Wire Drawing Machine,Straight Line Wire Drawing Machine,High/Low Carbon Straight Line Wire Drawing Machine
Table of Contents
I. TECHNICAL DATA
Inlet diameter : 16×Φ1.60 – 2.00mm
Outlet diameter : 16×Φ0.15mm-Φ0.50mm
Number of produced wires : 16 X copper bare / copper tinned
(2 Levels, with 16 wires)
Drawing speed : Max. 30 m/s
Drawing passes : Max. 22
Drawing rings : 100mm with 8 grooves,
For separate and parallel wire guidance
Material: zirconia
Final drawing ring : 100mm 8 grooves,
For separate and parallel wire guidance
Material: zirconia
Wire elongation : 11 x 25% / 5 x 19.44 % /3 x 19.04% /
three quick die change adjustable
Drawing dies casing : Diameter = 28 mm X 12 mm thickness
Cooling water supply : Max. 25℃ inlet temperature;
Differential pressure between cooling water inlet
and outlet is 2 bar (2 x 105 Pa)
Compressed air supply : 6 bar overpressure (7 x 105 Pa), water and oil free
Bobbin : PND 630 ( Drawing will be provided by users)
Operation direction : from left to right
Noise level :< 85 dbA (Except for main motor )
Gross installed capacity : 500KVA
Machine dimension : L×W×H 18500mm × 4500mm × 2200mm
or according to customer’s request.
Production efficiency :
| Inlet wire dia.: 16 X φ1.60-2.00mm (Soft or Hard ) Outlet wire dia.: 16 X φ 0.15mm-0.50mm | ||
| Wire Diameter | Line speed | Elongation |
| 16X φ 0.150mm | at v =25.0m/s | ≥25% |
| 16 X φ 0.200mm | at v =25.0m/s | ≥25% |
| 16 X φ 0.250mm | at v =23.0m/s | ≥25% |
| 16 X φ 0.300mm | at v =20.0m/s | ≥25% |
| 16 X φ 0.400mm | at v =15.0m/s | ≥30% |
| 16 X φ 0.500mm | at v =10m/s | ≥30% |
| Production efficiency for tinned wires at production speeds reduced by about 20%. | ||
II. SHORT DESCRIPTION
Quick die change system: Allows the production of various diameters without exchanging the complete die sets; The rpm adjustment of the last capstan to the final capstan (necessary due to omission of one or several drawing steps) is pre-set by the 2-motor-technique in connection with free-programmable control (PLC).
Wire traverse mechanism:
Driven by AC servo motor;
- Constant traverse speed
When in this mode, the traverse pitch changes with the filling degree of the spool, which means, the traverse pitch increase with the spool getting fuller. The filling weight is lower than with constant traverse pitch
- Constant traverse pitch
The traverse speed will be adapted to the spool speed when in this mode. The traverse pitch is kept constant during the complete winding process
Option: automatic adjustment of traverse width.
III. PROCESS SEQUENCE
- Pay-off
Structure : steel welding structure; pulleys; for 16 baskets type
- Multi-wire drawing machine (HT.MD100.16.22D.03)
Some technical data see in I.
Construction : Multi-wire tandem drawing machine without wire deflections,
drawing direction horizontal
Main drives : AC motors (connected by coupling) with encoder:
For main machine: 185KW 1 set
For haul-off capstan: 45KW 1 set,
AC inverter: Siemens,
Auxiliary drives : Gear oil pump: about 4 kw; none stop oil supply;
Capacity 300L/min; gear oil: MOBIL/SHELL 68
Drawing lubricant : Abt.300 l/min per level with 2.0 bar overpressure (3.0 x 105 Pa)
At 40℃ inlet temperature
Cooling water : Lubricant return cooling:
About 7 m3/h (with self-contained supply)
Gear oil return cooling:
About 1.2 m3/h
Gearing : High efficiency helical gear, hardened and ground
Bearings : Sweden SKF,
Lubrication : Oil circulation type lubrication for toothed wheels and bearings
Lubricant system : Drawing capstans sprayed in the drawing area,
drawing dies pressure-lubricated through die holders
Emulsion cooling and filter system : volume: 6m3
(installed under floor) Cooling: 25m2 heat exchanger connected with cooling water,
Pump motor: 5.5KW
Power of heating: 2 X 3KW
With temperature measurement
with a copper power filter; 680MM filter cloth.
The motor of filter is 0.37KW
- Online annealer (HT. MA160.16.2500A.03)
Construction : DC continuous resistance annealer
Annealing principle : Two and Three-zone system (optional)
Dive of contact pulleys : 6 shafts design, the finished capstans of drawing and annealer pulleys are integrate together, which makes change wire dia.more convenient. AC motors drive, the program synchronized with drawing machine and realize fine tunes. Motor power: AC 45kw, driven by flat belt via tension pulley, so that the belt tension is adjustable.
Annealing voltage : Max.60V, depending on max. Speed
Annealing current : Max.2500A-DC
Annealing power : Max.80KW
Contact pulleys : Φ160mm, with easily exchangeable nickel contact tubes
Contact pulleys can be used twice
Protection : Steam about 6kg/h at 0.3bar
Option:
Nitrogen about 300l/h, max. permissible pressure
reducing valve and a nitrogen monitoring.
Contact pulley bearing assemblies : Are designed as cartridge and installed electrically insulated in the annealer housing; rolling bearings are lubricated for lifetime;
Haul-off capstan : Contact pulley 4 serves also as haul-off capstan and is located in the annealer housing
Wire drying : Single wire drying, wire drier equipped with ceramic nozzles;
Adjustable in 16 groups manually with valve
Safety functions : Rolling shutter locked by a safety switch
Coolant : Lower contact pulley sprayed; annealer base serves as coolant tank
Power supply : By a regulating transformer and rectifier, variable with wire program
Annealing voltage control : Automatically, depending on the wire speed; annealing voltage factor can be preselected on operator’s panel
Cooling system of annealer shaft : volume 0.20 m3,
0.05m2 plate type heat exchanger connected with cooling water; works with pump 3X380V 370W, can cool the annealer shaft effectively.
The water should be treated without the calcium and chloridion; water pressure: 0.2MPa
Annealer cooling and filter system :volume: 6m3
(installed under floor) Cooling: 25m2 heat exchanger connected with cooling water,
Pump motor: 3KW
Power of heating: 1 X 2.2KW
With temperature measurement
with a copper power filter; 680MM filter cloth.
The motor of filter is 0.37KW
- Single spooler (HT.MT630D.03)
Spool shaft rpm : N=3000 r/min
Spool dimensions : PND 630mm
Barrel diameter 355mm
Bore 127mm
Total length 475mm
Traverse width 400mm
Spool weight gross 600 kg Cu
Balancing quality Q16 according to VDI1940
Deviation of center bore to barrel max.0.3mm
Drive motor : AC 18.5kw
Drive : By motor, driving the spool shaft via flat belt.
Traverse drive : AC servomotor 1KW , 3000r/min
Spool take-up : bobbin hold by clamping cones, automatic spooling
In case of expanding arbour bore diameter min. 127mm
Tension control : Pneumatic lever type; with line speed detective buffer pulley, winding speed auto adjusting.
Compressed air consumption : About 10 L/min
Brake : Disk brake with pneumatically actuated brake shoe, serving only as quick brake
Braking time : Adjustable, max. 5 s in case of emergency-off
Spool loading and unloading : By means of spool carrier with hydraulic lifting table, operated manually.
Speed control : By dancer, spooler follows synchronously the speed of the drawing line and annealer
Control desk : Mounted at the side of the spooler
IV. ELECTRIC EQUIPMENT
1. Power supply
– 3-phase voltage ~3×380VAC (±10%)
– Single-phase voltage ~220VAC (±10%)
– Frequency 50Hz (±2%)
Note: if the power supply is different from your system, pls. advice us.
2. Switch cabinet
2.1 All facilities required for the control of the drawing, annealing etc. are installed in the switch cabinet.
In addition, the control devices for driving and the linkage of all sets of the electrical equipment providing for the function of the whole line, with monitoring functions:
– gear oil circulation
– gear oil temperature
– lubricant circulation
– lubricant temperature
– motor thermo probe
– motor with thermo probe
– level and temperature control of lubricant
– carbon brush wear
– wire break
– coolant temperature
– ammeter
– voltmeter
– Etc..
2.2 Main electrical components:
TP1200 (12″ colour human-computer interface; maker SIEMENS) 1 set
SIEMENS S7 series PLC 1 set
DP communications interface 5 sets
Drivers:
For drawing motor: Siemens G120 series AC 1 set
For motor of finished capstan: Siemens G120 series AC 1 set
For motor of spooler: Siemens G120 series AC 2 sets
For traverse servo-motor: Siemens 6SL3210 series servo speed regulator 2 sets
AC motors: HENGLI brand, China famous 4 nos
Annealing control unit: Injet, made in CHINA (Digital Communication Series) 1 set
AC varible voltage power unit: 0-380V/250A 1 set
DC rectification power unit: 60V/2500A 1 set
Transformer for annealer: 230kVA 1 set
Low-voltage electrical components are China CHINT
The electrical control system is designed according to the CE standards.
3. Control panel
The operation of the line is carried out via Touch-Panel. Optimum visualisation of the production – and process data.
V. SCOPE of SUPPLY
– Pay-off for 16 wires 1 set
– Multi-wire drawing machine 1 set
– Emulsion cooling and filter system 1 set
– Online annealer 1 set
– Cooling system of annealer shaft 1 set
– Annealer cooling and filter system 1 set
– Single spooler 2 sets
– Electrical control cabinet 1 set
– Steam generator 1 set
– Machine lay-out drawing and foundation drawing 1 set
– Foundation anchors for installation
– Spears: tension regulation resistant 1 no
proximity switch 1 no
nickel tube 1 no
carbon brushes 4 nos
ceramic sticks. 20 pcs
VI．OPTIONALS
1. Cold welding machine : with welding die 2.00mm
2. Pointing machine : Suitable for copper wires range 0.50 – 3 mm
3. All cables connection between equipment; power cable and copper busbar connection between annealer and transformer.
Other auxiliary devices requested by customers.
The above items are not included in our scope of supply, customers can buy from us with extra prices if needed.
VII.PERFORMANCES by CUSTOMER
The following is not included in our scope of supply:
- High quality copper wires or tinned wires to be drawn;
- Drawing dies, at least 16 sets;
- Air drying dies (made as per wire dia. Produced), at least 32 pcs
- drawing emulsion and supply system;
- 4 drums of gear oil, brand MOBIL / SHELL 68;
- Compressed air (6kg/cm3) and supply system;
- 1 drum of annealing coolant (antioxidant) and cooing water;
- Dynamic balanced 630mm bobbins;
- Air compressor;
- Cooling water and supply source (pressure above 2kg/cm3; Temp. 20-25℃);
- Deionized water used to mix with the emulsion and annealing coolant
- Welding machine for connecting of copper wires;
- A drawing emulsion tank and an annealing coolant tank;
- Power cable from source to the electrical control cabinet; cables from cabinet to machines;
- Installation (Foundation drawings offered by Emre Baykal).
Please pay attention
The factory-provided connections, as e.g.
– Compressed air
– Cooling water (Water will be recycled through a closed circuit.)
VIII. COMMISSIONING
– Inspection and acceptance of customer’s assembly
– Training / introduction of the operating and maintenance personnel
– Acceptance / handing over of the complete line
– Commissioning (2 persons, one electrical engineer; one mechanical engineer; users will provide interpreter if necessary).
– Duration of commissioning: abt. 20 working days, 4 weeks.
– Daily working time: 8 hours
– Round-trip air tickets; local board & lodging; working meals at the user’s site and in Hotel as well as transfer between hotel and company should be paid by the user. And the user shall pay USD 100.00/person/day as allowance to our engineers.
If the commissioning is delayed for reasons which are beyond Emre Baykal’s control, the additional commissioning costs are to be borne by the customer.
Condition for the commissioning is that the line is completely assembled by the customer, and all required operating material is placed at disposal.
Packing: wellpacked on steel pallets in 2 x 40′ containers.
Suitable for long distance ocean freight transportation and to change of climate, well protected against moisture and shocks.
Terms of payment:
1. 20% at contract, 65% before shipment, 15% after acceptance test at user site in 1 month by T/T.
Warranty: 12 months counting from the date of signing the Certificate of Acceptance. But if due to the Buyer’s reason, the commissioning and acceptance of the line is delayed, the guarantee period of quality shall be no more than 18 months from the arrival date of equipment at the destination port.
Documentation:
1. Electrical manual (including electrical diagrams; wiring drawings, cabinet outline)
2. Mechanical manual (mechanical drawings; complete lay-out; foundation drawing; installation drawing, wearing parts list and drawings ).
Picture:
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