1.4에서
- 1. Urban Flood Control and Deep Tunnel Drainage: The Pipe Demand Background
- 2. Structure and Principle of the HDPE Hollow Wall Winding Pipe
- 3. 생산 라인 Equipment Composition and Commissioning Points
- 4. Material System and Compounding for Large-Diameter HDPE Pipes
- 5. Standards and Acceptance 사양
- 6. Engineering Application and Buried Installation
- 7. Special Challenges of Super-Large Diameter and 방지 조치s
- 8. Hollow Wall Winding Pipe 생산을 위한 Faygo 실제 기계 모듈
- 9. Requirement to Model Selection Recommendation
- 10. Common Quality Defects and 방지 조치s
- 11. Service Support and How to Start Your Project
- 12. 자주 묻는 질문
1. Urban Flood Control and Deep Tunnel Drainage: The Pipe Demand Background
Extreme rainfall events are becoming more frequent and more intense across densely populated metropolitan regions, and the resulting urban flooding has turned municipal drainage from a background utility into a front-line infrastructure priority. When a storm drops two hundred millimeters of rain inside a few hours, conventional gravity sewers sized for a ten-year return period simply cannot move the volume, and streets, subways, and basements fill with water. The engineering response that planners now favor is a two-tier system: a normal near-surface drainage network for routine flow, plus a deep storage and transfer tunnel bored far below the city to absorb the peak and release it slowly after the event. A super large HDPE hollow wall winding pipe production machine exists to manufacture the pipe that makes this second tier physically possible.
The deep tunnel concept changes every design parameter of the pipe. Instead of placing a pipe two or three meters below the road, engineers now thread a tunnel thirty to sixty meters down, where geology is stable and surface disruption is minimal. At that depth the pipe must carry enormous static earth and water loads, survive long-term external pressure without buckling, resist aggressive sewage chemistry, and remain serviceable for half a century with essentially no access for repair. The diameter requirement also expands dramatically. Where a typical municipal trunk line might be DN600, a deep drainage main frequently runs from DN800 up to DN3000 and beyond. These are not conventional extruded solid-wall pipes; they are structured-wall pipes where the wall is engineered as a hollow cavity to maximize stiffness per unit of material.
Long-term external stability is the decisive property. A pipe buried at forty meters depth carries a soil column plus groundwater head that can exceed three hundred kilopascals of sustained external pressure. A solid-wall pipe sized to resist that load would need a wall so thick that material cost and weight become impractical. The hollow wall winding concept solves this by placing the structural material where it contributes most to the section’s second moment of area, achieving high ring stiffness at a fraction of the mass. This is why hollow wall winding technology, rather than solid-wall extrusion, is the natural choice for super-large flood-control and deep-tunnel pipe.
Corrosion resistance is the second decisive property. Drainage and storage tunnel water is not clean. It ranges from mildly alkaline to acidic, carries suspended grit, and in combined systems can swing between pH 2 and pH 12 depending on industrial discharge and rainfall dilution. A steel or concrete pipe faces progressive degradation in that environment; an HDPE structured-wall pipe is chemically inert across the full pH range and does not support microbiological corrosion. The design life target of fifty years is therefore realistic rather than optimistic.
Installation method adds a final constraint. Deep tunnels are almost always installed by trenchless methods such as pipe jacking or segmental lining, while shallower trunk sewers may be laid in open cut. Both methods favor pipe that is light enough to handle, stiff enough to be pushed or pulled through ground without ovalizing, and jointed with a seal that survives ground movement. Hollow wall winding pipe meets all three because the low mass comes from the hollow structure, the high stiffness comes from the engineered wall, and the joints are made by electrofusion or heat-shrink collars that create a continuous, flexible, watertight connection.
Faygo, Wanplas 공장 with 22 years of dedicated experience in plastic pipe and profile extrusion, builds the production machinery that manufactures these pipes. Operating three specialized factories and holding 13 national patents, Faygo supplies the complete extrusion and winding line that turns HDPE resin into DN800 to DN3000 structured-wall pipe rated for the most demanding municipal flood-control duties.
2. Structure and Principle of the HDPE Hollow Wall Winding Pipe
The hollow wall winding pipe is a structured-wall pipe in which the structural load is carried by a hollow profile that is wound helically around the pipe axis, rather than by a uniform solid wall. Understanding how this structure compares with alternatives is the foundation for specifying the right production machine.
2.1 Comparison With Other Pipe Structures
Four structured-wall concepts dominate the large-diameter drainage market: the solid-wall pipe, the double-wall corrugated pipe, the steel-reinforced polyethylene pipe, and the hollow wall winding pipe. Each trades material efficiency, maximum achievable diameter, joint method, and cost differently. The table below compares them on the dimensions that matter for flood-control and deep-tunnel service.
| Structure Type | Ring Stiffness Efficiency (SN per unit mass) | Maximum Diameter | Typical 공동 방법 | Relative Cost Level |
|---|---|---|---|---|
| Solid-wall PE pipe | 저전압 | DN1200 typical, limited beyond | 엉금 융합 / 전기 융합 | 중간 |
| Double-wall corrugated pipe | 중간 | DN300에서 DN1200까지 | Integrated socket / rubber ring | 중간 |
| Steel-reinforced PE pipe | 높은 수준 | DN800 to DN2600 | Electrofusion / collar | 높은 수준 |
| Hollow wall winding pipe | 매우 높은 등급 | DN800 to DN3000 and above | Electrofusion tape / heat-shrink / steel clamp | 중간에서 높은 수준까지 |
The ring stiffness efficiency metric shown in the first column is the ratio of achieved ring stiffness to the mass of polymer used. Hollow wall winding pipe leads this metric because its cavity profile places material far from the neutral axis, where it most increases the second moment of area. That is precisely why it can reach DN3000 with practical wall mass, while a solid-wall pipe of equal stiffness would be prohibitively heavy.
2.2 The Winding Formation Principle
The defining process of this pipe is helical winding on a rotating mandrel. Molten HDPE is formed into a shaped hollow profile strip, sometimes called a profile or structural strip, in a dedicated profile die. This strip has a precise cross-section with one or more internal cavities. The strip is then delivered to a rotating mandrel, a large-diameter cylindrical forming drum, where it is laid down in a continuous helix. As each new turn of the strip is placed against the previous turn, the adjacent strip edges are fused together by a hot-melt welding unit so that the helix becomes a single monolithic wall. The cavities created between successive turns form the hollow structural wall.
Two layers are typically built. An inner liner, often a flat or lightly profiled strip, forms the smooth interior flow surface. Over or around this liner, the hollow structural profile is wound to create the load-bearing wall. Some designs add an outer protective strip or capping strip that seals the cavity edges and gives the outside a finished appearance. The key physical principle is that the strip is plastic and hot at the moment of contact, so the welding pressure and temperature cause the two strip edges to coalesce into one homogeneous wall with no weak seam.
Because the structure is built by winding rather than by extruding a complete pipe through a die, the achievable diameter is limited only by the size of the mandrel and the floor space of the line, not by die-tooling limits. This is the core reason hollow wall winding technology reaches DN3000 where extruded solid-wall tooling cannot.
2.3 Ring Stiffness Grades and Cavity Geometry
링 강성 is the resistance of a pipe to deformation under uniform external load, expressed in kilonewtons per square meter (kN/m²). For structured-wall pipes the standard grades are SN2, SN4, SN8, SN12.5, and SN16. A higher number means a stiffer pipe that deflects less under the same buried load, allowing it to be used at greater depth or under heavier fill.
링 강성 is controlled in a winding line by three geometric levers. The first is the height of the structural wall: a taller profile places material farther from the neutral axis and raises stiffness. 두 번째는 the cavity shape. Rectangular cavities are simple to tool and give predictable stiffness; trapezoidal cavities improve bridging between turns and resist local collapse; circular cavities offer the best hoop stress distribution but are harder to seal at the weld. The third lever is the number of cavities and the strip thickness. The table below maps typical cavity choices to stiffness grades.
| Ring Stiffness Grade | Typical Wall Height Range | 선호되는 동굴 형태 | Typical Buried Depth (compacted backfill) |
|---|---|---|---|
| SN2 | 저전압 | Rectangular | Shallow, low cover |
| SN4 | Low to medium | Rectangular / trapezoidal | Shallow to medium |
| SN8 | 중간 | Trapezoidal | Medium depth trunk sewer |
| SN12.5 | 중간에서 높은 수준의 내구성 | Trapezoidal / circular | Deep burial, heavy traffic |
| SN16 | 높은 수준 | Circular / composite cavity | Deep tunnel, high external load |
2.4 The Engineering Relation Between Inertia and Ring Stiffness
링 강성 is not an arbitrary label; it is rooted in the structural mechanics of a ring under radial load. In simplified form, the ring stiffness of a pipe relates to the product of the material’s flexural modulus and the second moment of area of the wall cross-section, divided by the cube of the diameter. Expressed in words rather than symbols, the stiffness grows in direct proportion to the material modulus and to the inertia of the wall, and it falls rapidly as the cube of the diameter increases. This is why diameter is such a dominant factor: doubling the diameter reduces the natural ring stiffness by roughly a factor of eight, unless the wall’s second moment of area is increased to compensate.
The hollow wall design is essentially an optimization of that second moment of area. By moving polymer into cavity walls positioned far from the pipe centerline, the winding structure achieves a much larger inertia for the same mass than a solid wall could. The production machine’s job is to reproduce that optimized geometry turn after turn, with consistent cavity shape and a weld strong enough that the structure behaves as one continuous ring. If the weld is weak, the section loses its continuity and the effective inertia collapses, so the welding unit is as important to final ring stiffness as the profile die itself.
3. 생산 라인 Equipment Composition and Commissioning Points
A super large hollow wall winding pipe production line is a sequence of synchronized stations, each with its own parameters and its own failure modes. The following sections walk through the main line segment by segment, giving the representative parameters and the commissioning points an engineer should watch.
3.1 Main Extruder
The main extruder melts and pumps the HDPE that forms the structural profile. For large-diameter hollow wall pipe, a single-screw extruder with a screw diameter from φ90 to φ150 mm is typical, with an L/D ratio of 33 to 36. The screw is an HDPE-specific barrier screw fitted with a mixing head that ensures uniform melt temperature and pressure before the material enters the profile die. Throughput scales with screw size: a φ120 mm machine delivers roughly 800 to 1500 kg/h, while a φ150 mm machine reaches up to 2000 kg/h.
Commissioning points: set the barrel temperature profile so the rear zones stay cool enough to build feed pressure and the front zones reach a uniform melt temperature around 200 to 220 degrees Celsius. Verify melt pressure stability; pressure swings translate directly into profile thickness variation. Check the barrier section is clean and the mixing head is free of carbon buildup before the first run.
3.2 Auxiliary Extruder
A secondary, smaller extruder supplies the inner liner layer and the hot-melt welding bead. Its output is a thinner, lower-viscosity stream that forms the smooth interior surface and the thin film that the welding unit fuses between adjacent profile turns. Using a separate extruder for the liner lets the line run a recycled or cost-optimized compound in the structural layer while keeping a clean virgin surface in contact with the flow.
시운전 지점: 보조 압출기의 용융 온도를 주 스트림과 일치시켜 두 층이 차가운 경계 없이 결합되도록 합니다. 라이너 두께가 맨드렐 둘레 전체에서 균일하게 유지되는지 확인하십시오. 불균일한 라이너는 이후에 수정하기 어려운 내부 표면 결함을 유발합니다.
3.3 Profile Die
The profile die shapes the molten HDPE into the hollow cavity strip. Its internal flow channel must be balanced so that every cavity of the profile fills completely and at equal pressure, otherwise one cavity walls is thin and the others thick. The die lips are adjustable to fine-tune the strip width and the cavity geometry after warm-up.
Commissioning points: after a full barrel warm-up, run a short scrap strip and measure the cavity dimensions against the drawing. Adjust the die lip bolts symmetrically. Confirm the strip exits straight without twist, because a twisted strip will not seat correctly on the mandrel.
3.4 진공 크기 조정 및 냉각 of the Profile
Before the strip reaches the mandrel, it passes through a vacuum sizing and cooling section that locks its dimensions. The target dimensional stability for the profile is within plus or minus 0.2 mm. Tight control here is what makes the final pipe meet wall-height and cavity tolerances.
Commissioning points: tune the vacuum level and the cooling water temperature together. Too much vacuum distorts the soft profile; too little lets it relax out of tolerance. Log the strip cross-section at line start, after one hour, and after the barrel reaches thermal steady state.
3.5 Rotating Winding Mandrel
The winding mandrel is the heart of the line. It is a large-diameter rotating drum whose diameter sets the pipe inner diameter. For this application the mandrel is variable-diameter, covering DN800 to DN3000, and it rotates slowly at 0.5 to 5 rpm. Synchronization between mandrel rotation, strip feed speed, and welding carriage travel is critical: if the mandrel turns too fast relative to strip delivery, the pitch stretches and the weld overlap shrinks.
Commissioning points: verify the mandrel surface treatment gives easy demolding and that the variable-diameter mechanism holds concentricity across its full adjustment range. Check the rotation encoder against the carriage encoder so the pitch is consistent over the full pipe length. Inspect the surface for scoring that would mark the liner.
3.6 Winding Carriage and Pitch Control
윈딩 캐리어는 프로파일 다이와 맨드렐에 스트립을 놓아줍니다. 스트립의 피치는 정해진 간격으로 유지되어야 하며, 각 회전은 이전 회전의 가장자리를 일정량만큼 겹치게 됩니다. 겹치는 부분이 바로 용접 단위에서 용접하는 부분입니다. 용접 온도는 일반적으로 210~240℃이며, 가열된 신발이나 휠을 통해 제어된 압력으로 적용됩니다. 용접은 원료의 90% 이상 강도를 유지해야 하므로 벽이 하나의 연속된 링처럼 동작합니다.
Commissioning points: set the pitch from the strip width minus the target lap. Run a calibration coil and cut a cross-section to measure the actual lap. Confirm the carriage tracks smoothly with no lateral oscillation that would vary the lap around the circumference.
3.7 Hot-Melt Welding Unit
스트립 회전이 놓이면서, 용접 단위는 가장자리를 이전 회전과 용접합니다. 용접 온도는 일반적으로 210~240℃이며, 가열된 신발이나 휠을 통해 제어된 압력으로 적용됩니다. 용접은 원료의 90% 이상 강도를 유지해야 하므로 벽이 하나의 연속된 링처럼 동작합니다.
Commissioning points: use an infrared pyrometer to verify the actual weld-zone temperature, not just the setpoint. Set the pressure wheel force so the melt squeezes into the joint without squeezing the cavity shut. Pull-test welded sample sections; a weld below 90 percent of parent strength is a line-stop condition.
3.8 Inner and Outer Shaping Rolls and Cooling
선언된 SN 등급(SN8, SN12.5 또는 SN16)을 충족합니다.
Commissioning points: align the shaping rolls to the mandrel centerline. Watch for roll marks on the liner; a roll set too hard leaves a permanent impression. Monitor cooling so the pipe does not distort during the temperature transition.
3.9 Fixed-Length Cutting
A large-diameter planetary or traveling cutter severs the pipe at the required length. For DN2000 and above the pipe wall is thick and the cut must stay square; the acceptance target is a cut perpendicularity within one degree.
Commissioning points: confirm the cutter follows the pipe rotation so the blade traces a true circle. Check the cut face with a square gauge on the first pipe of each diameter change.
3.10 Demolding, Ejection, and Socket Forming
Once cooled, the pipe is stripped from the mandrel and moved to finishing. The ends are prepared for jointing. The connection methods compared for this pipe are electrofusion tape, heat-shrink collar, and steel clamp coupling. Electrofusion tape embeds a heating wire that melts the socket interface; heat-shrink collar provides a sealed sleeve; steel clamp coupling uses a mechanical band for fast assembly, especially useful in trenchless drives.
Commissioning points: verify the socket dimensions against the joint specification, because a loose or oversized socket is the most common field failure. Confirm the coupling system chosen matches the installation method, whether open trench or jacking.
3.11 온라인 검사
The line monitors wall thickness, outer diameter, ovality, and weld-zone temperature in real time. Infrared cameras watch the weld temperature so a cold weld is caught immediately rather than after the pipe is buried. Thickness and diameter gauges feed the control system so drift is corrected before it becomes scrap.
Commissioning points: calibrate every gauge against a master sample at shift start. Set alarm limits tighter than the final acceptance limits so the operator has margin to react.
4. Material System and Compounding for Large-Diameter HDPE Pipes
중공벽 와인딩 파이프의 성능은 수지에서 시작됩니다. 이 용도에 적합한 표준 재료 등급은 HDPE PE80과 HDPE PE100입니다. PE100은 더 높은 스트레스 균열 저항성을 제공하며 동일한 압력 또는 강성 등급을 위해 더 얇고 가벼운 구조를 가능하게 하므로 대형 직경의 경우 선호됩니다. 주요 재료 매개변수는 용해 유동률, 밀도, 산화 저항력 및 탄소 블랙 함량입니다.
| 재질 | PE80 Typical | PE100 Typical | Test Condition / Note |
|---|---|---|---|
| 녹는 유동성 (MFR) | 0.2 to 0.5 g/10min | 0.2 to 0.5 g/10min | 190 degrees C, 5 kg load |
| 밀도 | 0.950 to 0.960 g/cm³ | 0.950 to 0.960 g/cm³ | ISO 1183 method |
| 산화 유도 시간 (OIT) | Not less than 20 min | Not less than 20 min | At 200 degrees C |
| 탄소 블랙 함량 | 2.0에서 2.5% | 2.0에서 2.5% | For weather resistance |
| 탄소 흑연 분산제 | Grade 1 to 3 | Grade 1 to 3 | Microscopic rating |
The antioxidant package is what delivers the fifty-year life. The oxidation induction time, measured at 200 degrees C, must stay above twenty minutes; a lower value signals insufficient stabilizer and predicts premature brittlement in the ground. Carbon black at 2.0에서 2.5% protects the polymer from ultraviolet degradation during above-ground storage and handling, and its dispersion grade matters as much as the quantity because poorly dispersed agglomerates become crack-initiation points.
Recycled content is permitted but must be placed carefully. The structural layer of a hollow wall pipe can incorporate 20 to 30 percent of properly cleaned regrind without a major loss of ring stiffness, because the structural duty is dominated by geometry rather than by absolute resin strength. The inner liner, however, should use full virgin material so the flow surface is smooth, clean, and free of contaminants that could harbor bacteria or leach odor. This split approach is the most cost-effective way to meet both performance and sustainability targets.
Compounding discipline is the practical lesson. Regrind must be dry, free of foreign polymer, and metered consistently; a fluctuating regrind ratio changes melt behavior and shows up as wall-thickness variation at the die. Faygo lines integrate gravimetric or loss-in-weight feeding so the regrind percentage is held constant pipe after pipe.
5. Standards and Acceptance 사양
Large-diameter structured-wall drainage pipe is governed by a stack of national and international standards. In China the governing product standard is GB/T 19472.2 for HDPE winding structured-wall pipes. 국제 표준ly, ISO 21138, EN 13476, and ASTM F894 define equivalent structured-wall pipe requirements. The performance tests referenced across these standards include ring stiffness per ISO 9969, impact resistance per ISO 3127, creep ratio per ISO 9967, oven test for dimensional stability, weld peel test, and water or air tightness test.
Acceptance is not a single number but a set of coordinated limits. The following table lists the principal acceptance items and their reference targets for a flood-control grade pipe.
| Acceptance Item | 참조 표준 | Typical Acceptance Limit |
|---|---|---|
| 링 강성 | ISO 9969 | 맨드렐의 기울기 및 동심성. 30미터 길이와 3미터 직경의 맨드렐은 큰 회전 질량입니다. 자체 무게와 윈딩 하중으로 인해 맨드렐은 구부러질 수 있으며, 결과적으로 원형이 아닌 파이프가 만들어집니다. 대책: 중간 지지 구조로 강화된 맨드렐, 정밀한 베어링 정렬, 그리고 동심성을 검증하기 위한 변형 가능한 지름 메커니즘입니다. |
| 충격 저항성 | ISO 3127 | No crack at specified drop energy, 0 degrees C |
| Creep ratio | ISO 9967 | Not more than 4.0 (long-term load) |
| 오븐 테스트 | Relevant product standard | No delamination, wall remains bonded |
| Weld peel strength | Internal method per standard | Not less than 90 percent of parent material |
| Water tightness | Closed water / closed air test | No leakage at test pressure |
| Ovality after demold | Internal control | Within specified tolerance for diameter |
The closed water or closed air test is the field-level proof that joints and wall are continuous. For deep-tunnel service, specifying SN12.5 or SN16 plus a verified weld strength is the difference between a pipe that survives forty meters of cover and one that ovalizes and fails. Faygo configures each line so that these acceptance items can be measured on the production floor, not only in a remote laboratory.
6. Engineering Application and Buried Installation
The hollow wall winding pipe serves a wide range of municipal and industrial duties: deep tunnel drainage mains, stormwater storage tank connections, municipal rain and sewage separation networks, pump station inlet and outlet lines, river channel regulation works, sponge-city infiltration and drainage systems, and industrial wastewater outfalls. The common thread is large flow volume, aggressive chemistry, and the need for a long, maintenance-free life.
Buried performance depends on the interaction between pipe stiffness, burial depth, trench width, and backfill quality. A stiffer pipe tolerates more cover and heavier traffic; a well-compacted, correctly graded backfill spreads the load so the pipe sees closer to the ideal uniform pressure. The following table gives a planning-level mapping of service condition to recommended ring stiffness grade and backfill requirement. These are starting points; a qualified engineer must confirm against local soil and traffic data.
| Service Condition | Recommended SN Grade | Burial Depth | Backfill Requirement |
|---|---|---|---|
| Shallow stormwater, light cover | SN4 to SN8 | 1 to 3 m | Graded, compacted to 90 percent |
| Municipal trunk sewer | SN8 | 3 ~ 6m | Graded, compacted to 95 percent |
| Deep trunk, heavy traffic | SN12.5 | 6 to 12 m | Controlled granular, 95 percent minimum |
| Deep drainage tunnel (30 to 60 m) | SN16 | 30 to 60 m | Engineered placement, monitored compaction |
| Industrial wastewater outfall | SN8 to SN12.5 | 2 to 8 m | Chemically inert backfill where required |
Trench width and backfill particle size also matter. A narrow trench concentrates load on the pipe crown, while an overly wide trench increases earth load. Backfill particle size should be free of sharp rocks that could puncture the wall, and the compaction level should reach at least 95 percent in the critical zone around the pipe. The pipe’s flexibility is an advantage here: a correctly installed flexible pipe deflects slightly and engages the surrounding soil in shared load carrying, which is exactly the behavior the ring stiffness grade is designed to support.
7. Special Challenges of Super-Large Diameter and 방지 조치s
Scaling a winding line from DN800 to DN3000 introduces problems that do not exist at smaller sizes. Each must be anticipated in the machine design and in the commissioning plan.
맨들 기울기 및 동심성. 30미터 길이와 3미터 직경의 맨들은 큰 회전 질량이므로, 자체 무게와 감기 부하의 영향으로 파이프가 완전히 원형이 되지 않을 수 있습니다. 대책: 중간 지지 구조를 갖춘 단단한 맨들 구조, 정밀한 베어링 정렬, 그리고 전체 범위에서 동심성을 검증하는 가변 직경 메커니즘을 사용합니다.
비균일한 냉각 수축으로 인해 난형도가 발생합니다. 두꺼운 감긴 벽은 외부에서 내부로 냉각되며, 외부 표면이 먼저 굳어지면서 내부 재료가 수축할 때까지 섹션을 원형에서 벗어나게 할 수 있습니다. 대책: 내부 온도 관리를 통한 제어된 구역별 냉각과 형상 롤이 올바른 형상을 유지할 때까지 지연시키는 것, 그리고 데몰드하기 전에 난형도 검사를 실시하는 것입니다.
대구경 용접 품질 관리. 큰 파이프에서는 용접 이음새가 길고 열 역사가 더 다양하기 때문에 냉각되거나 약한 용접이 발생할 위험이 커집니다. 대책: 모든 회전부에서 적외선 용접 온도 모니터링, 범위 밖의 이음새를 자동으로 거부하고 생산 일정에 주기적으로 이음새 피어 테스트를 포함하는 것입니다.
Long-distance transport. A DN2000 or larger pipe is too large to ship as a single long piece, so it is produced in shorter segments and joined on site. 방지 조치: design the line for clean, standardized socket ends and supply matching electrofusion or clamp jointing systems so field assembly is repeatable.
Hoisting and lowering. A large structured-wall pipe, though light for its diameter, still demands careful slinging to avoid point loads that dent the wall. 방지 조치: supply dedicated lifting bands and handling procedure documentation with each line, and engineer the wall to tolerate the specified lift points.
Single-piece weight and production节拍. As diameter grows, each meter of pipe weighs more and the winding cycle lengthens, so line throughput in meters per day falls even when extruder output is constant. 방지 조치: balance the extruder size, mandrel speed, and strip width so the bottle neck is managed, and select the configuration that matches the target annual output rather than the maximum possible diameter.
8. Hollow Wall Winding Pipe 생산을 위한 Faygo 실제 기계 모듈
Faygo, Wanplas 공장, builds the complete machinery to manufacture these pipes. The two modules below are drawn from Faygo’s pipe extrusion product family, which covers PE, PVC, and PP pipe from 12 mm up to 575 mm in the standard series and extends to super-large diameters through the hollow wall winding configuration. Both modules are CE and ISO certified and are delivered after 72시간 연속 작동 testing.
8.1 Faygo 대구경 HDPE 중공벽 와인딩 파이프 압출 라인
이 모듈은 DN800~DN3000 중공벽 감기 파이프의 핵심 기계입니다. 대형 단일 스크류 주조기와 변형 가능한 직경의 회전식 맨드렐, 동기화된 핫멜트 용접 캐리어가 결합되어 있습니다. 깊은 터널 배수 본선과 대형 도시용 폭우 배수망에 사용되는 구성입니다.
| 사양 | Faygo 감기 라인 (표준 대구경 구성) |
|---|---|
| 적용 가능한 파이프 직경 (DN) | DN800 to DN2000, expandable to DN3000 |
| Achievable ring stiffness grade | SN2 / SN4 / SN8 / SN12.5 / SN16 |
| 주 압출기 | Single-screw φ120 mm, L/D 33, HDPE barrier screw with mixing head |
| Throughput | 800 to 1500 kg/h |
| 보조 압출기 | Single-screw φ65 mm for liner and weld bead |
| Mandrel rotation speed | 0.5 to 4 rpm, variable-diameter DN800 to DN3000 |
| 설치된 전력 | Approx. 210 kW |
| Line length and footprint | Approx. 32 m by 6 m |
| 제어 시스템 | PLC with HMI, recipe management, remote monitoring |
8.2 Faygo HDPE 파이프 압출 라인 (시정용 수 및 배수구 시리즈)
이 모듈은 Faygos가 설치한 파이프 압출 라인으로, 수도 공급, 배수, 가스, 통신 및 농업 관개 용도로 중간 직경 범위를 커버합니다. 프로젝트가 트렁크용 대형 와인딩 파이프와 라인 및 연결용 기존 HDPE 파이프가 모두 필요할 때 보완적인 기계입니다. 핵심 장비 시리즈는 PE, PVC 및 PP의 12mm에서 575mm 직경에 최대 6.5mm 두께의 파이프를 처리합니다.
| 사양 | Faygo HDPE 파이프 압출 라인 (Medium-Diameter Series) |
|---|---|
| 적용 가능한 파이프 직경 (DN) | DN110~DN575 (단벽 및 구조화된 중간 직경) |
| Achievable ring stiffness grade | SN4 / SN8 / SN12.5 / SN16 (structured configurations) |
| 주 압출기 | Single-screw φ90 to φ120 mm, L/D 33 to 36, HDPE barrier screw |
| Throughput | 500 ~ 1200 kg/h |
| Materials | PE / PVC / PP, wall thickness up to 6.5 mm |
| Line speed control | 폐기물 수송 동기화 및 주조기 |
| 설치된 전력 | Approx. 160 kW |
| Line length and footprint | Approx. 28 m by 4 m |
| 제어 시스템 | PLC with HMI, recipe management, remote monitoring |
두 모듈 모두 Faygo의 지능형 제어 플랫폼을 사용하며, 이를 통해 운영자가 자유롭게 매개변수를 설정하고 실시간으로 조정할 수 있으며, 국제적으로 유명한 전기 부품 브랜드를 사용해 신뢰성을 확보했습니다. 프로젝트가 깊은 터널 본선과 배수망을 결합하는 경우, Wanplas는 설계 원천에서 감기 라인과 중간 직경 라인을 맞춤 구성하여 제공할 수 있습니다.
9. Requirement to Model Selection Recommendation
Choosing the right configuration starts from three variables: the pipe diameter range, the required ring stiffness grade, and the target annual output. The table below maps common project profiles to a recommended Faygo configuration.
| 직경 범위 | 링 강성 요구 사항 | Target Annual Output | Recommended Faygo 구성 |
|---|---|---|---|
| DN800 to DN1200 | SN8 | Up to 30,000 m/year | Winding line, φ120 mm main extruder |
| DN1200 to DN2000 | SN12.5 | 30,000 to 50,000 m/year | Winding line, φ150 mm main extruder |
| DN2000 to DN3000 | SN16 | 20,000 m/year and above | Winding line, heavy mandrel, φ150 mm plus auxiliary |
| DN110 to DN575 | SN8 to SN16 | 50,000 m/year and above | HDPE 파이프 압출 라인, medium-diameter series |
| Mixed trunk and laterals | SN8 to SN16 | Project-dependent | Winding line plus medium-diameter line from Wanplas |
The selection logic is straightforward. Match the extruder size to the required throughput, match the mandrel range to the diameter, and match the wall-tooling cavity to the stiffness grade. Over-specifying wastes capital; under-specifying forces the line to run beyond its design pace and degrades weld quality. Faygo engineers review the project’s diameter mix and output target before finalizing the configuration so the delivered line sits at the right point on this table.
10. Common Quality Defects and 방지 조치s
Even a well-designed line produces defects if parameters drift. The table below lists the typical failures in hollow wall winding pipe production and the corrective action for each.
| 결함 | 가능한 원인 | 방지 조치 |
|---|---|---|
| Weld virtual weld or cracking | Weld temperature below range, insufficient pressure | Raise weld zone to 210 to 240 degrees C, increase pressure wheel force, verify with peel test |
| 링 강성 below grade | Wrong cavity geometry, thin wall, weak weld | Recalibrate profile die, increase wall height, confirm weld continuity |
| Ovality exceeds limit | Uneven cooling, mandrel deflection | Balance zoned cooling, check mandrel support and alignment |
| 내부 벽 붕괴 | Liner under-extruded or vacuum loss | Raise auxiliary extruder output, restore vacuum sizing |
| 구멍 변형 | Profile die imbalance, over-pressure at die lip | Rebalance flow channel, adjust die lip symmetrically |
| 불균일한 벽 두께 | 녹는 압력 swing, unstable screw feed | Stabilize barrel temperature, check barrier screw and feeding |
| Surface weld line mark | Poor fusion at strip edge, contamination | Clean strip edge, optimize weld temperature and lap |
| 크리에트가 제한치를 초과합니다. | Material below grade, excessive regrind | Use certified PE100, reduce regrind in structural layer |
Most of these defects trace back to three root causes: unstable melt, mis-set weld, and uneven cooling. The on-line inspection package described earlier exists to catch the first two before the pipe leaves the mandrel, which is far cheaper than rejecting a finished length.
11. Service Support and How to Start Your Project
Buying a super-large winding line is the start of a long production relationship, and Faygo, Wanplas 공장, structures its support around that reality. Every line is run through 72시간 연속 작동 testing before shipment, so the customer receives a machine that has already proven its pace. 설치 및 시운전 are handled by Faygo engineers who set the line to the customer’s specific pipe program and train the local team on operation and maintenance.
The spare parts policy follows the Wanplas group commitment: USD 500 free parts every year, plus warranty replacement for damaged parts within the warranty period. Remote operation and maintenance support lets Faygo engineers read the PLC data and diagnose issues without waiting for a site visit, which keeps downtime short. Training covers not only machine operation but also the process knowledge needed to hold ring stiffness and weld quality across diameter changes.
Faygo also offers factory consulting services that extend beyond the machine itself: water and electricity design, 3D workshop layout, worker configuration and training, and support for new factory construction or capacity expansion. The open-factory policy welcomes customers to visit the Zhangjiagang facility, see the 26,650 square meter FAYGOPLAST plant, and witness a line running before placing an order.
먼저 프로젝트의 파이프 직경 범위, 요구되는 링 강성 등급, 목표 연간 생산량 및 설치 방법을 보내주십시오. Faygo는 맞춤 구성과 시운전 샘플을 준비하여 파이프가 수주 시 요구 사항을 충족하는지 확인할 수 있도록 해줍니다.
12. 자주 묻는 질문
What diameter can a hollow wall winding pipe machine produce?
A properly configured winding line covers from roughly DN800 up to DN3000 and beyond. The upper limit is set by the mandrel size and floor space rather than by die tooling, which is why winding technology reaches diameters that solid-wall extrusion cannot. Faygo’s large-diameter module is specified for DN800 to DN2000 as standard and expands to DN3000 with the heavy mandrel configuration.
Why is HDPE chosen over concrete or steel for deep drainage tunnels?
HDPE는 배수 및 저장 물에서 발견되는 pH 2에서 pH 12 범위 전반에 걸쳐 화학적으로 무해하므로 콘크리트 및 강철의 수명에 영향을 미치는 부식을 겪지 않습니다. 낮은 질량으로 인해 인양 및 트렌치리스 설치가 간단하며 유연한 결합은 지반 이동을 허용합니다. 검증된 SN16 등급과 용접된 벽을 갖추고 있어 내부 라이닝이나 음극 보호 없이도 50년 설계 수명을 충족합니다.
How is ring stiffness controlled on a winding line?
링 강성 is controlled by the height of the structural wall, the shape of the cavities, the number of cavities, and the quality of the weld between turns. The production machine sets these through the profile die geometry and the welding parameters. Because ring stiffness scales with the wall’s second moment of area and falls with the cube of diameter, the winding structure’s optimized geometry is what makes a large diameter achievable at practical mass.
재활용 자재를 이 파이프에 사용할 수 있습니까?
Yes, within limits. The structural layer can incorporate 20 to 30 percent properly cleaned regrind because the structural duty is dominated by geometry. The inner liner should remain full virgin material to keep the flow surface clean and smooth. Faygo lines use gravimetric feeding to hold the regrind ratio constant so melt behavior stays consistent pipe after pipe.
What standards apply to hollow wall winding drainage pipe?
The principal standards are GB/T 19472.2 in China, with ISO 21138, EN 13476, and ASTM F894 covering international equivalents. Performance is verified by ring stiffness per ISO 9969, impact per ISO 3127, creep ratio per ISO 9967, oven test, weld peel test, and a closed water or closed air tightness test. Acceptance targets should be specified per project together with the required SN grade.
What is the difference between hollow wall winding pipe and double-wall corrugated pipe?
Both are structured-wall pipes, but corrugated pipe is formed by a continuous corrugator with a fixed maximum diameter, typically up to DN1200. Hollow wall winding pipe is built by helically winding a hollow profile on a mandrel, which removes the diameter ceiling and reaches DN3000. Winding pipe also gives higher ring stiffness efficiency per unit mass, making it the preferred choice for deep trunk and tunnel service.
How does Faygo verify weld quality on a large-diameter pipe?
The line monitors weld-zone temperature with infrared sensors on every turn and automatically flags or rejects seams outside the 210 to 240 degrees C window. Periodic peel tests confirm the weld reaches at least 90 percent of parent material strength. Because a weak weld collapses the section’s effective second moment of area, weld verification is treated as a line-stop condition rather than a sampling check.
결론
Super-large HDPE hollow wall winding pipe is the enabling technology for modern urban flood control and deep drainage tunnels, where diameters up to DN3000, ring stiffness up to SN16, fifty-year life, and resistance across the full pH range are non-negotiable. The production machine that makes this pipe is a synchronized sequence of extrusion, profile die, variable-diameter rotating mandrel, hot-melt welding, shaping, cutting, and on-line inspection, each tuned so the hollow wall delivers maximum stiffness per unit of polymer.
Faygo, Wanplas 공장 with 22 years of pipe and profile extrusion experience, supplies the complete winding line and the complementary medium-diameter HDPE pipe line, both CE and ISO certified and tested for 72 hours before shipment. From material compounding through acceptance testing to installation, commissioning, and the USD 500 annual free parts policy, the support covers the full production life. If your project calls for DN800 to DN3000 flood-control or deep-tunnel pipe, send your diameter range, stiffness grade, output target, and installation method, and Faygo will configure a line and run a sample trial so you can verify the result before you commit.
