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Specification Of
Carriage Type Finning Machine
(240 Kw x 450 KHz)

JR INTERNATIONAL
316, HYUNGJIN PLAZA, 313-3, KANSUCK-DONG, NAMDONG-KU, INCHON CITY, KOREA.
TEL: 82-32-437-0016 FAX:82-32-437-0017
E-MAIL: kunsongok@yahoo.co.kr
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1. General of High Frequency Finning Machine

1-1. Outline of the machine

This High Frequency Finning Machine is the automatic machine that welds
continuously the fin to outside of the tube, with the fin is winded spirally.
The finned tubes manufactured by this machine are the principal parts of HRSG
(Heat Recovery Steam Generator).
All the processes for finning work, such as mounting bare-tube on the machine,
conveying, outside sanding, continuous feeding the fin, winding spirally the fin
round the tube, welding the fin to the tube and getting off the completed finned tube,
are performed automatically by touching the screen or pushing the buttons on
the operation panel. Each button on the operation panel has a function of its own.
All of such functions are a kind of procedure for operating the machine and
these procedures are recorded as programs in PLC(Programmable Logic Control).
When operator pushes a button, the machine is operated as programmed in PLC.
So, the automatic operation system as mentioned above provides that a operate
can operates this machine more easily.
Fin welding is by means of induction heating using high frequency.
It is possible to produce a finned tube of big diameter (up to 114.3 mm) by replacing
the collet chuck attached to the carriage.
This machine has various usefull functions such as automatic adjusting device for
uniform welding power, welding spark detector, plate OCR(Over Current Relay), grid OCR
and input OCR to minimize unexpected damage of welding quality and vaccum tube.
When over-current that be able to bring about damage of vaccum tube or welding quality is
occurred under operating, the OCR perceives it at once and signals this matter to PLC,
then PLC stop the machine from operating at once.
Also each system in the machine is protected doubly to prevent the machine from
unexpected damage.
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1-2. Composition of the machine

This machine consist of the parts as below

-. Fin Uncoiler
-. Fin Accumulator
-. Serrator
-. Dancer
-. Tube Entry Conveyer
-. Pinch Roller Device
-. Belt Sander
-. Welding Part
-. Carriager
-. Carriage Rail Frame, Fin Supporting Rollers and 90˚ Turning levers
-. Dust Collector ( to be provided by Purchaser )
-. Fin Butt Joining Welder and Fin Clamp
-. Operating Unit
-. High Frequency Induction Welder
-. Tig Welder ( to be provided by Purchaser )
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1-3. Finning Range

-. Raw material : Carbon steel tube

Heat-Resistant Alloy Steel
Stainless Steel
-. Fin width : Min. 8 mm
Max. 25.4 mm
-. Fin thickness : Min. 0.8 mm
Max. 2.5 mm
* Thickness and width range of the fin are different according to it's material
-. Tube diameter : Min.Φ22.0 mm
Max.Φ78.3 mm
-. Tube thickness Min. 2.0 mm
Max. 10.0 mm
-. Tube length : Min. 5,000 mm
Max. 23,000 mm
-. Tube Rotation speed : 400 to 750 rpm under normal operating for carbon steel
400 to 650 rpm under normal operating for alloy steel

-. Min. / Max. fin pitch : 1.1 to 7.85 fins per inch(25.4mm)

-. Welding Position from Tube to Min. 50 mm
end length.
-. Electric power source : AC 380 Volt, 3 Phase, 50 Hz
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1-4 H.F Resistance Welder.
* Power circuit.
- Input power : 330 KVA
- Input voltage : AC 380 V
- Constant & frequency : 3Phase 50Hz
- Control power : AC 220 V
: DC 24 V
- Circumstance temp : 5~55 ℃
- Circumstance humidity : 10~55 RH

* Rectifier circuit.
- Rectifying Method : 3 phases Full Bridge method
- Transformer Capacity : 500 KVA
- Constant & frequency : 3Phase 50Hz
- Rectifier voltage : DC 15 KV
- Rectifier current : DC 55 A
- Operating Temp : 5~55 ℃
- Rectification Element : Cathode On Stud Avalanche Silicone Diode

* Oscillation circuit.
- Standard of Vacuum Tube : RS 3150 CJ (THALES)
- H.F Output : 240 KW
- Oscillation Circuit Method : Colpitts
- Oscillation Frequency : Min. 450 KHZ
- Plate Voltage : DC 14 KV
- Plate Current : DC 22.3 A
- Grid Current : DC 3.1 A
- Filament Voltage : AC 15 V
- Filament Current : AC 255 A
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* Cooling Unit.
- Cooling Method : Closed Circuit Constraint Forced Circulation
- Inlet cooling water Temp : Max 35 ℃
- Vacuum-tube cooling air Flow : Min. 3 ㎥/min(Min)
- Vacuum-tube cooling water Flow : Min. 65 ℓ/min
- Vacuum-tube cooling pressure : Min. 3 ㎏/㎠
- Welding part cooling water Flow : Min. 2 ℓ/min
- Welding part cooling pressure : Min. 3 ㎏/㎠
- Cooling water kind : Distilled Water
- Heat Exchanger type : Plate Heat Exchanger
- Pump type : Multi Stage Turbine
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2. Specification of High Frequency Finning Machine

2.1 Fin Uncoiler

◎ Function :

This device is for loading and supplying continuously the fins to main machine.
Two uncoilers are required in order to supply the fins continuously for one
machine.

◎ Specification :

External Size : 2000W x 2110H x 800L (mm)

Coil I.D : Φ300 mm
Coil O.D : Max. 1,600 mm
Coil weight : 400kg
Fin width : Min. 8 mm
Max. 25.4 mm
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2.2 Fin Accumulator

◎ Function :

This device is accumulating the fins at normal operating.

When the fin coil on the 1st uncoiler is consumed, some time is needed for
joining 2nd fin coil to 1st fin coil in order to supply continuously the fins to the
machine. The accumulator releases the accumulated fins while the 1st and 2nd
fin coil are joined by welding.
The accumulator keeps and controls also a proper tension of fin in order to
feed uniformly the fins to the machine.

◎ Specification :

External Size : 710W x 1200H x 19350L (mm)

Capability : About 300 meters
Feeding speed : Depend on Tube RPM

Fin feeding system : By tension sensor

Max. fin width : 30 mm

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2.3 Serrator

◎ Function :

This serrator alters a solid fin to a serrated fin by means of cutting a fin using
a cutting roller. Fin cutting speed is controlled automatically according to
welding speed of tube.

◎ Specification :

External Size : 950 x 1350 x 550H (mm)

Cutting speed : depend on tube RPM

Driving unit : D.C Motor (30HP x 4P)

( 0 ~ 400V D.C Amateur - 220V D.C Field )

Fin thichness : 0.8 ~ 2.5 mm
Fin width : 8.0 ~ 25 mm
Cutting length : 0 ~ 15 mm
Cutting thickness : 0.8 ~ 2 mm
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2.4 Dancer

◎ Function :

Dancer keeps a uniform feeding speed and tension of the fin while the fin
is supplied to the welding part of the machine.
A wheel with suitable weight controls fin feeding speed and tension by
means of moving up and down along to the guide rails at both sides.

◎ Specification :

External Size : 480W x 1050L x 1380 (mm)

Tension Stroke : 900 mm
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2.5 Tube Entry Conveyer

◎ Function :

A tube stocked on the in-rack is moved to the endtry conveyer by the

kicker. This tube is forwarded to the pinch roller(2nd feeding device)
with rotating by means of the driven unit at front of the entry conveyer.
Then the pressure roller presses the tube so that the tube may not be
vibrated from a long length of the tube.
The pressure roller and the kicker are operated by air-cylinders.

◎ Specification :

External Size : 3225W x 1490H x 22400L (mm)

Tube length : 5,000 ~ 23,000 mm
Tube out-diameter : 25.4 ~ 76.2 mm

Automated tube feeding

Automated tube transfferring
Automated tube up-down
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2.6 Pinch Roller Device

◎ Function :

This device transfers a tube without vibration to the welding part.

This device consists of three urethane rollers and steel frame.
Then, three urethane rollers transfer the tube to the belt sander
without tube vibration by means of pressing the fin at both sides,
which allows a good surface cleaning by the belt sander.

◎ Specification :

External Size : 1325W x 850H x 1440L (mm)

Driving unit : A.C Motor(2HP × 4P)

(380V A.C - 50Hz)
Automated tube holding and releasing
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2.7 Belt Sander

◎ Function :
This is the tube sanding system for cleaning the tubes before welding process
to improve welding quality.

◎ Specification :

External Size : 780W x 1770H x 1280L (mm)

Belt type sand paper : 40 mesh x 75~150W mm

Driving unit : A.C Motor (3HP x 4P)

( 380V A.C - 50Hz )

Roller (Head and Tail)
Two times sanding type
Automated Belt Sander charging and discharging
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2.8 Welding part

◎ Function :

This is the place that a tube and a fin are welded.

The fin is welded to the tube, then the fin pitch is keeped uniformly
by a deforming wheel.
There are a C.T box frame for high frequency welding, water spraies
for cooling a heat from welding and deforming wheel for cotrolling
the fin slope and for guiding the fin.

◎ Specification :

External Size : 960W x 2560H x 2230L (mm)

Moving Table for Current Transformer

-. Up, down, left and right stroke : Max. 50mm

-. Front and rear stroke : Max. 50mm

-. Up&down cylinder C.T lift stroke : Max. 100mm
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2.9 Carriage

◎ Function :

This is the core part of the machine and a very complex device having
various functions. This carriage moves forward slowly with it holds
the end part of the tube and rotates the tube in uniform RPM.
Then the fin pitch is decided by forwarding speed of the carriager and
RPM of the tube.

◎ Specification :

External Size : 784H x 1310W x 2370L (mm)

Motor for forwarding : D.C 40HP x 4P

( 0 ~ 400V D.C Amature - 180V D.C Field )

Returning speed : with in 22m/min.

Tube rotation speed : 400 to 750 rpm under normal operating for carbon steel
400 to 650 rpm under normal operating for alloy steel
Max. 850 rpm
◎ Carriager consists of below items
Transmission with 63 fin pitch grades
: from 309.21 to 43.43 fins/m (7.85 to 1.1 fins per inch)
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2.10 Carriage Rail Frame, Tube Supporting Roller and 90˚ Turning lever

◎ Function :

Frame is very strong and the residual stress after welding was removed.
Therefore this rail frame provides a good stability during carriager operation.
The contact surface of Frame and Rail are milled minutely in order to
keep accurate horizon of the rail.
There are tube supporting rollers at spaces of 1.5m in parallel with the
rail between carriager rails and they are supporting the finned tube
under finning work progress.
90˚ Turning levers are for transferring the completed finned tube to
the out-rack.

◎ Specification :

External Size : 1100H x 1900W x 28640L (mm)

Automated finned tube supporting roller

Automated 90˚ turning lever
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2.11 Dust Collector (reference for purchaser because Dust Collect will be
provided by purchaser)

◎ Function :

This device collects a dust from the belt sander.

◎ Specification :

Capacity : 25 ㎥/min x 200 mmAq

Filter Area : 9 ㎡
Turbo Fan Power : 3HP x 4P

( 380V A.C - 50Hz )

Body Size : 900 x 900 x 2000 mm
Inlet Size : φ100 mm
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2.12 Fin Butt Joining Welder and Fin Clamp

2.12.1 Fin Butt Joining Welder (reference for purchaser because Welder will be
provided by purchaser)

◎ Function :

This is a Tig Welder that is used to butt join two fins after
the fins are fixed by Fin Clamp.

◎ Specification :

Welder Type : Tig Welder

Electric Power : 11 KVA

2.12.2 Fin Clamp

◎ Function :

This is used for fixing two fins in order to butt weld them each other.

◎ Specification :

Fin Clamp Frame Size : 400 x 500 x 500 (mm)

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2.13 Main Operation Unit

All kind of error messages and each production data can be shown on the
screen for easy maintenance and adjustment. The power and speed of
machine can be shown by each graph and digital values. The power is
adjusted automatically according to rotation speed and it allows easy control
by operator.

* Main operator control unit Including;

- Welding power control
- Pre-heat level potentiometer
- Welding Power on/off push button and indicate lamp
- Standby/shutdown switch and alarm reset button
- Emergency stop button
- Graphic touch screen monitor
- H.F Analog indicating meters
- Carriage unit Analog indicating meters
- Over voltage & current protection device
- Coolant circulation cooling device on/off push button and indicate lamp
- Spark detector (fin tube prorection)
- Auto welding power & welding speed sink controller
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2.14 High Frequency Induction Welder

1) Outline

This device is used in heat treatment or melting of metal by means of

induction heat principal and it is vacuum tube induction heater. Based on our
experiences and technologies, this principal is used at many industrial fields
and also we provide computer aided design for the oscillator station and the
other developments. Touch screen unit is applied for control unit and it allows
that operator can deal with each error and maintenances so to get high quality
products. Also, can control welding conditions by means of energy movement
circuit and possible to print data and values out and electric control can be
adjusted on the screen by using simple operation panel.

2) General rate

■ Name : High frequency resistance welding machine

■ Input voltage : AC 380 V

■ Input frequency : 50 HZ

■ Input power : 400 KVA

■ Oscillation output : 240 KW

■ Osc Frequency : 450 KHZ

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3) Other equipment, installation and remarks

Other installation so below are required to set induction welding machine up.

■ Cooling system
■ Cooling water tank and circulation pump.
■ Pipe arrangement
■ Electric power management

4) High frequency Resistance welder Including;

* Electric Power supply

- SCR power controller & stabilizer
- High voltage trans-former
- 3 Phase full brige rectifier
- Auto welding power & welding speed controller
- PLC (Programable logic controller)
- DC Power Filter
- High voltagr safety protector
- Auto circuit Breaker
- Magenetic contactor

* High frequency Oscillator

- Choke coils
- Grid spark-gap
- Step-start filament control circuit
- Safety protection circuit
- Analog indicating meters
- High voltage oil capacitors
- High voltage inductors
- Choke coils
- Ceramic triode vacuum tube
- Ceramic tank capacitors
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* Distilled water Closed Circuit Constraint Forced Circulation cooling system
- Plate heat exchanger
- Particle separation filter
- Non- ferrous pump & fitting
- Automatic constant temperature and control valve
- Header water tank

* Remote alphanumeric output display

* Power and fault diagnosis display

* Main operator control unit

- Welding power control
- Pre-heat level potentiometer
- Welding Power on/off push button and indicate lamp
- Standby/shutdown switch and alarm reset button
- Emergency stop button
- Graphic touch screen monitor
- H.F Analog indicating meters
- Carriage unit Analog indicating meters
- Over voltage & current protection device
- Coolant circulation cooling device on/off push button and indicate lamp
- Spark detector (fin tube prorection)
- Auto welding power & welding speed sink controller

* Remote operation unit

- Welding head control push button and indicate lamp
- Carriage control push button and indicate lamp
- Serrator control push button and indicate lamp
- Emergency stop button

* External weld head assembly

- Welding Welding leads
- Shelf & housing
- Serrator control push button and indicate lamp
- H.F CT(current transformer)
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* Welding head support table

- H.F Transmission line kit
- Equipped with quick lift package
- Pneumatic flexible contact adapters
- X.Y.Z adjust table

The End
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