This machine works to draw Φ8mm copper rod into copper wire ranging from Φ1.2-4.0mm and further softens the wire by direct annealing, and then the wire is taken up into Φ630 or Φ500 bobbin by dual spooler or coiler by Φ800 coiler. The product conforms to the the requirements of the Chinese National Standard GB3953.
1. Main Technical Data
1.1. Input diameter: Φ8mm cold-rolled copper rod
1.2. Output diameter: Φ1.2~4.0mm
1.3. No. of drawing dies: 13
1.4. Diameter of capstan: Φ450mm
1.5. Max. delivery speed: 25m/sec.
1.6. Take-up motor 2x22kw (DC)
1.7. Mode of annealing DC annealing
1.8. Main motor 280kw (DC)
1.9. Motor of final capstan 90kw (DC)
1.10. Coiling motor 22kw
1.11. Max. annealing power 360kva
2. Composition
2.1. Pay-off stand 1 set
2.2. Drawing machine proper 1 set
2.3. Horizontal annealer 1 set
2.4. Tensioner for accumulator 1 set
2.5. Dual spooler forΦ630 orΦ500 bobbin 1 set
2.6. Φ650 coiler 1 set
2.7. Pointing & threading unit 1 set
2.8. Electrical control system 1 set
2.9. Steam generator 1 set
2.10. Gearbox lubrication system 1 set
3. Components
0 Pay-off stand
Column type pay-off stand, with turnable cross arm under which two coils can be placed.
Equiped with full-line stop device.
Pay-off height 5m
1 Drawing machine proper
3.2.1. Input diameter Φ8mm
3.2.2.Output diameter Φ1.2~4.0mm
3.2.3. Max. delivery speed 25m/sec.
3.2.4. Number of pass 13
3.2.5. Diameter of final capstan Φ450mm
3.2.6. Diameter of dies Φ54xΦ38mm
3.2.7. Output die of rotary type
3.2.8. Inching switch for threading thru each die: 6 pedal switches with anti-reverse mechanism
3.2.9. Main motor power 280kw (DC)
3.2.10. Transmission power of final capstan and annealer 90kw (DC)
3.2.11. Gearbox lubrication system
A 4kw AC motor is used to pump oil, which flows via the oil channel, heat exchanger, and oil pipe with pressure gauge to each gearbox to perform lubrication;
3.2.12. Cover: made of stainless steel plate in inner layer and outer layer to be opened by hand. Drawing coolant will not splash out in the case of normal start-up;
3.2.13. Wire-breakage detector at exit;
3.2.14. Coolant supply system: supplying coolant to the dies in each section, which flows back to the circulating slot when it is full;
3.2.15. Space separation is set between the coolant slot and the gearbox to prevent the coolant from mixing with the gear oil;
3.2.16. Material of capstan: surface coated with tungsten carbide good for one year usage;
3.2.17. High precision ground bevel gears used for main transmission;
3.2.18. With emulsion pump and heat exchanger in 16m2 capacity;
2 Annealer
3.3.1. Input wire diameter Φ1.2~4.0mm
3.3.2. Max. annealing linear speed 20m/sec.
3.3.3. Annealing mode of continuous resistor type in 2 sections
3.3.4. Max. annealing current 6000A (DC)
3.3.5. Max. annealing voltage 60V (DC)
3.3.6. Diameter of annealing wheel Φ420mm (nominal)
3.3.7. Annealing wheel wrapped with cold-rolled nickel tape
3.3.8. Steam as protector in softening chamber, with manual pressure-regulating valve
3.3.9. Power transmission control
Power is transmitted with flat belt via the final capstan, in linked control. Annealing or non-annealing is optional with the help of clutch fitted with anti-reverse mechanism;
3.3.10. Annealing section
Sections include pre-heating section, annelaing section, cooling section, and some sections have differential length. Allowance to the length of the wire must be given in terms of the speed of the guide pulleys in each section;
3.3.11. Bearing lubrication system
Thin oil from the lubrication station performs lubrication to the gears in circulation;
3.3.12. Annealing wheel cooled with compressed air;
3.3.13. Drier is set at the exit
3.3.14. Circulating cooling water for annealing
3 Tension control for accumulator
3.4.1. Wire diameter applicable Φ1.2~4.0mm
3.4.2. Accumulated wire length ≥5m
3.4.3. Diameter of moving guide pulley Φ270mm
3.4.4. Diameter of fixed guide pulley Φ350mm
3.4.5. Guide pulley made of LY111 (cast aluminum), surface coated with tungsten carbide;
3.4.6. Tension control: continuous and adjustable, with pressure adjusted by air cylinder, and synchronized with take-up;
3.4.7. Wire-breakage detector: automatic stop upon wire-breakage
3.4.8. Inching switch: 1 No. pedal switch
4 Dual spoolerΦ630/ 500mm
Dual spooler applicable for Φ630 and Φ 500 bobbins, of the latest design, with excellent performance.
3.5.1. Diameter range of traverse Φ1.2~4.0mm
3.5.2. Take-up bobbin size PND 500, PND560, PND 630
3.5.3. Max. take-up speed 20-25m/sec.
3.5.4. Pneumatic butterfly brake
3.5.5. Automatic shift bobbin at preset length, pneumatic elevation, pneumatic clamping, and mechanical protection
3.5.6. Traverse control: 1 independent motor, twin-bar traverse, automatic traversing as per wire diameter and linear speed;
3.5.7. Wire catch: not less than 99% in success of catching the wire
3.5.8. Length counter: accurate and precision in counting, and bobbin change upon full bobbin
5 CoilerΦ800
3.6.1. Max. take-up speed 25m/sec.
3.6.2. Take-up stand Φ480×Φ860×1260mm
3.6.3. Weight of take-up stand 1300kg
3.6.4. Take-up motor power 22kw
3.6.5. Traversing motor power 0.55kw
3.6.6. Motor power for bobbin holder 1.1kw
3.6.7. Holder change at present wire length
6 Pointing & threading unit
3.7.1. Diameter of pointing roll Φ110mm
3.7.2. Input wire diameter Φ1.2～Φ8.0mm (cold-rolled copper rod)
3.7.3. Diameter of capstan Φ430×300mm
3.7.4. Rotation speed of capstan 16r/pm
3.7.5. Motor power…………………………… 5.5kw (DC)
7 Electrical System
3.8.1. Three-phase five-line system 380V(±10%)50Hz
3.8.2. Siemens PLC used for whole system
3.8.3. Electric control
1) Main control desk for rod breakdown machine with man-machine interface
2) Power panel and transmission panel for power source
3) Control panel for dual spooler
4) Control panel for coiler
5) Control panel for annealer
6) Power control panel for annealer, including transformer
3.9 Main Features of Electric System
3.9.1 Transmission
1)DC motor is used for the whole production, controlled by fully digital controller from Siemens. As numerical tachometer and numerical setting are adopted, the speed regulation accuracy can be up to 0.006%, thus ensuring the precision in speed regulation of the whole line.
3.9.2 Annealing
DC annealing is available in the annealer, with maximum output current at 6000A and maximum voltage at 60V, controlled by digital thyristor ignition board and adjusting board. Therefore the linearity of the output wire is excellent, stability is high, thus ensuring elongation stability of the copper wire after annealing.
3.9.3 Control
1) Due to the use of fully digital DC controller, the DC transmission can achieve high precision in speed regulation; the take-up follows the linear speed automatically, and the take-up speed is adjustable with the help of the accumulator so as to maintain synchronization with the main machine; at the same time, the annealer also adjusts the output voltage automatically by following the linear speed to make sure the elongation rate reaching the requirement under various linear speed.
2) Concentrated control by PLC, large screen man-machine interface for operators.
3) The PLC is connected with each DC controller through communication, and speed for each section is fed to each DC controller after calculation by the PLC so that precision of speed regulation by each motor is ensured in the course of wire drawing. The use of communication is stable and has a low breakdown rate, and ensures the success rate of the dual spooler in shifting the bobbin when it is full.
Operation is carried out through large screen man-machine interface, easy to operate and watch the running conditions or breakdown of the machine, as well as easy to service and maintain.
4. Main Features
4.1 This machine is from the latest design, so it is good in look, advanced in construction, and produces little noise in running, and able to achieve high performance.
4.2 The drawing capstans are arranged in inclined rows so as to avoid scratches to the wire. The machine has a high strength and rigidity; the drawing capstans and final capstan are driven by separate motors, and a general line construction is adopted to achieve adjustable synchronized speed, able to change the dies rapidly; The drawing capstans are fully submerged in the coolant so that the dies and the wire can be cooled and lubricated thoroughly;
4.3 The drawing capstans, the final capstan and the guide pulley are treated with tungsten carbide, so they have high hardness, high wearability, and a long service life;
4.4 Transmission is through helical gear with high precision teeth, which are provided with protector in case of low lube oil;
4.5 The annealer is of horizontal type in two sections performing continuous annealing by direct current, so it is particularly suitable for low-oxygen copper rod from scraps, as it softens the wire completely, and is rational in construction and easy in operation. Fully digital control board is used in the annealing process, so it is able to achieve high precision and stability. The digitalized adjustment of the annealing current and the automatic follow-up of the annealing voltage make it possible to produce wire at high and stable quality so that the wire always retains constant elongation at start-up, shutdown and continuous running, able to achieve zero-length annealing, i.e. there is no non-annealed wire on the bobbin from start to finish;
4.6 The main motor of the main machine, motor of the final capstan, and motor for take-up are all controlled by fully digital DC speed regulators, which can achieve high precision in speed regulation;
4.7 The dual spooler is of the latest design, which is stable in construction and is free from oil leakage, making it possible to maintain the wire tight even in the inner layer at the pay-off time;
4.8 Success rate of catching the wire over 99% at bobbin-shifting operation;
4.9 PLC and touch screen are used in the electric control system, into which process control parameters can be set up, revised and displayed. All parameters are controlled and diagnosed in a concentrated manner.
5 Auxiliary Units
5.2 Steam generator
5.3 Oil lubrication station
6 Requirements to the User
6.2 The user shall provide air compressor and external pipeline, cooling facilities, water pump and pipeline, external copper bus bar and various wires and cables.
6.3 Max. electricity consumption 800KVA
6.4 Total cooling water volume 30m3/hr at 25 0C
6.5 Total compressed air volume 18 m3/hr (P=0.6Mpa)