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Mönchengladbach, March 03, 2020

X-Pact® Quicksetting: Intelligent setting system for tube welding lines

Reduction of change-over and setting times

X-Pact® Quicksetting reduces change-over and setting times in welded tube plants and thus increases productivity.

ERW rolling stand

Welded tube production by means of high-frequency electric resistance welding (ERW) requires constant adjustment to the specifics of the individual product. The trend towards increasingly smaller batch sizes and ever more extensive product mixes is today the biggest challenge for this production process. This holds equally true for welded tubes produced for the automotive industry, the oil and gas sector and for the construction industry. Just as essential as these factors are innovative automation systems and advanced digitalization solutions for our customers to remain competitive in the market.

SMS group has developed an innovative integrated concept for HF ERW lines. Customers using this concept are impressed with the extremely short set-up times and the quick-change system for the rolls. SMS group’s highly flexible lines are designed to manufacture tubes with diameters from 10 to 710 millimeters and variable wall thicknesses.

Automatic adjustment after dimension change

As the core element of this concept, X-Pact® Quicksetting assures that – after a dimension change – the rolls are automatically adjusted to their new positions. Thanks to this data-based roll adjustment process, the times needed to set up the line or setting it for a dimension change are minimized. Moreover, line productivity increases and continuous improvement of the product quality is assured. The high production speed of up to 35 meters per minute, together with the extraordinarily wide range of possible diameter/wall thickness ratios and the extremely short change-over times, provides the ERW lines their exceptionally high flexibility to produce such a great variety of tubes.

Modern automation platform

By integrating the automation system with a database software, X-Pact® Quicksetting becomes a link between the plant, the engineering, the technological know-how and the production process. The new, intuitive web-linked HMI - in SMS group’s X-Pact® Vision design - makes it possible from now on to access the system via a web browser from virtually any computer device at any point of the plant-wide network. The operator may, for instance, enter a working preparation schedule and set-up data and receive feedback from the running production either at his workplace, or he may operate the system and view all relevant information directly at the line. The system assures smart connectivity and systematic networking of knowledge and data exchange, setting a new standard in plant automation.

Being a module of X-Pact® Process Guidance, X-Pact® Quicksetting is all set for future upscaling by additional modules and applications. The X-Pact® Process Guidance platform is unique in that it provides all it takes to advance the level of plant and process automation and get the best out of a plant by a maximum of transparency of all plant data and dialogs specifically tailored to different user categories. The system can be used just as efficiently for plant upgrades.