Page 29 - ITAtube Journal 1 2024

Technical Papers
many operations that are being performed by various equipment. In a tube mill, we can divide data into four subcategories: process data (i.e., HF welding process parameters, heat treating, cutting, bending, etc.), equipment data, raw material data, and inspection/ quality data. This article focuses on data collection during the HF welding process and equipment.
High Frequency (HF) welding is a multi- variable process with complex data. The key process parameters include power, frequency, tube OD and wall thickness, mill speed, as well as weld area parameters such as vee length, vee angle, impeder dimensions (OD, length, number of ferrite rods), induction coil length and ID, to name a few. It is important to keep track of key parameters during the run, in addition to knowing how parameters affect the final quality.
The recording of key process parameters for each piece of tubing is crucial for ensur- ing consistent product quality and perfor- mance. Product quality expectations should be in the Six Sigma range. This ensures customer satisfaction at the highest level.
It is acknowledged that for some commodi- ty-type tube and pipe products, the process window can be large and less critical.
While some have the approach “the more data- the better,” an argument can be made that the quality of the data is more important. The importance of a properly calibrated power supply was discussed
in a previous paper [1]. It is imperative to use properly calibrated instrumentation to ensure the correct measurement values are recorded.
The latest Thermatool HF welders are equipped with software that enables real-time monitoring and data logging of various process parameters such as power (kW), frequency (kHz), Current (A), voltage (V), line speed, and other parameters and
is also equipped with data analytics tools. This feature can show the length of mate- rial produced per day, week, or month, along with the equipment’s run time, down- time, and process efficiency. Data analytics tools allow the user to track values such as
ITAtube Journal April 2024
HAZControlTM Technology software screen with Process Limits
kWh per ton or length of pipe produced. To reduce variability, Thermatool’s HAZ- ControlTM Technology welder offers recipe creation and recall, ensuring the same process parameters are used on each and every run for a given product.
Thermatool now offers IIoT Cellular Con- nectivity available on select new welders as part of a commitment to expanding digital automation of routine tasks and data col- lection.
There are several benefits that data col- lection offers, and it can be utilized for various purposes.
The first and most obvious benefit of ana- lyzing data is process optimization. Data collection in tube and pipe manufacturing facilities allows for real-time monitoring of various production processes. The monitor- ing of process parameters ensures consist- ent welder operation within a defined and validated process window. The latest HF welding power supply technology includes precise control of weld heat input [2].
Data collection can also be used to facilitate quality metrics. Once the process param- eters have been validated, process limits can be set. With certain software capabil- ities and automation, it is now possible to create, save, and retrieve process “recipes” to ensure product quality and process
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