DONGGUAN WIREMAC MACHINERY EQPT. CO., LTD.

Process Principle and Performance Comparison of Imported and Domestic Copper Drawing Machines

Process Principle and Performance Comparison of Imported and Domestic Copper Drawing Machines   There are some differences in the structure, process principle and performance of imported and domestic RBD copper drawing machines, and each brand of large drawing machines has its own advantages and disadvantages. In this article, the process principle and performance are analyzed and compared with the 2 wires drawing machines of Nihoff in Germany, FRIGECO in Italy and Yongxiong in China, so as to find the basis for the purchase of wire drawing equipment.   Tongling Nonferrous Copper Co., Ltd. is a new high-tech copper processing enterprise. In addition to the SMS continuous casting and rolling production line imported from Germany, which produces 8mm low oxygen bright copper rods, in order to expand the product business model, expand downstream customers and form a complete copper rod and wire industry chain, it needs to be equipped with corresponding RBD copper wire drawing machines to process 8mm low oxygen bright copper rods into copper wires with smaller wire diameters, In order to match the RBD copper wire drawing machine with excellent performance, the company analyzed and compared the domestic and foreign first-class double head German Nihoff, Italian FRIGECO and domestic Yongxiong RBD wire drawing machines, and found a reliable basis for the selection of RBD wire drawing machines.   1. Classification of wire drawing machines   Copper wire drawing machine is a machine that uses the malleability of copper wire and the compression of mold to make its diameter smaller, so as to achieve the size of wire diameter we need. It can be divided into single head, double head and multi-head wire drawing machines according to the number of wire drawing heads at a time; According to the working principle, it can be divided into sliding type and non sliding type; According to the size of incoming wire and outgoing wire, it can be divided into 5 levels: RBD wire drawing machine, Intermediate wire drawing machine, fine wire drawing machine, super fine wire drawing machine and micro wire drawing machine; According to the modulus of copper wire drawing machine, there are 9, 11, 13 and 15 dies; Production process flow of copper wire: 8mm bright copper rod --- paying off --- drawing --- online annealing --- cooling --- drying --- take-up --- warehousing of finished products.   2. Process principle and performance of German Nihoff RBD drawing machine   2.1 Structure and process of Nihoff wire drawing machine   2.1.1 Wire drawing machine: Nihoff wire drawing machine is divided into sliding type and non sliding type, and its characteristics are as follows: ① The pull wire drum is completely immersed in the emulsion - the best cooling and lubrication. ② The drawing die is pressurized and lubricated. ③ Double cover sealed wire drawing machine base - no lubricant leakage(Double sealing system). ④ The casting box adopts a standardized modular structure - no vibration, bright and clean wire surface, and long service life of bearings and gears. ⑤ Wire drawing oil/gear oil sealing system: adopt safe passage and labyrinth seal. 6. Wire drawing die base: divided into standard die base, special die base (closed die base) and rotary sizing die base.   2.1.2 Nihoff RBD drawing annealing device, from the structure of the annealing machine, Nihoff RBD drawing machine is of discrete type and bedroom type; The annealing current can be divided into AC and DC. The structure and process are as follows: ① The wire route through the annealing device is simple, and there is no crossing of the wire route; ② Annealing transformers of different specifications can be combined with existing wire drawing production lines of various models for single wire and double wire production lines. ③ Mature and reliable AC annealing device is adopted. ④ The annealing shall be protected by nitrogen or steam.   2.1.3 Nihoff take-up system, which is divided into coil winding device, single reel take-up device and static reel take-up device. Features of coil winding device: ① Ceramic coating coil forming drum. ② Line pressing claw that can be centrally adjusted by pneumatic valve.   2.1.4 Nihoff MSM 85 motor. Nihoff is driven by water-cooled AC motor, which is more stable than air cooled motor and has lower noise.   3. Process principle and performance of Italian FRIGECO RBD drawing machine   3.1 Structural process of FRIGECO RBD drawing machine   FRIGECO wire drawing machine is mainly non sliding type, which uses independent motor system and has the following characteristics:   3.1.1 Wire drawing machine. ① Variability: The machine uses different surface reduction rates for wire rods of different dimensions to obtain the optimal wire rods and prolong the life of the mold. ② Energy consumption: the minimum sliding can increase the heat and reduce the energy loss due to the friction between the wire rod and the drum. The wire drawing drum behind is directly coupled with the motor, avoiding the use of a gearbox, which can reduce the total energy consumption in some cases. ③ When using fewer drums, the final wire drawing drum can be closed to minimize energy. ④ Wire quality: the sliding of low wire on the drum can significantly improve the wire quality by reducing the wear of wire. ⑤ The drawing die holder is designed to place the drawing die in a high-pressure lubrication space.   3.1.2 FRIGECO continuous annealing device: The structure of FRIGECO annealing device can be divided into vertical and horizontal, and the annealing current is AC annealing. ① The annealed wire is cooled by a high-pressure coolant nozzle. ② After cooling, the wire is dried by a double mold device filled with compressed gas. ③ The annealing shall be protected by nitrogen or steam.   FRIGECO paying off device. ① Automatic loop take-up. ② Single reel take-up. ③ Double reel take-up.   4. Process principle and performance of Yongxiong RBD drawing machine   4.1 Structural process of Yongxiong RBD drawing machine   4.1.2 Wire drawing machine. Yongxiong RBD wire drawing machine is a sliding wire drawing machine with the following characteristics: ① The RBD wire drawing machine adopts full immersion lubrication cooling, powered by two DC motors. ② The speed of the fixed speed wheel motor is adjusted according to the synchronous coefficient of the motor to ensure the tracking coordination between the wire drawing and the fixed speed wheel. ③ The sizing die adopts rotary design to improve the roundness of the finished product line. ④ The gear box of the wire drawing machine can choose to separate the last three drums of the wire drawing machine through a special clutch, so as to reduce the idling phenomenon of the gears in the non working part, improve the service life of the equipment and reduce the noise.   4.1.2 Yongxiong annealing machine. ① The annealing machine adopts the three section contact annealing principle and AC power supply, which is suitable for the continuous annealing production equipment of copper wire. ② The annealing machine adopts vertical and horizontal structure, and is composed of conductive system, anti oxidation protection system, cooling system, drying system, electrical system, etc. ③ The power of the annealing machine comes from the constant speed motor of wire drawing, which is driven by the clutch. When annealing is not used, it can be disengaged by the clutch to reduce mechanical wear and energy consumption. ④ The annealing shall be protected by nitrogen or steam.   4.1.3 Yongxiong take-up machine. Yongxiong take-up machine has coil take-up machine and disc take-up machine. The coiling take-up machine is composed of frame, coiling, wire dropping, wire storage, tray transport mechanism and electrical control system. The take-up machine is driven by DC motor. The wire dropping mechanism adopts eccentric rotation design, which makes the wire form a plum blossom shape, and has the characteristics of high loading density and no entanglement paying off.   5. Process principle and performance comparison of imported and domestic RBD drawing machines   ① Nihoff, Germany: Sliding and non sliding wire drawing machines are used. AC/DC annealing is used for annealing. Double ended annealing with a current of about 10000 amperes. The structural types of annealing machines are vertical and horizontal; Annealing is protected by nitrogen/steam; The take-up methods include reel take-up and coil winding. ② FRIGECO, Italy: The wire drawing is non sliding, and the annealing is AC annealing. The double end annealing current is about 10000 amperes. The structural types of the annealing machine are vertical and horizontal. The annealing is protected by nitrogen or steam; The take-up mode is the moving disc take-up and the looping off. ③ Domestic Yongxiong RBD drawing machine: the sliding type is used for wire drawing, and the AC annealing is used for annealing. The double end annealing current is about 8000 amperes. The structure of the annealing machine is mainly horizontal. The annealing is protected by nitrogen or steam; The take-up methods are disc type and coil type. ④ Compared with FRIGECO in Italy, Nihoff in Germany is an old brand enterprise in the wire drawing industry. Nihoff is very mature in the sliding wire drawing technology. Its technology development on the non sliding wire drawing machine is relatively late, and the technology is still developing. On the annealing current, Nihoff adopts AC and DC. But at present, AC annealing is used better. In terms of after-sales service, Nihoff's after-sales service fees are expensive. FRIGECO developed the non sliding wire drawing technology early, and the technology is relatively mature, but its control is complex. Moreover, FRIGECO is transferred from the steel wire drawing machine, and has no experience in copper wire drawing. From the perspective of production capacity, FRIGECO wire drawing speed is higher than Nihoff wire drawing speed, and the production capacity is correspondingly high. ⑤ Compared with the imported wire drawing machine, the domestic wire drawing machine is only sliding at present, and the take-up mode is only loop winding; In terms of production capacity and technology, there is a big gap between domestic wire drawing machines and imported wire drawing machines.   6. Conclusion   The wire drawing production process is a complex system engineering, involving many links. To produce high-quality products, it is necessary not only to be familiar with the structure and performance of the equipment, but also to have qualified staff, strict raw material procurement procedures and strict testing procedures. According to the actual situation, on the basis of detailed comparative study of the structure and performance of domestic and foreign copper wire drawing machines, the company finally selected the appropriate wire drawing machine equipment.

Common faults of copper wire drawing machine and solutions

Common faults of copper wire drawing machine and solutions   The quality of copper single wire production is an issue of great concern to all cable manufacturers, because the quality and efficiency of wire drawing directly affect the production process of the subsequent process, and also play a decisive role in the quality of the wire. In the production of copper wire drawing machine, it is particularly important to accurately control the outer diameter deviation of the product. Due to the continuous production of copper wire drawing machine, the wire drawing speed will gradually be out of sync with the annealing. During wire drawing, because the traction speed is fast and slow, the wire diameter appears discontinuous and irregular phenomenon of large and small segments. The reasons for this phenomenon during wire drawing are as follows:   1. The tension of the accumulator pulley is unstable. There may be more places where air pressure is used in the production workshop, which may cause the air pressure of the air pump of the wire drawing machine to be higher or lower sometimes, which may cause the deviation of the outer diameter of the monofilament to be unable to be accurately controlled.   2. Annealing wheel copper wire jitters. The copper wire jitter causes it to be annealed when it is loose and tight. The current density of annealing is sometimes larger, sometimes smaller, while the strength of copper wire is relatively low at a higher speed. Therefore, it is easy to ignite the copper wire on the annealing wheel, and the surface of the copper wire is uneven due to the effect of sparks.   3. The wear caused by long-term use of the main motor gearbox makes the speed of the fixed speed wheel of wire drawing not match with the traction speed and take-up speed, thus forming a single wire drawing.   For the above problems, there are the following solutions: provide good lubrication for the accumulator to prevent it from causing reverse friction on the wire during high-speed operation, thus making the wire thinner; Adjust the tension of the wire so that the drawing stroke of the wire is always close to the annealing wheel; Ensure the integrity of the annealing wheel rim and avoid unstable annealing current caused by surface defects of the rim. According to the actual situation of the wire drawing machine, the wire drawing machine is matched again, so that the matching die can meet the requirements.

Debugging and operation technology of copper wire drawing machine

Debugging and operation technology of copper wire drawing machine The quality of copper single wire production: it is a matter of great concern to all cable factories and enterprises. The quality and efficiency of wire drawing directly affect the production process of the next process and play a decisive role in the quality of cables. The following problems often occur in the production of wire drawing machines. I. Accurate control of outer diameter deviation of products Due to the continuous production of copper wire drawing equipment, the wire drawing speed will gradually be out of sync with the annealing. During the wire drawing, the wire diameter will appear discontinuous and irregular large and small sections due to the fast and slow traction speed. The reasons for this phenomenon are as follows:   1. The tension on the wire storage wheel is unstable, and there may be many places where the air pressure is used in the production workshop. This will cause the air pressure of the air pump of the wire drawing machine to increase and decrease, which will make the tension of the wire storage device unstable. Since the speed of wire take-up is constant, the tension on the wire drawing is also non constant, which may cause the deviation of the outer diameter of the monofilament to be unable to be accurately controlled.   2. The jitter of the copper wire on the annealing wheel causes the copper wire to be annealed in a loose and tight state. The current density of the annealed copper wire varies from large to small, while the strength of the copper wire at a high speed is relatively low. Therefore, it is easy to cause the copper wire to strike fire on the annealing wheel, and the surface of the copper wire is uneven due to the effect of sparks.   3. The wear caused by the long-term use of the gear box of the main motor can make the speed of the constant speed wheel of the wire drawing not match the traction speed and the take-up speed, so as to form the single wire drawing.   Solution: Lubricate the wire storage device well to avoid the reverse friction force on the wire during high-speed operation and then make the wire thin; Adjust the tension of the wire so that the stroke of the wire drawing is always close to the annealing wheel: ensure the integrity of the steel ring of the annealing wheel and avoid the unstable annealing current due to the surface defects of the steel ring.   Rematch the wire drawing machine according to the actual situation of the wire drawing machine: adjust according to the wire drawing principle so that the rotation speed of the annealing wheel / the rotation speed of the constant speed wheel = the front slip coefficient x the diameter of the constant speed wheel / the diameter of the annealing wheel, wherein the diameters of the constant speed wheel and the annealing wheel are known, and the rotation speed of the constant speed wheel and the annealing wheel can also be measured, so that the front slip coefficient can be obtained. The wire drawing machine can be re matched with the slip coefficient. In this way, the mold shell can meet the requirements. II. Reasons for surface oxidation of monofilament drawn by wire drawing machine 1. The temperature of the cooling water in the sealing chamber is too high, exceeding 40 ° C, so the sealing chamber cannot achieve the required cooling effect on the monofilament, resulting in the high temperature of the monofilament after annealing, and the monofilament will be oxidized when encountering oxygen in the air at high temperature.   2. The saponification liquid content of the cooling liquid in the sealing chamber is not enough, which will increase the friction force between the monofilament and each guide wheel, and then increase the monofilament temperature again, resulting in the oxidation of the monofilament surface.   3. The water pressure and quantity of the cooling water in the sealing chamber are insufficient, which makes the monofilament unable to achieve a satisfactory cooling effect.   Solution: regularly check whether the equipment for cooling circulating water operates normally and whether the cooling effect is normal; Add substances that can improve the concentration of saponification liquid in the sealed chamber at certain intervals, so as to change the star content of saponification liquid in the cooling water and ensure the normal operation of monofilament on the guide wheel; Regularly check whether the water pressure of circulating water is normal, and constantly change the pressure and water volume of cooling water entering the sealing chamber according to the change of water pressure during production. III. Reasons for frequent wire breaking in wire drawing 1. In the continuous production of the drawing die, the sizing area of the drawing die will become larger due to the constant wear.   2. Quality problems of various rod materials. In the production process, the rod materials appear quality defects irregularly, which causes the monofilament to be broken by various unpredictable tension during the drawing deformation. This situation rarely occurs when the rod material is good.   3. During production, the annealing current is not constant, and the current is suddenly high, and the single wire is pulled off or fused by sudden strong current during annealing.   Solution: before production, the copper rod shall be fully self inspected to find out the quality defects of the copper rod in time, and find corresponding countermeasures according to different conditions, or reduce the wire drawing speed, or eliminate the defects in this section. During production, continuously observe whether the annealing current of wire drawing is normal, especially when it is just started. Pay special attention to the change of annealing current. Adjust the size of annealing current according to the change of wire speed, so that the annealing current gradually increases with the increase of wire speed to ensure the normal operation of the equipment.   It is believed that as long as the above points are controlled in actual production, the quality and production efficiency of copper wire drawing products will be improved to different degrees, so as to provide a strong production guarantee for the next process production better and faster.

Working Principle of Copper Wire Drawing Machine

To use a wire drawing die for wire drawing, when the copper wire is dynamically wound and pulled, the copper wire will be pulled forward through the wire drawing die to produce extrusion plastic deformation, and the diameter will be uniformly compressed and extended.   The wire drawing machine uses the extensibility of copper wire and the compression of the die to reduce its diameter, so as to achieve the wire diameter we need. The machine is composed of two parts: wire extension and wire take-up, and the two are unified through frequency converter or mechanical adjustment.   What industries use wire drawing machines?   There are many kinds of equipment involved in the wire drawing machine industry. The visible wire drawing machines include water tank wire drawing machine, straight line wire drawing machine, pulley wire drawing machine, inverted wire drawing machine, etc. Wire drawing machine is mainly used in the processing of metal cable materials such as copper wire and stainless steel wire. It is a very important processing equipment in the cable manufacturing industry. With the continuous development of variable-frequency speed regulation technology, variable-frequency governor has been widely used in the wire drawing machine industry, undertaking wire drawing speed regulation, tension coiling, multi-level synchronous control and other links.   The application of frequency converter has greatly improved the automation level and processing capacity of wire drawing machine, effectively reduced the unit energy consumption and maintenance cost of equipment, and has been widely recognized by the industry. Pay off: for the whole wire drawing machine, the pay off of metal wire does not have too high accuracy requirements. For most wire drawing machines, the pay off operation is realized by driving the pay off frame by the frequency converter. But there are also some wire drawing machines with dual frequency conversion control. Even directly through the wire tension of the drawing link, draft the wire drawing machine to realize free paying off.   Wire Drawing: the wire drawing link is the most important work link of the wire drawing machine. Different metal materials, different silk varieties and requirements, the wire drawing link is very different. The later part of the article will explain in detail the specific operation process of the water tank wire drawing machine and water tank wire drawing machine;   Take-up: the working speed of the take-up link determines the production efficiency of the whole wire drawing machine, and it is also the most difficult part of the whole system to control. In the take-up part, the commonly used control technologies are synchronous control and tension control to realize the winding of metal products.

Function and application classification of wire drawing machine

The main function of wire drawing machine is to process copper wires into thin wires of various specifications. The equipment generally has the characteristics of impact load, large starting torque and low-speed full torque output. In the system, many sets of high-speed precision proportional linkage control are generally required, and the characteristics of the driving device require relatively high load.   According to different uses, it can be divided into metal wire drawing machine, plastic wire drawing machine and bamboo wood wire drawing machine. The purpose of metal wire drawing machine is to transport the wire rod or bar produced by steel manufacturers to metal product manufacturers such as standard parts through the drawing treatment of wire drawing machine, so that the diameter, roundness, internal metallographic structure, surface finish and straightening of wire rod or bar can meet the raw material treatment requirements required for the production of metal products such as standard parts; Plastic wire drawing machine is a kind of solid core, hollow round wire or flat wire produced from polyester, nylon, polyethylene, polypropylene, polyester chip and other raw materials for deep processing and drawing into fine wire. The plastic wire drawn by the equipment has the advantages of uniform thickness, smoothness, not easy to break and less energy consumption. According to the internal control mode and structure, the wire drawing machine can be divided into water tank type, pulley type, linear type and so on. The water tank wire drawing machine belongs to sliding wire drawing, and the diameter of the finished wire drawing is between 0.1 ~ 1.2mm, which can be drawn in multiple passes; The working characteristics of the pulley wire drawing machine are non sliding wire drawing with torsion, and the diameter of the wire drawing finished product is between 0.5 ~ 4.5mm; The diameter range of linear wire drawing finished products is higher than the above two, which is between 0.5 ~ 7.0mm. There is no sliding or torsion during operation.   The wire drawing process of wire drawing machine is composed of setting out, water cooling, take-up and wire arrangement. In addition to water cooling, motors are required for other processes. With the continuous improvement of science and technology, DC drive and torque motor used in electrical system have been gradually replaced by AC frequency conversion technology, which has played a leading role in wire drawing machine equipment.