BEAD WIRE MANUFACTURING
WIRE ROD PREPARATION LINE FOR BEAD WIRE PRODUCTION
Technological process of preparing wire rod for bead wire production
pay-off entangling
wire switch pressure
wash tank electrolytic acid
etching reservoir 3-stage water
washing reservoir water washing reservoir
with preheater wire blank
plating bath wire rod
dryer wire rod
separating
Equipment composition of wire rod preparation line
Line Speed | 120 m/min |
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Wire Rod Diameter | Ø5.50-6.5 mm. |
Carbon Content | 0.7~0.85 %C |
Number of rods for processing | 2 |
Wire rod extension height | 900 mm |
Equipment layout | working tank is located above solution storage tank, the solution is circulated upwards and downwards without underground structures. |
Wire Extension Type | straight through |
Concentration control method | manual detection supplemented by automatic mode |
Temperature control method |
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Type of water washing | Ladder-type, reuse, overflow drain. |
Type of heating | steam / electric heating. |
The length of the production line | about 36 meters (not including the distance from the dryer to the drawing mill). |
3. Parameters and description of technological equipment
Pay-off stands | |
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Type | "Duck neck" |
Productivity | >2.5 ton |
Unwinding supports for each wire | 2 sets (4 sets in total) |
Wire can be replaced without stopping the machine. | |
Entangling wire switch | |
Number of emergency stop switches | 2 pcs |
Purpose | on loss of production line must be protected. |
Entangling wire switch consists of a ring of large diameter fixed on spindle, ring and spindle are joined to the cover perpendicularly. In operation rod passes freely through the ring. However, if the rod is entangled it falls from the unwinding rod support, which makes the ring and spindle move forward, turn off the limit switch, located on the cover, and immediately stop the drawing machine setting the line in motion, in order to avoid wire breakage. | |
Reservoir for water washing under pressure | |
Length | 1.4 m |
Material | PP |
Circulation pump | 1 set with corrosion-resistant coating on 1.1 kW. |
Purpose | removing loose residues on the wire surface in order to reduce residues amount, entering the electrolytic acid etching reservoir that extends the service life of the acid etching solution. |
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Electrolytic acid etching reservoir | |
Length | 8.2 m |
Material | PP |
Rectifier | 2 sets, one set - the circulation pump with corrosion-resistant coating, a second set - plate heat exchanger, it is possible to cool the acid solution, the temperature is displayed in digital form, there is an ability of automatic adjustment. |
Purpose | The reservoir is designed for complete electrolysis acid etching, providing physical and chemical reaction on the wire surface in the electrolytic solution, as well as providing power control of physical and chemical reactions by adjusting the concentration, composition, temperature, current, time and polarity to achieve the removal of oxidation layer from the wire surface. |
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3- leveled reservoir for water washing | |
Length | 2.5 m |
Material | PP |
Circulation pump | 3 sets with corrosion-resistant coating. |
Purpose | complete removal of residual electrolytic solution from the wire surface. |
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Water washing reservoir with preheater | |
Length | 2.0 m |
Material | stainless steel. |
Temperature control | digital display, automatic adjustment accuracy ±4°C, heating temperature >60°C. |
Circulation pump | 1 set, with anti-corrosion coating, designed for high temperatures. |
Water supply | automatic control of the liquid level. |
Purpose | wire preheating before drilling, improving the efficiency of the coating. |
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Plating reservoir | |
Length | 2.4 m |
Material | stainless steel. |
Temperature control | automatic adjustment, digital display, accuracy ±4°C, heating temperature >90°C. |
Circulation pump | 1 set, 1.1 kW, with anti-corrosion coating, designed for high temperatures |
Solution | for plating |
Water supply | automatic control of the liquid level. |
Purpose | solution covers the wire surface, thereby improving the drawing at the next stage. |
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Reservoir for drying | |
Length | 4.0 m |
Material | steel |
Heat energy | electricity |
Thermal Insulation | heat-insulating wool is used for heat conservation around the tank |
Operational Principle | hot flow provides heat circulation. |
Heating temperature | >120°C |
Thermal power | 30 kW |
Purpose | complete removal of water from the wire surface. |
Wire separation | |
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