Wire Drawing Machine,Straight Line Wire Drawing Machine,High/Low Carbon Straight Line Wire Drawing Machine

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 DiameterLine speedElongation
16X φ 0.150mmat v =25.0m/s≥25%
16 X φ 0.200mmat v =25.0m/s≥25%
16 X φ 0.250mmat v =23.0m/s≥25%
16 X φ 0.300mmat v =20.0m/s≥25%
16 X φ 0.400mmat 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;

  1. 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

  1. 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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