Sapsons Electric Tube Expansion Systems are industrial-grade, advanced, fully automatic solid-state devices designed for precision tube rolling in boilers, heat exchangers, and condensers. The system features digital torque control, automatic shut-off/reverse, and, in some models, an auto-repeat cycle to prevent over-rolling and ensure maximum tightness without damaging tube sheets.
Main Components of Electric Tube Expansion System
• Electric Motor
The electric motor provides the power required to rotate the tube expander. It ensures smooth and continuous operation during the tube expansion process.
• Tube Expander
The tube expander is the main working tool that expands the tube inside the tube sheet hole. It consists of rollers and a mandrel which press the tube outward to create a tight joint.
• Flexible Shaft / Drive Unit
The flexible shaft connects the electric motor to the tube expander. It helps transmit the rotational power and allows the operator to work easily in different positions.
• Torque Control Unit
The torque control unit helps to control and limit the torque applied during expansion. This prevents over-expansion or damage to the tube and tube sheet.
• Control Panel / Switch
The control panel is used to start, stop, and control the speed of the motor. It allows the operator to operate the system safely and efficiently.
• Power Supply Unit
The power supply unit provides the necessary electrical power required for the operation of the system. It ensures stable and continuous functioning during the tube expansion process.
Key Features and Benefits
• Automatic Operation: The system automatically reverses after reaching the preset torque, ensuring consistent, high-quality tube expansion.
• Digital Control Panel: Allows for precise setting of torque, speed, and timing.
• Advanced Protection: In-built features protect the motor from overloading and short circuits.
• Versatility: Suitable for various applications, with specialized models for small diameter tubes (1/4' to 3/8' OD) and heavy-duty, large-diameter tubes.
• Optional Features: Available with foot or hand operation, and LED indicators for monitoring the process.
• Components: The system includes the drive unit, an electronic control panel, and optional accessories like torsion-controlled, self-feeding expanders.
Technical Specifications
• Voltage: Designed to operate efficiently between 180 and 270 volts.
• Torque: Electronically controlled via a digital display.
• Safety: Uses low voltage (24V) for the control circuit, ensuring safe operation.
• Modes: Single-cycle (Forward-Trip-Reverse) and Auto-repeat modes are available.
• Indicators: LED indicators for monitoring forward, reverse, and trip conditions.
These systems are designed for high productivity, allowing for rapid, accurate expansion and reducing operator fatigue.
Applications
• Used in boiler manufacturing and maintenance.
• Used for expanding tubes in heat exchangers and condensers.
• Used in power plants, refineries, and chemical industries.
• Helps in tube installation and repair work.
Advantages
• Provides accurate and uniform tube expansion.
• Saves time and labor compared to manual methods.
• Easy torque control for proper expansion.
• Produces strong and leak-proof joints.
Important Points
• Proper torque setting is necessary to avoid over-expansion.
• Suitable for high-volume tube expansion work.
• Improves efficiency and productivity in industrial applications.
