Chuck-type spray winding

Qingdao Hongcheng Hong Anti-Corrosion & Insulation Co., Ltd.'s Chuck-Type Spray Wrapping: A Revolutionary Force in Industrial Protection

In the fields of pipeline corrosion protection, composite material molding, and insulated pipe production, the chuck-type spray-winding technology is steadily becoming the industry's mainstream solution thanks to its efficient, precise, and integrated features. By leveraging the precise coordination of mechanical movements, this technology seamlessly integrates the two key processes—coating application and reinforcement material winding—into a single workstation, achieving breakthroughs in both protective layer quality and production efficiency.

Technical Principle: Precision Coordination in a Closed-Loop Process

At the heart of the chuck-type equipment lies a closed-loop process: "rigid fixation → uniform rotation → dynamic spraying → precise winding → intelligent control." Taking the anti-corrosion treatment of large-diameter steel pipes as an example, the equipment features a three-jaw hydraulic chuck mechanism. A hydraulic motor drives an umbrella-shaped gear assembly, enabling the three movable jaws to move radially in perfect synchronization, firmly gripping the inner wall of the steel pipe. This innovative design is not only suitable for large-diameter pipes ranging from DN1400 to DN2000, but also ensures stability during the rotation process—thanks to the combination of a vertical chuck body and a fixed motor assembly—thereby preventing the uneven coating often caused by vibrations in conventional fixtures.

During the rotating phase, the motor drives the chuck body to rotate at a constant speed via chain transmission, causing the steel pipe to spin at several revolutions per minute. At this point, the high-pressure spraying system is activated, and coatings such as polyurethane are atomized through high-pressure nozzles before being evenly applied onto the inner and outer surfaces of the pipe wall. The sprayer moves axially via an electric pushrod, creating a combined trajectory that complements the rotational motion, ensuring the coating thickness variation remains within ±0.1mm. Subsequently, the winding roller, driven by a servo motor, precisely wraps the polyethylene-reinforced tape around the coated surface in layers with a preset pitch. This process utilizes melt-bonding technology to firmly integrate the coating layer with the reinforcing tape, achieving a durable and seamless bond.

Craftsmanship Advantage: A Dual Enhancement of Quality and Efficiency

Compared to the traditional tube-in-tube process, the chuck-type spray winding stands out in terms of closed-cell rate, three-in-one effect, and material controllability. Taking insulation pipe production as an example, the high-pressure spraying process reduces the polyurethane foaming time by 30%, ensuring a more complete reaction and boosting the closed-cell rate to over 98%, thereby cutting heat loss by 15%. In the three-in-one structure, the molten extruded polyethylene outer jacket is directly wrapped around the polyurethane layer at high temperatures, and the mechanical interlocking formed by the rough interface enhances adhesion strength by 40%, significantly surpassing the results achieved with conventional processes involving corona treatment.

In terms of material control, this technology requires the use of pure-grade PE80/PE100 raw pellets and polyurethane composite materials specifically designed for spraying, ensuring that substandard materials are eliminated at the source. A company’s practical implementation demonstrated that, after adopting the chuck-type equipment, the cracking rate at the insulation pipe ends dropped dramatically—from 5% down to just 0.3%, while the issue of polyurethane cross-sectional delamination was completely eradicated. Moreover, the equipment features an intelligent control system that continuously monitors key parameters such as spraying pressure and winding tension, automatically adjusting the process to meet the demands of varying pipe diameters. As a result, single-shift production capacity has doubled compared to conventional methods.

Equipment Innovation: A Comprehensive Upgrade from Structure to Function

Modern chuck-based equipment continues to break new ground in mechanical design and functional integration. For instance, a patented three-jaw hydraulic chuck features a helical ribbed rod transmission system, enabling millimeter-level control of the jaws' radial movement through the precise coordination of a hydraulic pump and motor. Additionally, its vertical chuck body design not only streamlines the clamping process but also eliminates eccentric errors during rotation via a fixed motor mount at the base.

In terms of functional expansion, the equipment integrates a waste liquid recovery system, enabling closed-loop processing of spray-off waste liquid via filter mesh plates and collection bins—achieving environmental performance that meets EU standards. For specially shaped components like bent pipes, some manufacturers have developed an electric rotary table-driven wrapping mechanism. This system combines the coordinated movement of a feeding component and a rotating assembly to seamlessly wrap both curved sections and straight pipe segments, thereby broadening the scope of technical applications.

Application scenarios: Deep penetration across multiple fields

The chuck-type spraying and wrapping technology has been widely applied in the fields of energy, construction, and municipal engineering. In long-distance pipeline projects, this technology extends the service life of anti-corrosion coatings to up to 30 years while reducing maintenance costs by 60%. In the building insulation sector, the spray-wrapped insulation pipes—thanks to their robust three-in-one structural design—are recognized as recommended products for green buildings. Meanwhile, in municipal heating systems, the prefabricated insulated pipes produced by this technology boast a remarkably low heat-loss coefficient of just 0.02 W/(m·K), significantly boosting the efficiency of urban district heating systems.

Notably, the growing demand for small-batch customized production is driving equipment toward greater flexibility. For instance, a manufacturer has introduced a compact circular-line spraying system that integrates dust removal and spot-spray functions, occupying less than 5 square meters of space. This innovative solution enables efficient processing of small items such as handicrafts and wooden products, while maintaining a consistent quality rate of over 98%.

Future Outlook: Dual Drivers of Intelligence and Sustainability

As Industry 4.0 and carbon neutrality goals advance, chuck-based spray-winding technology is evolving toward智能化 (intelligent) and 绿色化 (green) solutions. On one hand, equipment manufacturers are integrating visual recognition systems with AI algorithms to enable real-time detection of coating defects and adaptive adjustments of process parameters. On the other hand, breakthroughs have been made in the research and application of waterborne coatings and bio-based polyurethanes, reducing VOC emissions by up to 90% and driving the industry toward a low-carbon manufacturing transformation.

It is foreseeable that the chuck-type spraying and winding technology will continue to reshape the production paradigm in the industrial protection sector, delivering robust momentum for the high-quality development of pipeline engineering, composite materials, and insulated pipe industries—with its core advantages of precision, efficiency, and environmental friendliness.

Qingdao Huatex Address: No. 36 Shandong Road, Beiguan Industrial Park, Jiaozhou City, Qingdao, Shandong Province
Sales phone: 0532-87286912
Fax: 0532-87286913
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