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System Capabilities

Core Features

Advanced automation and intelligent control systems designed to optimize production efficiency and ensure consistent quality.

Digital Control

Digital Control

Ethernet Interface

Ethernet Interface

Process Database

Process Database

Production Reports

Production Reports

Historical Data

Historical Data

Energy Calculation

Energy Calculation

One-Click Start

One-Click Start

Equipment Status

Equipment Status

Equipment Inspection

Equipment Inspection

Defect Detection

Defect Detection

Auto Grinding

Auto Grinding

Smart Shutdown

Smart Shutdown

Intelligent Sorting

Intelligent Sorting

Cutting Control

Cutting Control

Product System

Intelligent Welded Pipe Control System

Advanced centralized digital control solution for modern welded pipe production lines, delivering precision, efficiency, and intelligent automation for industrial manufacturing excellence.

System Overview

Our Intelligent Welded Pipe Control System revolutionizes modern manufacturing with centralized, digitalized control for welded pipe production lines. Seamlessly integrating with welding power supplies, bright annealing equipment, sizing mills, cutting units, and auxiliary devices to ensure optimal performance, consistent quality, and maximum operational efficiency.

Why It Matters

Centralized scheduling and real-time monitoring dramatically improve welding stability, production consistency, and enable comprehensive digital transformation across your entire manufacturing process.

Core Advantage

Advanced centralized architecture minimizes manual intervention, reduces changeover time by up to 50%, and optimizes cross-equipment coordination for unprecedented productivity gains.

Key Highlights

  • Centralized multi-equipment coordination
  • Dual-station HMI deployment
  • Real-time quality & process visibility
  • Secure role-based access control
  • Comprehensive data logging & reporting

Purpose-built for continuous, high-precision welded pipe production environments requiring 24/7 reliability and precision control.

Advanced Features & Capabilities

Integrated Digital Control

Unified system architecture enables seamless communication, real-time data exchange, and coordinated control across all major production equipment.

Multi-Station HMI Systems

Dual HMI deployment with main and auxiliary stations enabling flexible local parameter adjustment and comprehensive full-line control.

Advanced HMI Interface

Intuitive touchscreen controls for gas flow regulation, speed/current adjustment, production start/stop, and automated ignition systems.

Real-Time Monitoring

Continuous surveillance of forming mills, welding sources, robotic arms, annealing processes, sizing operations, and cutting systems.

Comprehensive Data Display

Live monitoring of motor speed, line velocity, current/voltage parameters, gas flow rates, production length, and temperature readings.

Precision Gas Flow Control

Integrated flowmeter with test-gas functionality ensuring consistent shielding conditions and optimal welding environment control.

Secure Access Management

Multi-level authentication with employee ID and password protection preventing unauthorized system access and ensuring operational security.

Intelligent Data Analytics

Comprehensive reporting system tracking specifications, current consumption, output metrics, gas usage - all printable and exportable for analysis.

Manufacturing Benefits & ROI

Superior Efficiency

40% less downtime

Centralized digital control reduces operational downtime by 40% and dramatically improves cross-equipment coordination and workflow optimization.

Enhanced Quality Control

99.5% quality rate

Real-time monitoring with precision parameter adjustment ensures consistent welding quality and reduces defect rates across production cycles.

Advanced Safety Features

Zero safety incidents

Comprehensive access control and automated emergency functions protect operators, equipment, and maintain strict safety compliance standards.

Complete Data Traceability

100% traceability

Automated reporting and analytics support continuous process optimization, regulatory compliance, and data-driven decision making.

System Control

Login, Access Control & Monitoring

Enterprise-grade role-based authentication and comprehensive access control with real-time production monitoring for secure, efficient, and traceable manufacturing operations.

Multi-Role Access
Secure Authentication
Real-time Monitoring
Data Traceability

Advanced System Login & Access Management

Intelligent Welded Pipe Control System Login Interface - Secure Role-based Authentication

Our intelligent welded pipe control system implements enterprise-grade security with a sophisticated multi-level authentication framework. The system supports two distinct user roles - Administrator and Operator - each with carefully defined permissions and operational boundaries.

Upon successful authentication, the system creates an automatic data association between production activities and employee accounts. This enables comprehensive audit trails, precise accountability tracking, and detailed performance analytics for continuous improvement.

1

Secure Authentication

Multi-factor login with encrypted credentials and session management

2

Role-Based Access

Granular permissions for administrators and operators with audit logs

3

Data Association

Automatic linking of production data with authenticated user accounts

4

Activity Tracking

Complete traceability of user actions and system modifications

Real-time Parameter Display & Monitoring Dashboard

The unified monitoring dashboard provides comprehensive real-time visibility into all critical production parameters. Our intuitive interface design consolidates complex manufacturing data into an easily digestible format, enabling operators to make informed decisions quickly and efficiently.

Advanced real-time analytics and predictive monitoring capabilities ensure optimal performance while providing early warning systems for potential issues.

Live Monitoring Capabilities

•

Production Metrics

Real-time tracking of line speed, temperature, pressure, and quality parameters

•

Equipment Status

Live monitoring of welding equipment, motors, and control systems performance

•

Process Analytics

Continuous analysis of production efficiency and quality trending data

•

Quality Assurance

Automated quality control with instant alerts for deviation detection

Real-time Production Monitoring Dashboard - Comprehensive Parameter Display for Welded Pipe Manufacturing
Live Production Data

Enterprise Security & Compliance Benefits

Comprehensive security framework ensuring data integrity, regulatory compliance, and operational excellence

Advanced Security

99.9% Security Uptime

Multi-layer security with encrypted authentication, secure data transmission, and access logging

Complete Traceability

100% Data Integrity

Full audit trail of all user actions, production data, and system modifications for compliance

Real-time Insights

25% Efficiency Gain

Instant visibility into production performance with predictive analytics and trend analysis

Ready to secure and monitor your welding operations with our advanced control system?

Get Started Today

Advanced System Capabilities

Enterprise-grade orchestration, process stability, operational assurance, and performance optimization capabilities designed for industrial manufacturing excellence.

Smart Orchestration
Process Stability
Operational Safety
Performance Analytics

1. Smart Orchestration Capabilities

Advanced coordinated startup, intelligent configuration management, and seamless equipment synchronization for reduced setup time and operational consistency.

1

Equipment Configuration

  • • Flexible configuration per welded pipe process
  • • Automatic device self-check prior to line start
  • • Coordinated auto-start on activation
  • • Shared state & interlocked alarms
2

Intelligent Line Start

One-button startup system mitigates common early-stage failure risks through intelligent monitoring.

• Arc ignition failure prevention
• Current / speed mismatch detection
• Manual adjustment defect reduction
Phases: Pre-start → Full-line

2. Advanced Process Stability

Real-time capture and intelligent control of critical welding and annealing parameters ensuring quality assurance and complete process traceability.

1

Welding Control & Acquisition

Continuous capture of current, voltage & gas flow parameters for optimal process stability and quality control.

2

Bright Annealing Parameters

Temperature, power & status monitoring surfaced on main HMI with comprehensive data storage and alarm integration.

⚠️ Alarm if annealing offline during welding
3

Wireless Remote Control

Industrial-grade jog forward/back controls for precise setup and alignment optimization during production.

3. Operational Assurance & Safety

Multi-tier alarm system with automated shutdown protocols ensuring operator safety, equipment protection and comprehensive fault management.

A

Advanced Fault Detection

Real-time monitoring with immediate response protocols for critical fault conditions.

Critical Faults (Auto-Stop)

  • • Catastrophic pressure failure
  • • Emergency stop activation
  • • Safety interlock violations

Warning Conditions (Operator Alert)

  • • Parameter drift detection
  • • Temperature variations
  • • Gas flow irregularities
B

Intelligent Gas Flow Management

Automated protection against gas supply disruptions with predictive monitoring.

Flow Rate Monitoring
Continuous tracking with threshold alerts
Supply Line Protection
Automatic isolation on pressure loss
Contamination Detection
Real-time purity analysis and response
Backup System Activation
Seamless switch to secondary supply

4. Performance Analytics & Optimization

Comprehensive energy profiling, predictive analytics, and cost optimization tools delivering measurable ROI through intelligent resource management and operational insights.

1

Smart Resource Management

Intelligent automation of lubrication & grinding pumps with manual override capabilities, significantly reducing idle energy consumption.

Auto-managed pump operations
Manual override controls
Idle energy reduction
2

Advanced Energy Analytics

Line-level energy aggregation enabling precise cost-per-ton analytics and comprehensive operational expense visibility.

Per-line consumption tracking
Cost-per-ton analytics
OPEX transparency
⚠️ Note: Excludes annealing gas consumption

Measurable Business Impact

15-25%
Energy Savings
Reduced consumption
40-50%
Setup Time
Faster configuration
30%
Pump Efficiency
Idle time reduction
100%
Cost Visibility
Per-line tracking

Ready to Transform Your Manufacturing Operations?

Experience the power of advanced system capabilities with our comprehensive implementation and support services.

Schedule Consultation View Live Demo
Control Platform

Advanced Line Group Control Platform

Comprehensive data integration platform enabling centralized control, real-time monitoring, and seamless coordination across multiple production lines for enhanced operational efficiency.

Ethernet Integration
Real-time Control
Centralized Management
Multi-line Scalability

Enterprise Integration Platform

Our advanced Group Control Platform (GCP) provides seamless data integration and centralized management capabilities. Through industrial-grade Ethernet connectivity, production line data flows to a central server enabling real-time monitoring, parameter control, and comprehensive production management from planning to quality assurance.

Key Business Benefits

1
Reduced Management Costs
Centralized control eliminates redundancy
2
Improved Efficiency
Real-time optimization and coordination
3
Enhanced Quality Control
Full-process digital management
4
Scalable Architecture
Multi-line deployment support

Core Platform Capabilities

Industrial Ethernet Integration

Secure, high-speed data exchange with redundant communication protocols

Real-time Parameter Control

Bidirectional parameter dispatch and feedback with instant response

Centralized Production Management

Complete planning → execution → quality control digital workflow

Multi-line Scalability

Flexible architecture supporting unlimited production line expansion

Advanced Line Control Interface - Real-time monitoring and control dashboard
Configuration Management Page - Parameter setup and system configuration
Configuration Management

Parameter setup & control

Operation Control Panel - Centralized production line control
Operation Control

Centralized line management

Technical Specifications

Advanced technical capabilities ensuring robust, scalable, and reliable line control operations

Industrial Ethernet
Communication Protocol
High-speed, reliable
Real-time
Data Exchange Rate
Instant synchronization
Universal GCP
Platform Compatibility
Multi-vendor support
Unlimited Lines
Deployment Scale
Scalable architecture

Ready to implement centralized control across your production lines?

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Documentation System

Smart On-Site Report Printing

Advanced Manufacturing Documentation System enabling seamless integration with multiple production lines, connecting to distributed network printers across manufacturing facilities for instant comprehensive reporting.

Industrial production report printing interface showing real-time data visualization and automated report generation for manufacturing quality control

Core Platform Features

1

Comprehensive Reports

Production output analytics, quality control metrics, energy consumption tracking, and equipment performance data

2

Flexible Distribution

Multi-location printing, digital export capabilities, secure cloud backup, and remote audit accessibility

Key Benefits

• Instant report generation with real-time production data integration
• Enhanced compliance documentation for ISO and industry standards
• Reduced manual documentation time by up to 75%

Ready to streamline your production documentation and reporting processes?

Learn More
System Standards

Electrical Control System Requirements

Comprehensive electrical safety and performance standards ensuring reliable, compliant, and maintainable control systems for industrial manufacturing environments.

1

Safety & Installation

Comprehensive safety protocols and installation standards for electrical systems.

Key Requirements

  • • All electrical components are installed in dedicated control cabinets with cooling fans
  • • High-voltage and low-voltage circuits are separated and labeled; grounding complies with standards
  • • All control wiring is shielded to prevent interference
2

Quality & Infrastructure

High-quality components and infrastructure standards for reliable operation.

Key Requirements

  • • Signal cables and components use modular connectors with labels for easy replacement and maintenance
  • • Control components are high-quality branded products; non-standard or unbranded components are not used
  • • Control and power lines are routed via overhead galvanized trays, preventing corrosion, mechanical damage, or accidental contact
  • • Tray design separates high and low voltage lines; low-voltage cables are shielded to ensure equipment stability

Need detailed electrical specifications for your manufacturing project?

Get Technical Specifications
Support & Guidance

Frequently Asked Questions

Get answers to common questions about our ZNHG-40 Intelligent Welded Pipe Control System, its capabilities, implementation, and benefits for your production operations.

Zhong Yong's intelligent welded pipe control system is a comprehensive digital integration platform designed specifically for pipe welding production. It unifies welding power sources, servo drives, electrical controls, sensors, cooling units, and information interfaces under a single architecture. The system provides precise control over welding current, voltage, wire feed, and speed parameters while enabling closed-loop process optimization through real-time data collection, computation, and feedback. Features include equipment self-diagnosis, one-touch start/stop, automatic weld defect detection, intelligent shutdown, and production report generation, with direct integration to MES and ERP systems for complete digital manufacturing and management.
Traditional production lines rely heavily on operator experience for parameter adjustments, have poor inter-process coordination, long setup cycles, and unstable production rhythms with changeover times often requiring several hours of downtime. Zhong Yong's intelligent control system utilizes 'servo drive + PLC + industrial Ethernet' architecture to create electronic shaft synchronization, ensuring highly consistent speeds across slitting, forming, welding, sizing, and cutting processes with error control within 0.01%. The integrated TIG-SJ high-speed weld tracking and TEC-2000 electromagnetic control technology automatically corrects weld seam deviation and stabilizes the arc during welding, reducing human error and transforming production from 'experience-driven' to 'data-driven' with significantly improved stability and traceability.
Zhong Yong's intelligent production line achieves efficiency improvements through three key mechanisms. First, electronic shaft synchronization replaces traditional mechanical shafts with servo motors, combined with electronic gear and cam control for highly precise multi-stand operation, eliminating strip accumulation and stretching issues caused by transmission gaps. Second, one-touch start/stop and recipe management allow operators to preset process curves for different pipe diameters and materials, enabling quick parameter package selection via HMI interface for 30-50% faster changeover times. Third, intelligent shutdown logic ensures the system completes current pipe cutting before stopping when encountering insufficient cooling or weld deviation, preventing material waste. These mechanisms typically deliver 15-30% overall capacity improvement compared to traditional production lines.
For TIG welding, Zhong Yong's proprietary TIG-SJ high-speed weld tracking system creates closed-loop control through CCD optical acquisition, T-Follow algorithm, and servo execution. It captures weld seam center position in real-time and corrects torch deviation within milliseconds, achieving ±0.1mm tracking accuracy while effectively resisting arc light, spatter, and vibration interference for stable weld seams. This system is widely used in sanitary fluid pipe and pharmaceutical pipe production, significantly reducing misalignment, humping, and porosity while generating deviation curves for quality traceability. For laser welding, the LW-TD laser high-speed tracking system uses non-contact optical scanning principles with laser beam detection of weld edges, algorithmic filtering of stray light, and servo system correction of welding head in three dimensions, achieving ±0.05-0.1mm accuracy ideal for high-speed thin-wall stainless steel welding.
Zhong Yong's intelligent system features current/voltage sensors, gas flow meters, laser diameter gauges, and eddy current flaw detection units with all data transmitted and stored in real-time via industrial Ethernet. During production, the system monitors critical parameters including arc stability, water cooling flow, and gas pressure with immediate alarms for anomalies. When laser diameter gauges detect dimensional deviations, they can drive servo sizing stands for compensatory correction. Historical energy consumption, production volume, and yield data are automatically archived by batch for process analysis and quality verification, enabling true full-process traceability.
For remote maintenance, our equipment features industrial VPN gateways enabling after-sales engineers to directly access customer site systems from our Foshan headquarters. When gas flow is insufficient or arc unstable, the system automatically generates logs and pushes them to remote servers. Engineers can remotely read PLC, welding power source, and sensor data for rapid problem identification. Additionally, process recipes and firmware updates can be remotely deployed without shutdown for on-site maintenance. This model has been validated at customer sites in India and Southeast Asia, typically improving maintenance efficiency by 20-30%.
Zhong Yong's intelligent production line energy-saving design spans power, gas, and cooling systems. Inverter welding machines replace power frequency units for more stable arcs and higher efficiency, avoiding energy losses from fluctuations. TEC-2000 electromagnetic control concentrates heat, reducing redundant heat input and base material overheating. For gas control, digital flow valves prevent gas overshoot during start/stop processes, saving approximately 15-20% consumption. The cooling system employs dual-mode compressor refrigeration combined with water cooling for more stable temperatures and lower energy consumption. Actual projects demonstrate comprehensive energy savings of 20-30%, with particularly notable results in large-diameter stainless steel and high-alloy pipe production.
The system employs multiple detection solutions including eddy current testing, laser diameter measurement, and visual imaging for comprehensive quality control throughout the process. Eddy current flaw detection identifies surface cracks and lack of fusion in weld seams, laser diameter gauges monitor pipe diameter and ovality in real-time with 0.01mm accuracy, while visual imaging monitors dynamic stability of weld bead formation. Upon detecting anomalies, the system immediately alarms and triggers sorting to ensure defective products don't proceed to subsequent processes, achieving 100% inline quality control.
Zhong Yong's control system supports TIG, plasma, laser, and hybrid welding processes with rapid switching through parametric recipe management. Operators select appropriate processes on the HMI interface, and the system automatically adjusts welding current curves, speed, gas flow, and other parameters while driving servo systems to complete motion trajectory switching without complex mechanical adjustments. For customers, this means flexible response to different specification and material orders on the same production line, meeting diverse production requirements.
Zhong Yong's intelligent welded pipe production line control system not only helps customers achieve 15-30% production efficiency improvements and 20-40% weld defect reductions, but also reduces energy consumption by 20-30% through inverter power sources and digital gas control, lowering operational costs. More importantly, the system provides intelligent functions including remote diagnostics, full-process data traceability, and predictive maintenance, helping factories upgrade toward digitalization and intelligence. Currently successfully deployed at customer projects including Zhejiang Jiuli, Shanxi Taigang, and Wenzhou Wanhua, extensively serving high-end industries such as nuclear power, petrochemicals, automotive, and semiconductors, becoming crucial support for customers' competitive advantage enhancement.
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