Observation:
If you want to purchase a spiral duct machine, you can check the details here.
What is spiral duct machine?
First, let's look at what a spiral duct machine is.
Spiral duct machine is used to manufacture spiral air ducts.
It has applications in various military industries, as well as in the production of ventilation and exhaust pipes for trains and subways in our daily lives.
The main purpose of the machine is to facilitate air circulation between two locations, serving as a means of ventilation.
The Spiral Duct, with its high quality, operates silently, without any significant noise, water leakage or air leakage. Furthermore, it has excellent corrosion resistance.
The spiral duct machine was initially developed and produced in Switzerland. Other nations depended on imports for some time, but with the introduction of advanced technology, many countries, including China, began to develop their own spiral duct machines.
There are many reliable spiral duct machine manufacturers, Artizono is one of them.
The Spiral Duct is currently the most used air duct on the market.
Statistics show that the use of Spiral Ducts in office buildings, shopping malls and subways in the United States is 95.6%, while the use of Spiral Ducts for central air conditioning in residential buildings is 72.5%.
Spiral ducting is typically coated with a layer of zinc on iron ducting to protect it. The innovative spiral pressure rib technology provides the Spiral Duct with excellent strength to withstand pressure.
After adding the spiral rib, the thickness of the locking seam is four times that of the tube, resulting in a highly rigid tube that can withstand maximum pressure without any damage. Furthermore, the material thickness can be reduced by 15%, leading to cost savings.
Spiral ducts were first introduced in the military industries of Western countries, such as in the exhaust (air supply) systems of warships and ships, before being adopted in civilian installations such as trains, subways and mines.
Features of Spiral Duct Machine
Spiral duct machine is high-quality round tube processing equipment.
Compared with other round tube manufacturing equipment, this machine has the qualities of versatility and flexibility and is capable of processing circular tubes with diameters ranging from Φ80mm to 1500mm.
It is simple to adjust and does not require a fixed die. The length of the round tube can be adjusted as desired and the cutting is carried out automatically by a saw.
The spiral duct machine is controlled by a PLC program and operated via a touchscreen interface. The main machine can be frequency modulated and has a stepless speed control feature.
Linear movement is achieved through pneumatic means, and sealing pressure is created through gas-liquid pressurization (pressure force can be adjusted from 6-12MPa). All linear movements feature adjustable speed and pressure regulation.
Now, let's delve into the Spiral Duct features.
Iron sheets are prone to chemical reactions in various environments, causing corrosion and rust. On the other hand, zinc is relatively stable in dry air and forms a dense zinc carbonate film on its surface in humid air.
To protect the iron sheet, the Spiral Duct is mainly coated with a layer of zinc. After undergoing passivation treatment and photoresist coating, the zinc coating significantly improves its protection and appearance.
Compared to the traditional white iron pipe that is beaten by hand, the spiral duct made by a spiral duct machine has the following advantages:
- Good sealing
- A smooth appearance, free of zinc, burrs and a silvery white color
- Easy installation with fewer connection points and low resistance to ventilation and noise
- Good strength and rigidity
- The thickness is controllable and can be selected between 5-107μn
- No hydrogen embrittlement or temperature hazard, ensuring material mechanical properties remain unchanged
- Can replace some hot dip galvanizing techniques
- Good corrosion resistance, with 240-hour neutral salt spray test
- Completed using hot-dip galvanizing method and suitable for various strong corrosive environments such as strong acid and alkaline fog
- Can be designed and customized to meet customer needs
- High quality and beautiful appearance.
Spiral duct machine technical parameters
- Tube diameter: ￠80mm-￠1500mm
- Processing plate thickness: 0.4-1.2mm Note: galvanized (cold rolling, such as DC51D+Z, DX51D+Z, sGCC)
- Processing plate width: 137 mm
- Production speed: 1-36m/min, adjustable
- Power: 5.5 kW
- Cutting power: 4Kw
- Electronic control system: computer PLC control
- Dimensions: 2200*2000*2530mm
Handling, installation and commissioning of spiral duct machine
Instructions for installing a spiral duct machine:
- Remove the mold base during long-distance transportation and install it on the bottom frame.
- Position the rack and rear rack and tighten with bungee screws.
- When lifting the machine, install four ring screws into the screw holes on both ends of the arc guide rail under the discharge rack, and install the mold frame screw holes on the platform.
- Load the mold base from the lower frame to the platform during installation, and place the unloading rack (pipe support) vertically in line with the center rail of the mold base.
- Mount the travel switch to the unload rack.
- Connect the plug and the machine.
- Ensure basic leveling when positioning the spiral duct machine.
- The rack and foundation should not swing, according to the horizontal and vertical of the center rail of the mold base.
- Proper grounding is required.
- Grounding affects the sensitivity of the inverter and the PLC.
- Turn on the power, open the touch screen interface and press the (start cutting) button. Observe the running direction and sawtooth direction during operation.
Spiral Duct Machine Operation
Spiral duct machine control panel
The spiral duct machine has touch screen operation control.
Below is an introduction to the operator interface and touch screen buttons:
Touch screen operation interface diagram
(1) Manual/Automatic:
- Manual: Allows slow, single-stage operation of the spiral duct machine.
- Jog: The motor will reverse and pressing the cutting motor button will initiate a single cycle cutting. When changing pipe specifications, the steel strip must be operated in this mode when restarting.
- Automatic: After the pipe diameter, length dimension and lock are properly adjusted, the spiral duct machine will run continuously in an automatic cycle.
(2) High speed: The machine will run continuously at high speed in manual mode.
(3) Low speed: The machine will run continuously at low speed in manual mode.
(4) Forward/Reverse: In manual mode, the machine generates slow forward and reverse movement in jog mode.
(5) Compression: Controls the compression and release of the upper sewing wheel.
(6) Cut: Press this button to start a single cycle cut.
(7) Time setting: Press the “System Maintenance” button to open a page to set the time interval for the next automatic cycle after the current one ends. The time unit is seconds.
(8) Start: To avoid incorrect operation, press this button twice in the natural state. The spiral duct machine will start in an automatic reciprocating cycle. Press the button again to stop the machine.
(9) Jog: Press and hold this button to run the machine slowly forward and backward.
(10) Emergency stop: Press the emergency stop switch in case of abnormal situation.
(11) Speed regulation: Adjust the inverter frequency for continuous variable speed control.
(12) Pedal: In manual mode, it works in jog mode and can cut off the power and stop the Spiral Duct Machine in automatic working mode.
The operation method of spiral duct machine
(1) Install a 137mm wide steel strip on the cargo rack and adjust the rear rack so that the diameter of the round tube matches. Apply normal engine oil to the oil wheel at the material feed inlet.
(2) Assemble the steel strip mold on the mold base based on the pipe diameter. Check that the lower pivot wheel matches the strip thickness. There are 4 matching sewing wheels available depending on the thickness of the strip.
(3) Insert the strip into the feed port and move it through the four rollers and platen to the upper and lower sewing wheel. During this process, adjust the symmetry of the lock on both sides of the strip and the angle of the joint.
Adjust lock size |
Sewing angle |
(4) At a slow speed, rotate the strip into a spiral tube shape in the mold, press the upper pressure wheel, and insert the wheel port into the female port. Slowly unmold a small section and use the saw to flatten the mouth. Check the pipe diameter and make fine adjustments if necessary.
(5) Transfer the nozzle to the discharge rack at slow or medium speed. Adjust the height of the discharge rack, the axial parallelism of the round tube and the length of the tube and the stroke switch.
(6) Repeat the above adjustment process until a smooth transfer can be obtained after making the first tube. Continued observation and adjustment may be necessary.
Spiral Duct Machine Maintenance
Lubricant:
Mechanical Oil: Use 46# and refill once every 8 hours of operation.
Grease: refill once every 40 hours of operation. The refueling points are all bearings and gears.
Maintenance:
Each time you change the pipe size, you need to remove any debris and iron filings from the corner opening. Be sure to clean the area before starting work and clean it thoroughly. If there is a prolonged period of inactivity, it is recommended to turn off the power, turn off the gas and carry out the necessary lubrication.
Spiral Duct Machine Components
Electrical system
Taiwanese touch screen
Frequency Converter: Common KEMRON
PLC: Japan Omron
The upper and lower rollers of the spiral duct machine are made of Gr15 steel, the quenching hardness reaches HRC58-62 degrees, and the belt mold is made of elastic steel.
Pneumatic system
The air pressure system of the spiral duct machine consists of a compression cylinder, a return cylinder and a lifting cylinder.
The spiral duct machine circuit diagram can be found below.
Fig. Spiral duct machine wiring diagram
You can also download the PDF file here. (in high definition)
Advantages of spiral duct
(1) Installing spiral ducts minimizes leaks at junction points, reducing the number of connections between pipes.
Typically, spiral ducts are 3 to 6 meters long, while rectangular ducts are only 1 to 1.5 meters. Connecting two spiral ducts requires only one gasket, while connecting conventional rectangular ducts often requires a separate double flange system.
(2) Standardized products:
The production of round spiral duct fittings, including tubes and gaskets, is highly automated, systematic and subject to industrial quality control.
(3) Low installation cost:
The installation time for a circular duct system is only one-third of the installation time for a similar rectangular duct.
(4) Minimum installation space required:
A circular tube with a diameter of 200mm can replace a rectangular tube of 250x150mm in the same installation space without increasing pressure. Several parallel circular tubes can replace flat rectangular tubes without requiring additional space.
When taking all these factors into account, circular tubes generally take up less space than rectangular tubes in most cases. For the same pressure characteristics, the installation space of several circular pipes is often equal to or less than that of a rectangular pipe.
Many rectangular piping systems require a 4-bolt system for installation, which adds 40-80mm to the pipe in all directions.
Low pressure :
It is well known that the wind resistance of a circular duct is much lower than that of a rectangular duct.
Precision lock forming process :
The equipment uses molds made from specialized steel. Even after several years of use, the surface of the pressing mold remains unchanged, ensuring that the surface of the galvanized steel sheet is not damaged. This extends the life of the air duct and results in uniform seams, tight locks, strong connections and excellent sealing properties.
Safety seal leak prevention system .
Advanced spiral pressure rib technology increases the strength of the spiral air duct to withstand pressure.
The addition of the spiral rib increases the thickness of the locking seam by four times that of the tube body, resulting in greater rigidity. The duct can withstand maximum pressure loads without deformation and reducing material thickness by 15%, thus reducing costs.
In comparison, when the cross-sectional area is the same, the circumference of a rectangular duct with a 1:3 aspect ratio is 40% larger than that of a spiral duct, making the latter a more efficient choice in terms of material use. . Likewise, the shorter circumference of the spiral duct allows for a corresponding reduction in insulation material.
Spiral duct machine structure
Used material:
The material is commonly used in galvanized iron strip (commonly known as star iron), stainless steel belt and soft aluminum belt.
Material thickness:
0.3 to 1.2mm
Material width:
125mm
Tube diameter:
φ125~φ1500mm (with appropriate diameter and thickness), continuous choose.
Spiral Duct Applications
The spiral duct is a thin-walled metal tube, made up of metal strips. It is circular in shape and does not require welding, resulting in no air or water leaks. It is used for air and bulk material transportation, replacing traditional iron tubes with manual locks. It's a type of air duct.
The main uses of spiral ducts are as follows:
(1) Air supply and ventilation:
This includes fresh air supply and exhaust, with a wide range of applications such as in factory workshops and production sites. The discharge of harmful gases and the influx of outside air into a room require the use of a high-flow, low-pressure air transport tube, making the spiral air tube an ideal solution. Typically, galvanized iron pipes are used, while stainless steel pipes are used in corrosive and highly humid environments.
(2) Cold air transport:
The most common application is in central air conditioning pipes, which require insulation. Spiral ducting can be covered with insulating material, resulting in a visually appealing appearance.
(3) Smoke exhaust:
Restaurants and hotels generate large quantities of carbon black that need to be discarded. The circular duct serves as an oil chimney, also known as a carbon black pipe.
(4) Dust removal:
Some factories produce significant amounts of dust in their workshops, requiring a specialized dust removal device. For pipelines with high airflow, a spiral duct is an effective solution.
(5) Transportation of bulk materials:
In some factory production processes, it is necessary to transport loose particles, especially those with low specific gravity, such as plastic foam pellets. The use of spiral ducts is economical and efficient for this purpose.
Auxiliary equipment for manufacturing spiral ducts
Since the spiral duct machine can only produce straight pipes, it has developed equipment such as elbow machines.
