BEAD WIRE MANUFACTURING
BEAD WIRE PHOSPHATING LINE
Bead Wire Phosphating Process
in lead bath water
water washing hot water
(borax treatment) wire
Bead Wire Phosphating Line Technical Specification
|Processed material||0.70 - 0.85%C|
|Legislation limits of processed steel wire parameters||Ø2.20 - Ø4.00 mm|
|Number of processed steel wires||20 wires|
|Line speed||15 - 27 m/min. (DV=60)|
|Distance between the wires||30 mm|
|Upper Elevation of steel wire movement||950 mm|
|Equipment layout method||processing reservoir located above the storage reservoir of the solution, the solution is circulated upwards and downwards|
|Steel wire moves in the direct mode||Direct movement|
|Determination of the concentration, the control mode||artificial determination supplemented by automatic mode|
|Determination of the temperature control mode||Automatic temperature control, digital display|
|Heating method||steam / electric heating.|
Composition of the bead wire phosphating line
|Horizontal feed bobbin||DIN800 (equipped with 20 sets of feed blocks)|
|Single mass of accumulated wire||1.0 ton|
|Feeding tension can be adjusted by mechanical damping|
|Electrical resistance furnace|
|Preheating phase length||3 m|
|Heating zone length||3.5 m|
|Hardening zone length||10 m|
|Reservoir Heating Power without preheating||150 kW|
|Hardening Reservoir Heating power||200 kW|
|Current Rectifier||1 pcs., 7000A; Voltage: 80V.|
Application of uniform lead temperature for wire austenitizing and conversion of sorbitol structure in the moment the wire is in the lead reservoir to give some technological properties to the wire.
|The frame for wire separation|
It is a sectional steel frame structure, equipped with a single roller guiding device for wire and a column for wire separation, thus ensuring independence of the steel wire, wire direct hit in the cooling water reservoir. Water cooling system guarantees stable and long-term performance of the bearing.
|Heat-resistant lifting pump||1 pcs., power 0.75kW|
|Device for wiping and absorbing liquid||1 set for the simultaneous reduction of the residual liquid entering the subsequent process.|
|Reservoir for chemical acid etching without formation of vapors|
|Type of etching||
Whirlpool systems based on the latest technologies of acid etching has the advantage of washing the wire rod with severtal heads, as well as high efficiency, lower consumption of acid, high environmental performance. Whirlpool multistage system of acid etching, company guarantees the stability and efficiency of the etching.
|Acid etching reservoir length||12 m|
|Working length||7 m|
top of the acid etching reservoir is equipped with a sealing cap made of reinforced PPU material, preventing the release of gas. The sealing cap is fixed to the water reservoir, placed on the upper edge of the reservoir body to form a reliable seal.
using a special spray nozzle mounted in the upper part of the working reservoir to form therein a vortex acid solution. Steel wire is completely immersed in the vortex acidic solution, effectively destroying the border of the reacted acid. Continuous acid can significantly accelerate the etching process, reduce etching time and the depth of immersion. Each stage of vortex etching operates independently, controlling the concentration and temperature of the acid solution in accordance with the process requirements.
highly intelligent control system exposes concentration and temperature of the vortex acid etching solution automatically. Due to the metering pump computer performs periodic replenishment in accordance with the parameter adjusted by technological personnel.
|Method of wire cutting||Method of wire cutting is carried out at the direct-axis working sides of the etching reservoir, its implementation does not cause difficulties.|
|Centrifugal pump||corrosion-resistant, submersible, such pumps are low-maintenance does not require frequent replacement of expensive mechanical sealings, the need for which always occurs working with horizontal pumps.|
|Steel wire wiping and liquid removing device||
One set is installed between each stage of acid etching, which allows to remove the residual liquid from the wire during the manufacturing process. At the output, and between the water reservoir and the acid etching reservoir a device for wiping and removing gas and liquid is used to reduce the amount of residual liquid on a removable wire, which reduces the amount of wastewater.
|Design of the reservoir for chemical acid etching without formation of vapors:||
|Reservoir for multi-stage water washing|
|Number of processed wires||20 pcs|
Water washing is carried out in four stages, and therefore there are 4 independent lifting pumps to perform steel wire washing by landwash. At each stage of washing a device for wiping and removing gas and liquid is installed to minimize carryover of liquid and improve the washing efficiency. In the last stage pure water is added which flows from step to step, causing the overflow of the first stage.
|Reservoir Body Length||2 m|
|Reservoir Body Material||made of reinforced PPU plate|
|Multi-stage water washing reservoir is equipped with:||
Drain pipe of the first stage is connected to the water curtain reservoir to feed it, that’s why the water curtain reservoir recycles waste acid solution and provides the recharge of water to acid etching reservoir, the amount of feedings is automatically adjusted.
|Reservoir for hot water washing|
|Length||1.5 m, the washing water circulates up and down, steel wire stroke is linear.|
made of stainless steel sheet 304. Inside the reservoir the steam heating device is installed with stainless steel pipes for steel wires preheating prior to its entering the phosphatizing reservoir.
to keep warm heat-insulated wool is used that is placed on the body of the reservoir. On top of the reservoir body sealing cover made of stainless steel 304 that opens upward, which facilitates the operation.
|Hot water temperature||≥60°C, the temperature control accuracy ±4°C.|
|Lifting pump||1 pc., Stainless steel, power 0.75.|
|Device for wiping and removing gas and liquid||
1 set, allows the production process to remove residual liquid and prevent it from entering the subsequent process stage.
|Heating temperature is adjusted automatically on a digital display.|
|Heating steam condensation water is used for feeding the reservoir, excess water is drained.|
|Reservoir for phosphatizing|
|Reservoir for phosphatizing length||15 m|
|Reservoir Body||divided into 2 groups, front and back, on front and back parts are mounted two groups of guide rollers to feed the wire to the reservoir.|
|Body material||stainless steel 304|
Inside the reservoir steam heating device with circular tubes of stainless steel is installed to retain heat insulating reservoir body wrapped with cotton, which saves energy. On top of the reservoir body sealing cover made of stainless steel 304 that opens upward, which facilitates the operation.
|Solution temperature control system of the reservoir||
mainly it includes a heating device, a servo valve, an actuator, a temperature sensor, a programmable logic controller, the temperature is controlled automatically by the digital display.
Temperature control accuracy ±3°C.
The surface of the heating device is coated with a special material that reduces slagging, makes the heat more stable and easy to clean.
1 pc., for supplying phosphatizing solution in the automatic mode, the operator only needs to enter the acid concentration or volume parameters into computer that calculates the amount of recharge itself and will automatically adjust the feeding using a metering pump, ensuring process stability.
|Phosphate deposits removal||
deposits removal is held regularly according to the actual condition after use. Before purification solution from the reservoir for phosphatizing is discharged into the solution storage reservoir through an adjustable overflow pipe for removing phosphorus sediment at the bottom of the reservoir to the appropriate amount of water is added and after shaking the solution is discharged into the compartment with gravel through the drain hole, then clean fluid is returned to the reservoir for phosphatizing by self-priming pump, and phosphorus deposits are cleaned by hand.
|3-leveled reservoir for water washing|
|Number of processed wires||36 pcs.|
Water washing is carried out in three stages, that’s why there are 3 independent lifting pump to perform steel wire washing. At each stage of washing a device for wiping and removing gas and liquid is installed to minimize carryover of liquid and improve the washing efficiency. In the last stage pure water is added which flows from stage to stage, causing an overflow to the second stage.The first stage of the water washing is dedicated to the reservoir for recovery of washing liquid and phosphatizing solution, it uses phosphatizing solution water for feeding, the amount of feedings is automatically adjusted.
|Length of hull reservoir||1.5 m|
|Body material||reinforced PPU plate|
|3- tiered reservoir for washing with water is equipped with:||
|Reservoir for neutralization|
|Length||4 m. While neutralizing an appropriate solution circulates upward and downward, wire stroke is linear.|
|Body material||made of 304 stainless steel sheet|
installed inside the reservoir, the steam heating device with circular tubes of stainless steel carries out wire saponification. The body is wrapped with heat-insulated wool to keep warm. On top of the reservoir body sealing cover made of stainless steel 304 that opens upward, which facilitates the operation.
Temperature control system of the solution in the reservoir consists essentially of a heating device, a servo valve, an actuator, a temperature sensor, a programmable logic controller, the temperature is controlled automatically by the digital display. Temperature control accuracy ±3°C.
Reservoir for neutralization is equipped with a stainless steel lifting pump with a capacity of 0.75.
Inside the reservoir body liquid level controller for automatic recharge is installed that provides normal operating level of liquid in the reservoir.
At the output of the reservoir body gas blowing device is installed, which allows to reduce the amount of residual liquid on wires during manufacturing process.
|Reservoir for drying|
|Furnace length||6.0 m|
|Operating method||Direct movement|
|Body material||made of stainless steel sheet, thermal insulation is wrapped around the body to keep warm wool.|
|Source of heating energy||Electricity, power 42 kW|
|Method of drying||hot circulating stream heating|
|Temperature control||automatic, digital display, temperature control accuracy ±5°C|
|In front and back parts guide rollers are installed for feeding the wire in the cabinet.|
|SS800 Tension Unit|
|Tension type||horizontal tension device, frame is made of welded steel construction.|
|Drawing Engine||2.2 kW, AC|
|Tension Engine||3.0 kW, AC|
|Capstan diameter||450 mm|
|Wire laying system||double threaded screw rod|
|Wire laying power||from a group of coils|
|Tension bobbin size||Ø800|
System diagram is shown in figure below, the system consists mainly:
- computer for process control;
- operating panel;
- programmable logic controller;
- acid etching panel (which includes water washing, acid etching, multistage water washing, hot water washing, phosphatizing);
- phosphatizing control panel (consists of phosphatizing solution recovery + water rinsing);
- drying control panel (includes drying and reservoir for neutralization etc.).
Computer control system is used, lower level computer communicates with upper level computer, control is carried out in real time in upper level computer. The system provides the following functions, for example, animated images creating, parameter setting, actual data measurement, real-time graphic, statistics, signaling data, password setting, data searching request, report printing and data saving, etc.
The main components are provided by well-known domestic and international brands, such as:
- Temperature control sensor - OMRON.
- Programmable logic controller and display screen - SIMENS.
- Switch, button, alarm LED - Schneider.
- Control cabinet and Circuit Breaker - CHINT.
- Relays, contactors, etc. - Schneider.
- Acid etching - Super Company.
- Metering pump - OBL, Italy.
- Lifting Pump - Yongan Pump Company.