ELECTRIC TUBE EXPANSION SYSTEM

SAPSONS Electric Tube Expansion Systems

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: Provides the power required to rotate the tube expander. It ensures smooth and continuous operation during the tube expansion process.

  • Tube Expander: 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: 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: 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: 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: 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

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