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EQUIPMENT FOR BEAD WIRE PRODUCTION

 

BRONZED BEAD WIRE CONTINUOUS PRODUCTION LINE

bead wire bronzing line

Bronzed bead wire continuous production line used for the production of chemically hardened bronzed bead wire.


Production process of bronze bead wire

wire unwinding
device
wire straightening
device
wires separating
device
lead hardening
furnace
wires separating
device
water cooling
reservoir
acidic electrochemical
etching reservoir
3-stage water
washing reservoir
tin bronze
bronzing reservoir
3-stage water
washing reservoir
weak alkali
etching reservoir
3-stage water
washing reservoir
hot water
rinsing reservoir
drying
device
reservoir
for plating
wires separating
device
wire winding
device



Technical description of bronzed bead wire continuous production line

The raw material to be processed high carbon steel wire (carbon content of 0.65 ~ 0.84%)
Steel Wire Diameter Ø0.76 - 2.00 mm
Max. processed wire tension force: 2450 Н/mm2
Working time 7920 hours/year
DV value 400 mm × m/min
Pitch between the wires 30×7 + 130 + 30×7 mm (apply the structure of the wire 8 + 8)
The number of wires to be processed 16 wires
Electrical power Three Phase, 380V, 50Hz
The height of the steel wire feeding into the reservoir 1750 mm
Steel wire feeding mode direct (except for hardening reservoir)
Water flushing mode ladder mode - re-use, drain at the end of the wire input.
Equipment location mode operating reservoir is located above the reservoir for liquid storing, up and down liquid recirculation device, no underground constructions.
Method of determination / concentration control Manual detection, automatic dosage.
Method of monitoring/temperature control
  1. Reservoir for lead bath hardening: automatic temperature control, digital display
  2. Acid electrochemical etching: automatic temperature control, digital display
  3. Chemical bronzing: automatic temperature control, digital display. Hot water: automatic temperature control, digital display
  4. Drying: automatic temperature control, digital display



The composition of the equipment of the bead wire bronzing line

Unwinding device
Type Bobbin-type DIN800
Bobbin position horizontal
Clamp method Vertical pneumatic clamp
Steel wire tension control Manual tension adjustment with concentrated cooling air supply to the regulating position, 8 wire positions per group.
Braking device Braking clamp with air cylinder to ensure stable efficiency of the brake disc. It is equipped with system stopping device.
Straightener device Straightener platform is installed in front of the reservoir for lead bath hardening, each wire is completed with 2 groups of 5 + 4 straighteners.
Method of unwinding devices placing Use 16 sets of unwinding devices and arrange them in a row. 
Winding device
Type Bobbin-type TS762
Bobbin position horizontal
Clamp method Vertical pneumatic clamp
Braking device Braking clamp with air cylinder to ensure stable efficiency of the brake disc;
It is equipped with system stopping device.
Requirements for the quality of wires winding Tight wire winding, final surface of the wound wire is even, bobbin height is 285-295 mm (height of the core 280 + 1 mm).
Tensioning drum 410 mm working diameter, "V"–shaped tray-type chase;
its surface is resistant to runout high-hardness, 3 years service life, the speed of each device is individually controlled.
Tension drum management
  1. AC inverter;
  2. self-cooled electric drive with AC inverter motor does not require separate air cooling.
Winding device management
  1. electric drive with AC inverter, electric drive is cooled by cooling concentrated group, every 8 wires for group.
  2. AC inverter
  3. wire placing device:
    • system: "ring-sharp" type timing belt with pneumatic clamp;
    • drive: synchronous electric drive of winding device;
    • transmission: synchronous, belt and geared;
    • laying pitch: 14mm.
  4. before winding unit mounted rocker arm device stacking wire vertical-horizontal combination of the 5 + 4 rectifiers;
  5. winding device 16 includes blocks arranged in one row.
Lead hardening furnace

Length of 8.8 meters, is made of steel plates. The furnace and a lead tray lined with insulating brick, the gap between the lead tray and thermally insulating bricks filled with cotton wool. As press to force the wires into the lead wire tray steel pipe is used.

Heating System: internal heating
Heating source electricity
Heating power 432 kW
  • Installed capacity of heating provides simultaneous heating up to temperature of 16 1.6mm diameter wire.
  • Hardening lead pallet is divided into three heating zones, the temperature of each zone is individually monitored by the power control, the accuracy of adjustment of temperature: ±2°C.
Water cooling reservoir after hardening lead reservoir
Reservoir length 2.4 m
Reservoir body material 3mm stainless steel 304; Upper and lower stainless steel reservoir, that garantees no corrosion.
Temperature normal temperature
The method of recycling through thermo anticorrosive centrifugal pump.
In place where steel wire comes from water reservoir low pressure blower is installed.
Reservoir for acid electrochemical etching
Reservoir length 11.3 m
Reservoir body material reinforced polyurethane
Temperature 50°C (the temperature of inlet cooling water is less than 29°C)
Display function of the water level detection and alerting.
Automatic temperature control, digital display, cooling method plate-type heat exchanger (steel 316L, warranty for 2 years).
Anticorrosive pump 2 pcs., one operating, one auxiliary.

The design of acid electrochemical etching reservoir must guarantee that there is no contact between anode and cathode in acid solution, the width and the amount of lead pole plates must satisfy the requirements of acid electrochemical etching effect (after etching wire surface should not have passivation black film, wire must be original steel color ), lead alloy pole plate is installed inside the upper operating reservoir.

Wire positions 1 ~ 8 - 9 ~ 16 are equipped with separate rectifier of 1500A current, 18V voltage.

Digital display for voltage and current, the display is equipped with RS485 interface.

  • Adding and draining of the acid solution is carried out automatically by the PLC.
  • In a place where steel wire comes out of water reservoir low pressure blower is installed.
  • Above the reservoir ventilation system should be installed, the customer must supply the acid vapors cleaning system.
3- leveled reservoir for washing with water after acid etching
3-leveled reservoir for washing with water after alkaline etching
3- leveled reservoir for washing with water after chemical bronzing
Reservoir length 1.5 m
Reservoir material reinforced polyurethane
Temperature normal temperature
Circulation form heat resistant anticorrosive centrifugal pump, in the third stage of water washing is protected by low water level.
Anticorrosive centrifugal pump 3 pcs., the power of each pump 1.1kW

At the third level a spray of pure water is used, spray water flows into the storage reservoir of the second level, at the second level of washing a circulation pump is used for spray washing, spray water flows into the reservoir of the first level, at the first level of washing circulation pump is used for spray washing , after spraying water is drained.

Reservoirs for chemical tin bronze bronzing
Reservoir length 13.7 m
Reservoir material reinforced polyurethane
Temperature 30 - 40°C operating temperature, +2°C control accuracy, automatic temperature control, digital display, has temperature display function, detection and alerting, managing tool is equipped with RS485 interface.
Heating method electric heating
Circulation method 2 corrosion-resistant heat-resistant suction pumps for special purposes (wire positions 1 ~ 8. 9 ~ 16 are equipped with separate pump).
Filtering mechanism 1 pcs
  • Adding and draining of the acid solution is carried out automatically by the PLC.
  • In a place where steel wire comes out of water reservoir low pressure blower is installed.
  • It equipped with a ventilation system for acid fumes.
Reservoir for etching with weak alkaline
Reservoir length 2.0 m
Reservoir material the lower part of impounding reservoir and the upper part of the operating reservoir are made of reinforced polyurethane.
The form of circulation It equipped with a corrosion-resistant circulation pump.
Display function of the water level detection and alerting.
  • pH value control of the alkaline solution is provided.
  • In a place where steel wire comes out of a water tank installed low pressure blower.
  • Equipped with a flap lid.
Reservoir for washing with hot water
Reservoir length 3.4 m
Reservoir material 3 mm steel 304.
Hot flushing water temperature >75°C, control accuracy of ±5°C, automatic temperature control, digital display, has temperature display function, detection and alerting, managing tool is equipped with RS485 interface.
Display function of the water level detection and alerting.
Circulation method corrosion-resistant heat-resistant suction pump for special purposes.
Heating method heating from stainless steel coil to provide stable temperature.
  • Hot water is supplied automatically, the reservoir is equipped with a tube for draining excess water.
  • In a place where steel wire comes out of water reservoir low pressure blower is installed.
Reservoir for drying
Reservoir length 7.0 m
Reservoir material 3 mm steel plate and high-grade steel, a layer of insulating wool acts as a thermal insulator.
Drying temperature 120°C.
Temperature control accuracy ±5°C, automatic temperature control, digital display, has temperature display function, detection and alerting, managing tool is equipped with RS485 interface.
Drying effect After drying, the surface of the steel wires must be dried.
At the inlet low pressure blower is installed.
Plating reservoir
  • Reservoir material - 3 mm stainless steel 304.
  • Temperature: normal temperature.
  • It is equipped with automatic diaphragm pump for automatic feeding, and the device with a hole for manual feed.
  • It provides even wire coating surface.
  • Unit for the antioxidant solution is sealed.
  • Coating composition - material for special purposes.



Accessories

Reservoir for concentrated sulfuric acid storage

  • Reservoir material: reinforced polyurethane.
  • Reservoir Volume: 1 m3
  • Operating method: automatic control with PLC can feed solutions by dosing pump into the reservoir for acid electrochemical etching and copper sulfate reservoir.


Configuration copper sulphate reservoir

  • Reservoir material: reinforced polyurethane.
  • Reservoir Volume: 1 m3
  • Operating method: automatic control with PLC, the configuration reservoir is equipped with preliminary mixing system, feeding of corresponding quantity of fresh water, sulfuric acid, copper sulfate to the configuration reservoir and complete mixing with regular addition of solution to the production line.


Ventilation System

Reservoirs such as a reservoir for acid electrochemical etching and a reservoir for chemical bronzing etc., while operating produce gases that pollute the environment, that’s why ventilation pipes are installed into these reservoirs, providing good working conditions in the workshop, tower for acid fumes cleaning is supplied by the Customer.


Display fault and alarm

  • Feeding device is equipped with wire breakage sensor, feeding control panel for each wire position with press switch for feeding start, feeding indication lamp and stop button.
  • Circulating pump, rectifier, etc. of the production line are equipped with audible and visual alarm; for fault indication of feeding and winding devices display and alarm are provided.
  • Display and change the settings: for feeding and winding devices a display for settings showing and modifying is provided.
  • Device for steel wire length control: 0.1% accuracy, it is equipped with advance full length warning.


Electrical Equipment

  • Class of electrical control cabinet protection: IP54.
  • PLCs manufactured by SIEMENS.
  • Rectifier for electrochemical acid etching from Jiangyin Tianma company, digital display for output voltage and current is equipped with RS485 interface.
  • Winding device is equipped with an electric motor with AC inverter from Wuxi Hengda company, among other things, self-cooling engine, bobbin winding engine is equipped with cooled concentrated group, one group for every 8 wires.
  • The circulation pump is completed with production line equipment from Shanghai Yongan Company, part of the circulation pump, where the liquid passes is made of special corrosion-resistant material.
  • Heat exchanger tube of the production line, a tank for washing with hot water in stainless steel tube heating tank for chemical tin bronze bronzing made of a titanium alloy.
  • Temperature control devices manufactured by OMRON.
  • Inverter manufactured by ABB.
  • Proximity sensor, low-voltage electrical appliances from Schneider company.
  • SIEMENS Color Display.


Security measures

Each operating position of feeding and winding devices is equipped with emergency stop button.



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