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BEAD WIRE MANUFACTURING

 

WIRE ROD PREPARATION LINE FOR BEAD WIRE PRODUCTION

wire rod preparation line


Technological process of preparing wire rod for bead wire production

wire rod
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
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
  • Acid etching: automatic temperature control, digital display.
  • Preheating: automatic temperature control, digital display.
  • Plating: automatic temperature control, digital display.
  • Drying: automatic temperature control, digital display.
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).
In preheating and plating reservoirs automatic water addition is used, the liquid level is adjusted.


3. Parameters and description of technological equipment

Pay-off stands
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.
  • Water is fed into the upper working reservoir via circulation pump arranged to jet direction, water supplied to the upper working reservoir, pours back into the circulation reservoir.
  • Gas purification system is installed at the outlet of the reservoir body, it prevents water drops on wires entering the reservoirs of the next processing stage. Gas resource used for gas cleaning, is a stream of medium pressure provided by the Customer (the same way).
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.

  • Upper working tank is installed with a lead plate inside. The polarity of the lead plate for each group of the working tank is arranged as follows: ++ - ++ reservoir is fully equipped with 3 groups of upper working tank.
  • Gas purification system is installed at the outlet of the tank body, preventing water drops on wires entering the reservoirs of the next processing stage.
  • Extract hood is mounted on the tank body, behind the mating flange of the extract hood exit section the Customer will provide a connection to equipment for processing or diversion.
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.
  • Pure water is added to the third block of the storage reservoir, third block rinsing is performed by means of circulating pump jet rinsing.
  • After rinsing water is poured into the second block of the storage reservoir again, at the same time the second block rinsing takes place by means of circulating pump jet rinsing and so on. Then after rinsing water is drained.
  • Gas purification system is installed at the outlet of the tank body, preventing water drops on wires entering the reservoirs of the next processing stage.
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.
  • The reservoir is equipped with a steam heater inside.
  • Heat-insulating wool is used for heat conservation around the tank, preventing heat dissipation.
  • On top of the tank there is a hinged cover, convenient to use.
  • Gas purification system is installed at the outlet of the tank body, preventing water drops on wires entering the reservoirs of the next processing stage.
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.
  • Bath is equipped with a steam heater inside.
  • Heat-insulating wool is used for heat conservation around the tank, preventing heat dissipation.
  • On top of the tank there is a hinged cover, convenient to use.
  • Gas purification system is installed at the outlet of the tank body, preventing water drops on wires entering the reservoirs of the next processing stage.
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
  • Each wired is equipped with two Ø320 mm guide pulleys separating wires, which are installed behind for the drying tank and in front of the drawing machine.
  • Guide pulleys for wire separation located in front of the drawing machine must be at the same level with the first drawing channel of the drawing machine.



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