei)本機(ji)組頂(ding)頭(tou)結構，圖(tu)6-19（b）為(wei)原18in頂(ding)頭(tou)結構），頂(ding)頭(tou)由(you)原來的(de)實心(xin)體(ti)改為(wei)空腔體(ti)，以(yi)至于內部冷卻(que)水(shui)能(neng)一直貫通(tong)整個(ge)頂(ding)頭(tou)的(de)內腔，使頂(ding)頭(tou)的(de)尖端及(ji)工作段能(neng)得到徹底冷卻(que)，從而(er)延長了頂(ding)頭(tou)壽命。
本機組的(de)毛管橫移(yi)采用可伸縮(suo)的(de)大(da)擺臂移(yi)送到硼砂工位，吹完硼砂后由帶擺動(dong)撥(bo)叉地(di)面小車將毛管移(yi)送到PQF連(lian)軋機前臺(tai)。
穿(chuan)孔機主要參數(shu)包括(kuo)：
最大／最小(xiao)軋輥直徑(jing)：1700mm／1550mm；
最(zui)大出口(kou)速度：0.8m／s；
最(zui)大軋制力矩：3165kN·m；
主(zhu)電(dian)機功率：8200kW×2臺(tai)；
主電機最大轉(zhuan)速(su)：354r／min；
氣(qi)霧(wu)冷卻系統：水壓0.5～0.7MPa；氣(qi)壓0.4～0.5MIPa。
3. PQF連軋管機
本(ben)機(ji)組PQF連(lian)軋(ya)(ya)(ya)(ya)(ya)管機(ji)為(wei)5機(ji)架(jia)的(de)軸(zhou)向換輥(gun)(gun)連(lian)軋(ya)(ya)(ya)(ya)(ya)管機(ji)見(jian)圖6-20，優點是隧(sui)道式筒(tong)形(xing)牌坊剛度及強度好，傳動布置緊湊，軋(ya)(ya)(ya)(ya)(ya)制(zhi)(zhi)穩定性好。每架(jia)軋(ya)(ya)(ya)(ya)(ya)機(ji)的(de)三個互成120°的(de)軋(ya)(ya)(ya)(ya)(ya)輥(gun)(gun)安裝(zhuang)在(zai)(zai)獨(du)立(li)的(de)軋(ya)(ya)(ya)(ya)(ya)制(zhi)(zhi)單(dan)元一軋(ya)(ya)(ya)(ya)(ya)輥(gun)(gun)小機(ji)架(jia)內，安裝(zhuang)在(zai)(zai)隧(sui)道上的(de)伺(si)服(fu)液壓小倉，可以對(dui)軋(ya)(ya)(ya)(ya)(ya)輥(gun)(gun)輥(gun)(gun)縫進(jin)行同(tong)步調整(zheng)也可以單(dan)獨(du)調整(zheng)，即采用了(le)(le)輥(gun)(gun)縫自動控(kong)制(zhi)(zhi)系統(tong)（HCCS），從而(er)保證(zheng)了(le)(le)軋(ya)(ya)(ya)(ya)(ya)制(zhi)(zhi)質(zhi)量，另外，該連(lian)軋(ya)(ya)(ya)(ya)(ya)管機(ji)在(zai)(zai)生產過程中采用了(le)(le)工(gong)藝過程控(kong)制(zhi)(zhi)系統(tong)（PSS），實現了(le)(le)溫(wen)度補償、咬入沖擊(ji)控(kong)制(zhi)(zhi)、錐形(xing)芯棒伺(si)服(fu)和頭尾削尖等功(gong)能。
由(you)于該(gai)機(ji)組軋制節奏(zou)較(jiao)慢（最快40s／支(zhi)），只有在(zai)線(xian)(xian)穿(chuan)芯棒方式(shi)，不設預(yu)穿(chuan)線(xian)(xian)，減(jian)(jian)少了(le)芯棒在(zai)線(xian)(xian)數量，減(jian)(jian)少了(le)芯棒與毛管接觸時間，減(jian)(jian)少了(le)毛管的溫(wen)降，提高了(le)芯棒壽命，節省了(le)設備投資。
連軋機主要參數包括：
荒(huang)管外徑(jing)：ф294mm，φ383mm，φ454mm，φ530mm；
軋輥直徑：φ1060～1130mm；
最大(da)入口速度：1.5m／s；
最大出(chu)口速度：4.0m／s；
最大軋制力：620kN；
最大軋(ya)制(zhi)力(li)矩：250kN·m；
電(dian)機(ji)功率：1～4號機(ji)架(jia)(jia)各3×1000kW，5機(ji)架(jia)(jia)為3×500kW；
限動力(li)：2900kN；
限動電(dian)機功率：500kW×6臺；
限動最大前進(jin)速度：2.5m／s；
限動最大返回速度：4.5m／s；
軋(ya)制中限動速度：1.5m／s。
4. 定徑機(ji)
采(cai)用(yong)12架(jia)三輥式定(ding)徑機(ji)，見圖6-21，每架(jia)都有一臺電機(ji)驅動(dong)(dong)，機(ji)架(jia)采(cai)用(yong)傘齒(chi)輪內傳動(dong)(dong)結構，在機(ji)架(jia)外有一根傳動(dong)(dong)軸通過聯(lian)軸器(qi)與12架(jia)組合式的(de)減(jian)速器(qi)相連接(jie)，奇偶架(jia)的(de)電機(ji)前后排上(shang)下兩層排列，整個(ge)定(ding)徑機(ji)布置(zhi)緊(jin)湊(cou)。該機(ji)組在定(ding)徑機(ji)前設置(zhi)了高(gao)壓水除(chu)鱗裝置(zhi)，提高(gao)鋼管的(de)外表面(mian)質量，延(yan)長軋輥壽命。
定徑機(ji)主(zhu)要參(can)數包(bao)括：
軋輥名義直徑：φ1000mm；
機架間距：880mm；
入口(kou)鋼管速度：0.8～1.5m／s；
出口鋼(gang)管速度：0.85～2.0m／s；
電(dian)機(ji)功率：350kW×12臺(tai)；
電機轉(zhuan)速：200～600／1200r／min。
五、機組工(gong)藝(yi)控(kong)制系(xi)統(tong)和質量保證系(xi)統(tong)
PQF三(san)輥連軋(ya)(ya)(ya)管(guan)機(ji)(ji)組數量(liang)(liang)(liang)的(de)不(bu)斷(duan)增多，使(shi)得PQF連軋(ya)(ya)(ya)管(guan)機(ji)(ji)的(de)工(gong)(gong)藝控制系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)和質(zhi)量(liang)(liang)(liang)保(bao)(bao)證系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)不(bu)斷(duan)提高完善，從(cong)而保(bao)(bao)證了(le)更好的(de)產(chan)品(pin)質(zhi)量(liang)(liang)(liang)，更高的(de)成材率(lv)和設(she)(she)備利(li)用率(lv)以(yi)及較低的(de)工(gong)(gong)具消耗。整個(ge)機(ji)(ji)組的(de)過程(cheng)管(guan)理系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)包(bao)括通常(chang)所說的(de)MTS系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)、HCCS系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)、PSS系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)等在內的(de)CARTA系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)以(yi)及QAS系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)兩大部(bu)分組成。整個(ge)熱軋(ya)(ya)(ya)線的(de)CARTA系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)是(shi)(shi)(shi)用來生(sheng)產(chan)計劃及生(sheng)產(chan)管(guan)理的(de)工(gong)(gong)藝控制系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)，由穿孔機(ji)(ji)CARTA系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)、PQF軋(ya)(ya)(ya)管(guan)機(ji)(ji)CARTA系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)及定徑機(ji)(ji)CARTA系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)三(san)部(bu)分組成，其中PQF軋(ya)(ya)(ya)管(guan)CARTA是(shi)(shi)(shi)核心部(bu)分，穿孔機(ji)(ji)CARTA系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)主要是(shi)(shi)(shi)工(gong)(gong)藝參數設(she)(she)定、頂頭導(dao)板軋(ya)(ya)(ya)輥等軋(ya)(ya)(ya)制工(gong)(gong)具設(she)(she)計等內容；張減機(ji)(ji)CARTA系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)主要是(shi)(shi)(shi)孔型設(she)(she)計、工(gong)(gong)藝參數設(she)(she)定等內容。QAS系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)是(shi)(shi)(shi)用于熱軋(ya)(ya)(ya)線質(zhi)量(liang)(liang)(liang)控制的(de)檢測系(xi)(xi)(xi)(xi)統(tong)(tong)(tong)(tong)(tong)(tong)(tong)(tong)。
六、在線檢(jian)測質量保證系統(tong)QAS
QAS是一個在(zai)線(xian)獨立工(gong)作站，通過對(dui)物(wu)料(liao)(liao)(liao)的跟(gen)蹤檢(jian)測，對(dui)數據進行收集分(fen)析(xi)(xi)和存(cun)儲，并將分(fen)析(xi)(xi)的結果及(ji)時(shi)反饋給CARTA系統以(yi)(yi)實施對(dui)物(wu)料(liao)(liao)(liao)的控(kong)制(zhi)，保證(zheng)鋼管(guan)(guan)(guan)(guan)質(zhi)(zhi)量。QAS檢(jian)測的具體(ti)內容包括：管(guan)(guan)(guan)(guan)坯(pi)(pi)稱(cheng)重(zhong)以(yi)(yi)控(kong)制(zhi)坯(pi)(pi)料(liao)(liao)(liao)超重(zhong)，實現坯(pi)(pi)料(liao)(liao)(liao)跟(gen)蹤；環形爐出口(kou)測溫(wen)以(yi)(yi)優化管(guan)(guan)(guan)(guan)坯(pi)(pi)加熱，滿(man)足(zu)穿(chuan)孔(kong)及(ji)連(lian)(lian)(lian)軋(ya)(ya)工(gong)藝要求(qiu)，確保鋼管(guan)(guan)(guan)(guan)質(zhi)(zhi)量；穿(chuan)孔(kong)后(hou)測長以(yi)(yi)控(kong)制(zhi)毛(mao)管(guan)(guan)(guan)(guan)幾(ji)何(he)尺寸(cun)，確保連(lian)(lian)(lian)軋(ya)(ya)的咬入(ru)及(ji)軋(ya)(ya)制(zhi)的穩定；芯棒(bang)潤(run)滑(hua)前測溫(wen)以(yi)(yi)滿(man)足(zu)芯棒(bang)噴涂潤(run)滑(hua)劑的工(gong)藝要求(qiu)，確保鋼管(guan)(guan)(guan)(guan)內表面質(zhi)(zhi)量和芯棒(bang)使用(yong)壽命(ming)；連(lian)(lian)(lian)軋(ya)(ya)人口(kou)測溫(wen)以(yi)(yi)控(kong)制(zhi)毛(mao)管(guan)(guan)(guan)(guan)溫(wen)度(du)(du)確保軋(ya)(ya)機正常咬入(ru)及(ji)軋(ya)(ya)制(zhi)的穩定性；連(lian)(lian)(lian)軋(ya)(ya)后(hou)測厚(hou)測長測溫(wen)以(yi)(yi)控(kong)制(zhi)連(lian)(lian)(lian)軋(ya)(ya)出口(kou)荒(huang)管(guan)(guan)(guan)(guan)幾(ji)何(he)尺寸(cun)，確保荒(huang)管(guan)(guan)(guan)(guan)壁厚(hou)精(jing)度(du)(du)；定徑前測溫(wen)以(yi)(yi)控(kong)制(zhi)荒(huang)管(guan)(guan)(guan)(guan)溫(wen)度(du)(du)，確保定徑軋(ya)(ya)制(zhi)穩定性。
七(qi)、機組特(te)點(dian)
1. 增大管坯直(zhi)徑(jing)，降低穿孔的擴(kuo)徑(jing)率，提(ti)高毛管的幾何尺寸精度
與(yu)相近機(ji)組相比(bi)（如表6-11所示），該(gai)機(ji)組增(zeng)大(da)管(guan)(guan)坯(pi)直徑的(de)(de)意義在于：對(dui)于環(huan)形(xing)(xing)爐(lu)(lu)，大(da)口徑厚(hou)壁(bi)管(guan)(guan)生產(chan)時(shi)降低(di)了(le)坯(pi)料(liao)的(de)(de)長(chang)度，設計中減(jian)少了(le)環(huan)形(xing)(xing)爐(lu)(lu)的(de)(de)中徑，在環(huan)形(xing)(xing)爐(lu)(lu)建設中減(jian)少了(le)近5％投資；對(dui)于穿(chuan)(chuan)孔(kong)機(ji)而言，管(guan)(guan)坯(pi)外徑增(zeng)大(da)了(le)，但毛管(guan)(guan)的(de)(de)幾何(he)尺(chi)寸(cun)和同類機(ji)組一樣，這樣毛管(guan)(guan)的(de)(de)擴徑率降低(di)了(le)近10％，在穿(chuan)(chuan)孔(kong)斜(xie)軋(ya)過程中，大(da)大(da)降低(di)了(le)軋(ya)件的(de)(de)橫(heng)向變(bian)形(xing)(xing)，能很(hen)好抑制穿(chuan)(chuan)孔(kong)的(de)(de)附加(jia)變(bian)形(xing)(xing)程度，提高毛管(guan)(guan)的(de)(de)幾何(he)尺(chi)寸(cun)精度。
2. 穿孔(kong)機采用(yong)新型的(de)頂(ding)桿頂(ding)頭連接形(xing)式(shi)(shi)和更(geng)換(huan)方式(shi)(shi)
與φ460機(ji)(ji)組(zu)(zu)相比，天淮508機(ji)(ji)組(zu)(zu)穿(chuan)(chuan)孔(kong)后(hou)臺二段(duan)形式徹底改進(jin)，針(zhen)對大(da)機(ji)(ji)組(zu)(zu)節奏較(jiao)慢（最(zui)快40s以(yi)上）的(de)(de)特點，為提高設備(bei)的(de)(de)運行(xing)穩(wen)定(ding)性(xing)，增(zeng)加頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)上下料小車，實(shi)現頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)的(de)(de)在線循環(huan)，改變了(le)同類(lei)錐形穿(chuan)(chuan)孔(kong)機(ji)(ji)組(zu)(zu)單頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)在線自動快換(huan)(huan)頂(ding)(ding)(ding)(ding)頭模式（設備(bei)精(jing)度要求較(jiao)高），采用(yong)頂(ding)(ding)(ding)(ding)頭和(he)頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)通過過盈錐面配合外加定(ding)位(wei)銷(xiao)連(lian)接(jie)，見圖6-19，并線外裝配作業，這樣減少了(le)換(huan)(huan)規格過程(cheng)的(de)(de)設備(bei)調整時(shi)(shi)間，改進(jin)后(hou)還避免生產過程(cheng)中在線頂(ding)(ding)(ding)(ding)頭安裝不(bu)上出現無頂(ding)(ding)(ding)(ding)頭軋制工藝(yi)事(shi)故，節省(sheng)了(le)頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)消耗和(he)工藝(yi)事(shi)故擴(kuo)大(da)化造成的(de)(de)機(ji)(ji)械(xie)故障(zhang)，節省(sheng)工具費用(yong)同時(shi)(shi)提高了(le)作業率。另外，采用(yong)頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)更換(huan)(huan)小車形式，換(huan)(huan)孔(kong)型(xing)時(shi)(shi)提前準備(bei)好新孔(kong)型(xing)的(de)(de)頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)，10min 內完(wan)成穿(chuan)(chuan)孔(kong)機(ji)(ji)組(zu)(zu)的(de)(de)頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)更換(huan)(huan)，較(jiao)同類(lei)型(xing)機(ji)(ji)組(zu)(zu)穿(chuan)(chuan)孔(kong)孔(kong)型(xing)更換(huan)(huan)時(shi)(shi)換(huan)(huan)頂(ding)(ding)(ding)(ding)桿(gan)(gan)(gan)節省(sheng)近90％的(de)(de)時(shi)(shi)間。
3. 改(gai)進了穿孔(kong)機組頂(ding)頭的冷卻方式(shi)
天淮φ508機(ji)組(zu)(zu)穿孔頂(ding)頭(tou)(tou)的(de)(de)(de)冷(leng)(leng)(leng)(leng)卻(que)方式增(zeng)加了頂(ding)頭(tou)(tou)的(de)(de)(de)內(nei)水(shui)(shui)(shui)冷(leng)(leng)(leng)(leng)并改進了外(wai)水(shui)(shui)(shui)冷(leng)(leng)(leng)(leng)方式，該(gai)機(ji)組(zu)(zu)冷(leng)(leng)(leng)(leng)卻(que)水(shui)(shui)(shui)能直接到達(da)頂(ding)頭(tou)(tou)的(de)(de)(de)腔體內(nei)（見圖(tu)6-19），設(she)計(ji)(ji)時增(zeng)加了內(nei)水(shui)(shui)(shui)冷(leng)(leng)(leng)(leng)的(de)(de)(de)水(shui)(shui)(shui)壓(ya)，由同(tong)(tong)類機(ji)組(zu)(zu)的(de)(de)(de)8bar增(zeng)加到12bar，提高了冷(leng)(leng)(leng)(leng)卻(que)速率(lv)。改進了外(wai)水(shui)(shui)(shui)冷(leng)(leng)(leng)(leng)的(de)(de)(de)形式，在同(tong)(tong)類穿孔機(ji)組(zu)(zu)頂(ding)頭(tou)(tou)更換裝(zhuang)置的(de)(de)(de)位置，設(she)計(ji)(ji)了頂(ding)頭(tou)(tou)外(wai)冷(leng)(leng)(leng)(leng)的(de)(de)(de)專(zhuan)用(yong)裝(zhuang)置，該(gai)裝(zhuang)置采用(yong)氣霧冷(leng)(leng)(leng)(leng)卻(que)方式，見圖(tu)6-18，并配套(tao)電氣控(kong)制系統(tong)，根據頂(ding)頭(tou)(tou)規格和(he)溫度調整噴吹(chui)壓(ya)力和(he)時間(jian)，保證頂(ding)頭(tou)(tou)冷(leng)(leng)(leng)(leng)卻(que)均(jun)勻(yun)，避免了軋制后的(de)(de)(de)高溫頂(ding)頭(tou)(tou)由冷(leng)(leng)(leng)(leng)卻(que)不(bu)均(jun)造成頂(ding)頭(tou)(tou)開裂報廢。該(gai)機(ji)組(zu)(zu)頂(ding)頭(tou)(tou)內(nei)外(wai)水(shui)(shui)(shui)冷(leng)(leng)(leng)(leng)的(de)(de)(de)方式，從近半年(nian)生(sheng)產統(tong)計(ji)(ji)鍛造頂(ding)頭(tou)(tou)的(de)(de)(de)平(ping)均(jun)壽(shou)(shou)命(ming)達(da)到450支（個(ge)別達(da)到900支）以上，頂(ding)頭(tou)(tou)平(ping)均(jun)壽(shou)(shou)命(ming)是其他同(tong)(tong)類機(ji)組(zu)(zu)的(de)(de)(de)1.5倍以上。
4. 連軋短管(guan)模式
為(wei)保(bao)證大(da)口徑厚(hou)壁管的(de)生(sheng)(sheng)產(chan)，連(lian)軋(ya)機(ji)(ji)組增加(jia)短管模(mo)式(shi)，設(she)計(ji)中連(lian)軋(ya)機(ji)(ji)與脫(tuo)(tuo)管機(ji)(ji)間距為(wei)11.5m，在(zai)生(sheng)(sheng)產(chan)短于11.5m大(da)口徑超厚(hou)壁管時(shi)，開發連(lian)軋(ya)的(de)短管模(mo)式(shi)，在(zai)設(she)計(ji)過程中考慮實現最短8m管生(sheng)(sheng)產(chan)，脫(tuo)(tuo)管電機(ji)(ji)選型(xing)時(shi)保(bao)證低(di)速性能穩(wen)定，依靠限動齒條將連(lian)軋(ya)后(hou)(hou)管送進脫(tuo)(tuo)管機(ji)(ji)，這時(shi)脫(tuo)(tuo)管機(ji)(ji)的(de)線速度和限動速度一致，咬入后(hou)(hou)脫(tuo)(tuo)管機(ji)(ji)升(sheng)速實現荒(huang)管和芯棒脫(tuo)(tuo)開。
5. 為保證大(da)口徑薄壁管表面(mian)質(zhi)量(liang)，移送設備創新結(jie)構，做到輕(qing)拿(na)輕(qing)放
為(wei)保(bao)(bao)(bao)證(zheng)大口(kou)徑(jing)薄壁管(guan)(guan)(guan)(guan)表(biao)面質量，防(fang)(fang)(fang)止鋼管(guan)(guan)(guan)(guan)在(zai)(zai)(zai)(zai)移(yi)送(song)過(guo)程(cheng)(cheng)出(chu)現(xian)嗑(ke)(ke)傷(shang)及(ji)劃痕(hen)(hen)(hen)現(xian)象，本機(ji)(ji)組(zu)(zu)(zu)的(de)(de)(de)毛(mao)(mao)管(guan)(guan)(guan)(guan)橫(heng)移(yi)機(ji)(ji)構(gou)及(ji)脫(tuo)管(guan)(guan)(guan)(guan)后(hou)(hou)(hou)(hou)橫(heng)移(yi)鏈(lian)撥(bo)(bo)料(liao)(liao)機(ji)(ji)構(gou)都進(jin)(jin)行改(gai)進(jin)(jin)創新。在(zai)(zai)(zai)(zai)ф460mm機(ji)(ji)組(zu)(zu)(zu)中，毛(mao)(mao)管(guan)(guan)(guan)(guan)從(cong)三(san)輥定心(xin)由(you)(you)一個撥(bo)(bo)料(liao)(liao)鉤撥(bo)(bo)出(chu)由(you)(you)另一個撥(bo)(bo)料(liao)(liao)鉤接料(liao)(liao)放(fang)(fang)到(dao)旋轉托輥上(shang)(shang)吹硼砂，見(jian)圖(tu)6-22（a），吹完硼砂后(hou)(hou)(hou)(hou)由(you)(you)高架小(xiao)車移(yi)送(song)到(dao)帶(dai)高度調整的(de)(de)(de)受料(liao)(liao)鞍(an)座上(shang)(shang)，毛(mao)(mao)管(guan)(guan)(guan)(guan)滾(gun)落到(dao)鞍(an)座輥道上(shang)(shang)進(jin)(jin)而由(you)(you)連軋(ya)前(qian)臺(tai)的(de)(de)(de)回(hui)轉臂(bei)(bei)(bei)(bei)取(qu)(qu)走；防(fang)(fang)(fang)止大口(kou)徑(jing)薄壁管(guan)(guan)(guan)(guan)（特別是徑(jing)壁大于48）在(zai)(zai)(zai)(zai)撥(bo)(bo)料(liao)(liao)滾(gun)動中出(chu)現(xian)的(de)(de)(de)嗑(ke)(ke)傷(shang)和(he)劃痕(hen)(hen)(hen)，天淮ф508mm機(ji)(ji)組(zu)(zu)(zu)在(zai)(zai)(zai)(zai)此進(jin)(jin)行了(le)(le)改(gai)進(jin)(jin)創新，見(jian)圖(tu)6-22（b），三(san)輥定心(xin)出(chu)來的(de)(de)(de)毛(mao)(mao)管(guan)(guan)(guan)(guan)由(you)(you)可伸縮的(de)(de)(de)大擺(bai)臂(bei)(bei)(bei)(bei)移(yi)送(song)到(dao)硼砂工位，吹完硼砂后(hou)(hou)(hou)(hou)由(you)(you)地面小(xiao)車的(de)(de)(de)撥(bo)(bo)叉(cha)將毛(mao)(mao)管(guan)(guan)(guan)(guan)取(qu)(qu)走，小(xiao)車到(dao)行程(cheng)(cheng)后(hou)(hou)(hou)(hou)，小(xiao)車上(shang)(shang)的(de)(de)(de)撥(bo)(bo)叉(cha)將毛(mao)(mao)管(guan)(guan)(guan)(guan)移(yi)到(dao)垂(chui)直升降的(de)(de)(de)放(fang)(fang)料(liao)(liao)叉(cha)，小(xiao)車回(hui)退，然后(hou)(hou)(hou)(hou)由(you)(you)連軋(ya)前(qian)臺(tai)的(de)(de)(de)回(hui)轉臂(bei)(bei)(bei)(bei)取(qu)(qu)走毛(mao)(mao)管(guan)(guan)(guan)(guan)，在(zai)(zai)(zai)(zai)毛(mao)(mao)管(guan)(guan)(guan)(guan)的(de)(de)(de)三(san)次(ci)接力傳遞中都避免(mian)了(le)(le)在(zai)(zai)(zai)(zai)撥(bo)(bo)叉(cha)及(ji)鞍(an)座臺(tai)架上(shang)(shang)的(de)(de)(de)滾(gun)動沖(chong)擊，都是輕拿(na)輕放(fang)(fang)，避免(mian)了(le)(le)嗑(ke)(ke)傷(shang)和(he)劃痕(hen)(hen)(hen)，提高了(le)(le)表(biao)面質量。另外，本機(ji)(ji)組(zu)(zu)(zu)在(zai)(zai)(zai)(zai)脫(tuo)管(guan)(guan)(guan)(guan)機(ji)(ji)后(hou)(hou)(hou)(hou)橫(heng)移(yi)鏈(lian)冷(leng)(leng)床(chuang)入口(kou)撥(bo)(bo)料(liao)(liao)采用了(le)(le)撥(bo)(bo)料(liao)(liao)防(fang)(fang)(fang)護機(ji)(ji)構(gou)，見(jian)圖(tu)6-23，當(dang)鏈(lian)床(chuang)的(de)(de)(de)撥(bo)(bo)料(liao)(liao)臂(bei)(bei)(bei)(bei)抬起過(guo)程(cheng)(cheng)中附帶(dai)在(zai)(zai)(zai)(zai)撥(bo)(bo)料(liao)(liao)臂(bei)(bei)(bei)(bei)上(shang)(shang)的(de)(de)(de)防(fang)(fang)(fang)護板(ban)也(ye)隨之升起以(yi)保(bao)(bao)(bao)護鋼管(guan)(guan)(guan)(guan)防(fang)(fang)(fang)止在(zai)(zai)(zai)(zai)撥(bo)(bo)料(liao)(liao)盤(pan)上(shang)(shang)嗑(ke)(ke)傷(shang)，當(dang)撥(bo)(bo)料(liao)(liao)臂(bei)(bei)(bei)(bei)落下(xia)時反向連桿(gan)機(ji)(ji)構(gou)使(shi)防(fang)(fang)(fang)護板(ban)也(ye)落下(xia)，將鋼管(guan)(guan)(guan)(guan)慢慢放(fang)(fang)下(xia)，從(cong)而避免(mian)了(le)(le)在(zai)(zai)(zai)(zai)以(yi)前(qian)18in機(ji)(ji)組(zu)(zu)(zu)上(shang)(shang)薄臂(bei)(bei)(bei)(bei)管(guan)(guan)(guan)(guan)總(zong)在(zai)(zai)(zai)(zai)小(xiao)冷(leng)(leng)床(chuang)入口(kou)嗑(ke)(ke)傷(shang)的(de)(de)(de)后(hou)(hou)(hou)(hou)果。在(zai)(zai)(zai)(zai)天淮φ508mm機(ji)(ji)組(zu)(zu)(zu)中，類似以(yi)上(shang)(shang)保(bao)(bao)(bao)護措施及(ji)結構(gou)應用較多(duo)，進(jin)(jin)一步(bu)提高了(le)(le)大口(kou)徑(jing)薄壁管(guan)(guan)(guan)(guan)的(de)(de)(de)表(biao)面質量。
八、結(jie)論
Φ508mmPQF機組是當今世界上最大的(de)熱(re)連軋管生(sheng)產機組，擁(yong)有(you)了世界上最先進(jin)的(de)工(gong)藝設計和過程控(kong)制水(shui)平，同(tong)時設計過程中對同(tong)類機組的(de)不足之處和薄弱(ruo)環節進(jin)行了重大改進(jin)，創新(xin)了5項技術：
1. 在(zai)吸(xi)收(shou)以(yi)往的(de)(de)MPM和(he)PQF機組(zu)經驗的(de)(de)基礎(chu)上，采用8200kW大(da)功(gong)率(lv)穿孔(kong)機加大(da)了(le)(le)穿孔(kong)機的(de)(de)變形(xing)量(liang)，減小(xiao)了(le)(le)后續工序(xu)變形(xing)，穿孔(kong)機的(de)(de)延伸系數最大(da)能(neng)夠達(da)到4.7。并設(she)計減小(xiao)了(le)(le)穿孔(kong)毛管(guan)與連(lian)軋芯棒之間的(de)(de)間隙(xi)，因此更(geng)有(you)利于(yu)生產(chan)薄壁(bi)管(guan)和(he)高(gao)合金管(guan)，已(yi)成功(gong)生產(chan)的(de)(de)φ508mmx9.5mm鋼(gang)管(guan)徑壁(bi)比達(da)到56。同時最大(da)限(xian)度(du)地消(xiao)除了(le)(le)PQF軋機的(de)(de)內(nei)壁(bi)傷(shang)問題，提高(gao)了(le)(le)鋼(gang)管(guan)壁(bi)厚精度(du)和(he)均(jun)勻(yun)度(du)。表(biao)6-12及圖6-24為φ508mm機組(zu)生產(chan)的(de)(de)φ508mmx12.5mm鋼(gang)管(guan)取樣情(qing)況：A～H為沿鋼(gang)管(guan)同一斷面測(ce)得的(de)(de)8個壁(bi)厚數據。由圖表(biao)可知鋼(gang)管(guan)各斷面的(de)(de)壁(bi)厚偏(pian)差率(lv)都在(zai)±8％以(yi)內(nei)。
2. 穿(chuan)孔機組采用(yong)新型的頂(ding)桿和頂(ding)頭連接(jie)和更(geng)換方式，保證(zheng)設備(bei)運(yun)行穩定(ding)，減(jian)少(shao)了(le)事故，提高了(le)作業率，降低了(le)頂(ding)桿費用(yong)。
3. 穿孔機(ji)組頂頭(tou)增加了(le)內水(shui)冷并設計外水(shui)冷裝置(zhi)，保證頂頭(tou)冷卻均(jun)勻，提(ti)高了(le)頂頭(tou)冷卻效果，頂頭(tou)壽命(ming)提(ti)高近(jin)50％，為同類(lei)機(ji)組提(ti)供(gong)了(le)改進技術。
4. 連軋機組開發了短管模式，實現8m以上的大口徑厚壁(bi)管的生產，擴大了該機組生產的產品大綱。
5. 設計開發了輕拿輕放的鋼管移送機構，避免了大(da)口徑薄(bo)壁(bi)管移送過程出現磕碰和劃傷，提高了薄壁管產品的一次合格率。
