CN113680629B - 一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法 - Google Patents

一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法 Download PDF

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CN113680629B
CN113680629B CN202110869141.7A CN202110869141A CN113680629B CN 113680629 B CN113680629 B CN 113680629B CN 202110869141 A CN202110869141 A CN 202110869141A CN 113680629 B CN113680629 B CN 113680629B
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roller
equal
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strip steel
coating
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李伟刚
王滕
许倩
杨平
李超
陈泓业
李志庆
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Maanshan Iron and Steel Co Ltd
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Abstract

本发明公开了一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，属于钢板后处理领域。本发明在现有的S型卧式辊涂机的基础上设置托辊，并根据带钢厚度、带钢密度和带钢单位张力对托辊位置和带钢移动速度进行合理的控制，设计出一套独特的控制方法，使带钢与下涂敷辊之间形成合适的包角，提高带钢下表面钝化膜的重量均匀性，并减少下涂敷辊的磨损。

Description

一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法
技术领域
本发明属于钢板后处理技术领域，更具体地说，涉及一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法。
背景技术
钝化指金属由于介质的作用生成的腐蚀产物如果具有致密的结构，形成了一层薄膜(往往是看不见的)，紧密覆盖在金属的表面，则改变了金属的表面状态，使金属的电极电位大大向正方向跃变，而成为耐蚀的钝态。其是钢板的常用后处理工艺，常见的钝化方式包括六价铬钝化、三价铬钝化、无铬钝化、耐指纹钝化等，钝化后产品性能的好坏与钝化膜重的均匀性有较大的关系。
目前，立式辊涂相比较卧式辊涂、卧式喷淋等方式在膜层均匀性、膜层厚度控制、膜层耐蚀性、成本等方面有明显优势，因此大多数热浸镀生产线采取立式辊涂对带钢进行涂覆，然而，立式辊涂机的空间占用面积较大，而卧式辊涂机布置较为紧凑，空间占用面积较小，一些产线由于空间的限制，无法采用立式辊涂而只能采取卧式辊涂。
目前，卧式辊涂机分为S型、水平型等几种，对于S型辊涂机，带钢下表面由于重力的作用，与涂辊的接触面积较大，不仅会造成涂辊磨损严重，而且容易导致钝化不均等缺陷，钝化膜重量的均匀性难以控制。
中国专利申请号为：CN201320781090.3，公开日为：2013年12月3日的专利文献，公开了一种可以对提升辊行程进行控制的卧式辊涂机，属于卧式辊涂机设备技术领域，用于对带钢进行表面涂覆。其技术方案是：它包括耐指纹液托盘、上蘸料辊、上涂辊、转向辊、提升辊、下蘸料辊、下涂辊、液压升降装置，两套液压升降装置的液压缸分别位于提升辊的两侧，液压缸推杆的上端与提升辊两端的轴承座下部相连接，液压控制装置通过液压管路与液压缸相连接。该实用新型通过液压升降装置改变提升辊高度，将带钢重量合理分配给提升棍和下涂辊，优化带钢与下涂辊的包角大小，实现对带钢与下涂辊的接触面积的调节，有效避免带钢下表面出现的条痕缺陷、漏涂缺陷，提高带钢下表面的涂覆均匀性，同时降低下涂辊与带钢之间的磨损，提高下涂辊使用寿命。该专利应用于电镀锌生产线，侧重于结构设计，提升辊结构布置较为复杂，且不涉及具体控制带钢下表面钝化膜重量的均匀性的方法。
中国专利申请号为：CN201821546083.4，公开日为：2019年9月17日的专利文献，公开了一种卧式辊涂机，属于冷轧生产设备附件设计制造技术领域。所述的卧式辊涂机包括上涂敷辊，所述的卧式辊涂机还包括挡液刮取装置，所述的挡液刮取装置从钢板移动方向的前方斜向上的安装在所述上涂敷辊的两端；涂敷过程中，上涂敷辊上多余的纯化液通过所述的挡液刮取装置刮除并收集。该专利主要解决上涂敷辊甩液问题，不涉及控制钝化膜重量的均匀性的方法。
中国专利申请号为：CN201020188892.X，公开日为：2010年12月15日的专利文献，公开了一种辊涂机，尤其是公开了一种在热镀锌工艺中对带钢表面涂钝化液或其它防锈膜的可逆卧式辊涂机。其包括动力机构，由上粘液辊、上涂辊和上托盘组成的上涂敷机构，由下粘液辊、下涂辊和下托盘组成的下涂敷机构，所述上、下涂敷机构安装在机架主体并与该机架主体滑动滑合，所述上涂敷机构和下涂敷机构的辊子分别通过该上涂敷机构和该下涂敷机构水平的安装在所述机架主体上；所述上涂敷机构的上涂辊和所述下涂敷机构的下涂辊分别位于被涂产品上表面和下表面的不同垂直面内。该专利侧重于结构设计，不涉及控制带钢钝化膜重量的均匀性的方法。
综上所述，现有技术中的卧式辊涂机基本是通过对辊涂机的结构进行改进来控制带钢钝化膜的质量，改进后的辊涂机的结构布置较为复杂，并不适用于一些布置空间紧凑的生产线，且所需成本较高，尤其是，现有技术均不涉及具体卧式辊涂中控制带钢下表面钝化膜重量的均匀性的方法。
发明内容
1、要解决的问题
针对现有的S型卧式辊涂工艺中带钢下表面的钝化膜重量的均匀性采用现有技术难以控制的问题，本发明提供一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，能够使带钢下表面获得均匀的钝化膜重，解决带钢下表面钝化不均和下涂覆辊易磨损的问题。
2、技术方案
为解决上述问题，本发明采用如下的技术方案。
一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，包括如下步骤：使带钢下表面经过卧式辊涂机的托辊和下涂敷辊的上端面，之后进入固化段和冷却段，并满足以下关系式；
0.2m＜L1＜0.5m，L2≥4m；
当0.3mm≤t＜0.8mm时，-10mm≤h＜-5mm，120m/min≤v＜150m/min；
当0.8mm≤t＜1.2mm时，-5mm≤h＜-3mm，100m/min≤v＜120m/min；
当1.2mm≤t＜2.0mm时，1mm≤h≤3mm，60m/min≤v＜100m/min；
当2.0mm≤t≤3.0mm时，3mm＜h≤5mm，30m/min≤v＜60m/min；
10KN＜F1＜35KN；
①当t＜0.8mm时，ρtg＜F1*{|h|/(h2+L12)1/2}；
②当t≥0.8mm时，ρtg＞F1*{|h|/(h2+L12)1/2}；
其中，t为带钢厚度，h为下涂敷辊中心距离托辊中心的垂直距离，v为带钢移动速度，L1为下涂敷辊中心距离托辊中心的水平距离，L2为下涂敷辊中心距离固化段入口的水平距离，F1为带钢单位张力，ρ为钢板密度，g为重力加速度。
作为技术方案的进一步改进，所述卧式辊涂机采用S型辊涂机，包括上涂敷段、下涂敷段和托辊；所述下涂敷段包括下涂敷辊、下取料辊和下接液盘，所述下取料辊的下端面位于下接液盘内，所述下涂敷辊的表面与下取料辊的表面接触；所述上涂敷段和下涂敷段之间设有升降机构，所述托辊设置在升降机构上。
作为技术方案的进一步改进，所述上涂敷段包括上接液盘、上取料辊、上涂敷辊和转向辊；所述上取料辊的下端面位于上接液盘内，所述上涂敷辊的表面与上取料辊的表面接触，所述转向辊安装在位于上取料辊侧边的转向辊支架上。
作为技术方案的进一步改进，定义下涂敷辊的转速为v1，0.7≤(v1)/v≤1.5。
作为技术方案的进一步改进，定义下取料辊的转速为v2，0.25≤(v2)/v≤0.9。
作为技术方案的进一步改进，定义下涂敷辊与下取料辊(10)之间的压力为F2，1.5KN≤F2≤4KN。
作为技术方案的进一步改进，下涂敷辊的硬度为50～60HS。
作为技术方案的进一步改进，定义下涂敷辊的粗糙度为Ra1、下取料辊的粗糙度为Ra2，Ra1-Ra2≤0.7，且0.6μm≤Ra2≤0.9μm。
作为技术方案的进一步改进，定义固化段的带钢固化温度为T1，70℃＜T1＜130℃。
作为技术方案的进一步改进，定义带钢出冷却段出口的温度为T2，T2＜50℃。
3、有益效果
相比于现有技术，本发明的有益效果为：
(1)本发明一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，其在现有的S型卧式辊涂机的基础上设置托辊，并根据带钢厚度、带钢密度和带钢单位张力对托辊位置和带钢移动速度进行合理的控制，设计出一套独特的控制方法，使带钢与下涂敷辊之间形成合适的包角，提高获得的带钢钝化膜的重量均匀性，并减少下涂敷辊的磨损，尤其是，该方法通过对现有的S型卧式辊涂机进行简单的改进即可使用，能够广泛地应用于镀锌、镀锌铝镁等连续热浸镀生产线上，适用性极佳；
(2)本发明一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，通过控制不同厚度的带钢在合适的速度v下运行，同时控制下涂敷辊距固化段入口距离L2＞4m，令带钢在进入固化段前停留合适的时间，使带钢下表面钝化膜流平性良好，获得均匀的钝化膜重；
(3)本发明一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，通过对下涂敷辊转速v1、下取料辊转速v2和下涂敷辊与下取料辊之间的压力F2进行相互配合控制，能够使得对带钢下表面的涂敷均匀，有效地提高带钢下表面获得的钝化膜的重量均匀性；
(4)本发明一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，通过对下涂敷辊硬度、下涂敷辊的粗糙度Ra1和下取料辊的粗糙度Ra2进行控制，能够提高钝化液在带钢下表面上的分布均匀性，提高涂敷效果；
(5)本发明一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，通过对固化温度和带钢出冷却段的温度进行控制，能够有效地提高钝化膜的表面质量。
附图说明
图1为本发明的后处理流程示意图；
图中：1、上接液盘；2、上取料辊；3、上涂敷辊；4、转向辊；5、转向辊支架；6、托辊；7、安装架；8、升降机构；9、下涂敷辊；10、下取料辊；11、下接液盘；12、固化段；13、冷却段。
具体实施方式
下面结合具体实施例和附图对本发明进一步进行描述。
一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，其能够广泛应用于镀锌、镀锌铝镁等连续热浸镀生产线上，只需对现有的S型卧式辊涂机的结构进行简单地改进，即可采用本发明的控制方法实现对带钢下表面钝化膜的重量均匀性的控制，提高钝化膜质量。下面对本发明的控制方法和辊涂机的结构和工作原理进行描述。
如图1所示，该卧式辊涂机采用S型卧式辊涂机，包括上涂敷段、下涂敷段和托辊6。其中，上涂敷段用于对带钢的上表面涂敷钝化液并引导带钢从竖直移动方向转变为水平移动方向，托辊6从带钢下方将带钢托起，下涂敷段用于对带钢的下表面涂敷钝化液并引导带钢进入后续固化段12和冷却段13。
具体的，上涂敷段包括上接液盘1、上取料辊2、上涂敷辊3和转向辊4。上取料辊2的下端面位于上接液盘1内，上涂敷辊3的表面与上取料辊2的表面接触，转向辊4安装在位于上取料辊2侧边的转向辊支架5上。
转向辊支架5上固定装有升降机构8，升降机构8可以采用油缸、丝杆升降等多种常见的升降设备，本实施例具体采用丝杠升降机构。转向辊支架5上设有安装架7，丝杠升降机构安装在安装架7上，其传动连接位于其上端的托辊6，用于控制托辊6的升降。
下涂敷段包括下涂敷辊9、下取料辊10和下接液盘11。下取料辊10的下端面位于下接液盘11内，下涂敷辊9的表面与下取料辊10的表面接触。
对带钢进行后处理钝化作业时，上取料辊2从上接液盘1中蘸取钝化液，上取料辊2蘸取的钝化液在上取料辊2和上涂敷辊3之间的压力作用下转移至上涂敷辊3上。同理，下取料辊10从下接液盘11中蘸取钝化液，下取料辊10蘸取的钝化液在下取料辊10和下涂敷辊9之间的压力作用下转移至下涂敷辊9上。
带钢沿竖直方向从上涂敷辊3和转向辊4之间向上移动，上涂敷辊3向带钢上表面涂敷钝化液，同时，带钢在转向辊4的作用下由竖直移动方向转变为水平移动方向。带钢下表面与托辊6和下涂敷辊9的上端面接触，下涂敷辊9向带钢下表面涂敷钝化液，托辊6在升降机构8的作用下完成上移或下降工作，根据带钢厚度调整带钢与下涂敷辊9形成合适的包角，在合适的张力作用下，完成下表面钝化过程。带钢表面钝化后，在一定的速度下，向前经过一定的距离，进入固化段12，钝化膜在一定的温度下完成固化过程，再经冷却段13，使钝化膜冷却到一定温度，进而完成整个后处理过程。
具体的，为了保证带钢下表面钝化膜的重量均匀性，采用常规的工艺控制参数根本无法得到，因此本发明结合可以升降的托辊6的结构，设计了如下一套完整独特的控制过程参数：
(1)带钢与下涂敷辊9的包角的控制
0.2m＜L1＜0.5m；
当0.3mm≤t＜0.8mm时，-10mm≤h＜-5mm，120m/min≤v＜150m/min；
当0.8mm≤t＜1.2mm时，-5mm≤h＜-3mm，100m/min≤v＜120m/min；
当1.2mm≤t＜2.0mm时，1mm≤h≤3mm，60m/min≤v＜100m/min；
当2.0mm≤t≤3.0mm时，3mm＜h≤5mm，30m/min≤v＜60m/min；
10KN＜F1＜35KN；
其中，t为带钢厚度，h为下涂敷辊9中心距离托辊6中心的垂直距离，v为带钢移动速度，L1为下涂敷辊9中心距离托辊6中心的水平距离，F1为带钢单位张力，ρ为钢板密度，g为重力加速度。
其原理如下：带钢厚度不同，下涂敷辊9所承受的重力不同，在一定的张力作用下，带钢与下涂敷辊9呈现一定的包角，包角不合适将造成钝化不均等缺陷。而当L1过大时，对下涂敷辊9与带钢包角的控制影响较小，当L1过小时，又不利于下涂辊与带钢包角的控制，因此，本发明控制0.2m＜L1＜0.5m。再者，带钢下表面受到张力、重力以及下涂敷辊9与带钢摩擦力的作用，因此，本发明根据带钢厚度分级设定上述h和v的工艺，而且发明人发现当t、ρ与F1、h、L1满足以下关系式时：
①t＜0.8mm时，ρtg＜F1*{|h|/(h2+L12)1/2}；
②t≥0.8mm时，ρtg＞F1*{|h|/(h2+L12)1/2}；
带钢与涂辊之间的包角最为合适，获得的钝化膜重最为均匀，同时，可减少涂辊的磨损。
(2)钝化膜流平性的控制
因经钝化后的钝化膜呈液态，在进入固化段12前，带钢停留的时间将显著影响钝化膜的流平性。下涂辊中心距固化段入口距离L2距离过小时或带钢速度v过大时，都不利于钝化膜的流平，因此，本发明通过控制不同厚度的带钢在合适的速度v下运行(即在满足包角控制参数的基础上)，同时控制下涂敷辊9距固化段12入口距离L2＞4m，使带钢下表面钝化膜流平性良好，获得均匀的钝化膜重量。
(3)钝化工艺控制
当下涂敷辊9转速v1与带钢移动速度v的比值过大或过小时，不仅无法保证钝化液的涂敷量，而且容易造成带钢表面划伤及涂敷辊磨损。因此，其控制0.7≤(v1)/v≤1.5。
当下取料辊10转速v2与带钢速度v的比值过大时，钝化膜较厚，容易造成涂敷不均；当下取料辊10转速v2与带钢速度v的比值过小时，不仅影响涂敷效率，而且容易造成涂敷不均。因此，其控制0.25≤(v2)/v≤0.9。
当下涂敷辊9与下取料辊10的压力较大时，下涂敷辊9上蘸取的钝化液量有限，难以保证涂敷效果，而且容易造成下涂敷辊9及下取料辊10的磨损，导致涂敷不均；当下涂敷辊与下取料辊的压力较小时，难以保证合适的钝化膜重，且影响辊间钝化液挤压的均匀性。因此其控制下涂敷辊9与下取料辊10之间的压力为1.5KN≤F2≤4KN。
通过对该三种工艺进行相互配合控制，能够使得对带钢下表面的涂敷均匀，有效地提高带钢下表面获得的钝化膜的重量均匀性。
(4)下涂敷辊9与下取料辊10的表面状态控制
下涂敷辊9硬度对涂敷效果有较大的影响，当下涂敷辊9硬度过小时，容易造成磨损；当下涂敷辊9硬度过大时，弹性较小，下涂敷辊9在一定的压入量下与带钢接触不充分，导致带钢横向存在钝化膜膜重不均匀现象；因此，本发明控制下涂敷辊9硬度为50～60HS。
同时，下涂敷辊9与下取料辊10的表面粗糙度对涂敷效果有较大的影响，下取料辊10的粗糙度过小时，不利于钝化液的拾取；下取料辊10的粗糙度过大时，易造成钝化液在辊面上分布不均。因此，本发明控制下取料辊10的粗糙度0.6μm≤Ra2≤0.9μm。
而且，当下涂敷辊9的粗糙度Ra1与下取料辊10的粗糙度Ra2差值过大时，钝化液在辊间挤压力作用下，在下取料辊10与下涂敷辊9之间传递效果较差，容易造成涂敷不均，因此，本发明控制Ra1-Ra2≤0.7。
(5)固化与冷却工艺控制
当固化温度过低时，钝化膜无法完全固化，折弯等成形后容易脱落；当固化温度过高时，钝化膜易出现粉化及龟裂。因此，本发明控制固化温度T1为70℃＜T＜130℃。
当带钢出冷却段13的温度高于50℃时，带钢表面的钝化膜易于后续的辊系摩擦产生划伤，因此，本发明控制带钢出冷却段13出口的温度T2＜50℃。
下面通过给出本方法的具体实施数据来进一步体现本方法的效果。
带钢下表面后处理过程的工艺参数控制如下表1和表2所示。
表1
Figure BDA0003188356350000071
表2
Figure BDA0003188356350000081
带钢下表面涂覆效果及钝化膜重如下表3所示。
表3
Figure BDA0003188356350000091
注：1)▲个数越多，表示涂覆效果越好，▲个数越少，表示涂覆效果较差、存在钝化不均；
2)●个数越多表示下涂辊磨损程度越大。
从表中可以看出：本发明的实施例涂覆效果较好，钝化膜重量控制较为均匀，且下涂敷辊9的磨损程度较小。
综上所述，本发明的一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，根据带钢厚度合理的分级设定托辊位置、带钢速度及带钢张力，使带钢与下涂敷辊之间形成合适的包角，配合钝化工艺、固化工艺、冷却工艺以及下涂敷辊与下取料辊的表面状态的控制，解决了带钢下表钝化不均等问题，获得较好的涂覆效果。带钢下表面钝化膜重量控制在0.6～1.5g/m2，且带钢宽度方向任意三点钝化膜重量的两点差值的绝对值|△m|≤0.1，其可广泛应用于镀锌、镀锌铝镁等连续热浸镀生产线上。
本发明所述实例仅仅是对本发明的优选实施方式进行描述，并非对本发明构思和范围进行限定，在不脱离本发明设计思想的前提下，本领域工程技术人员对本发明的技术方案作出的各种变形和改进，均应落入本发明的保护范围。

Claims (3)

1.一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，其特征在于：包括如下步骤：使带钢下表面经过卧式辊涂机的托辊（6）和下涂敷辊（9）的上端面，之后进入固化段（12）和冷却段（13），并满足以下关系式；
0.2m＜L1＜0.5m，L2≥4m；
当0.3mm≤t＜0.8mm时，-10mm≤h＜-5mm，120m/min≤v＜150m/min；
当0.8mm≤t＜1.2mm时，-5mm≤h＜-3mm，100m/min≤v＜120m/min；
当1.2mm≤t＜2.0mm时，1mm≤h≤3mm，60m/min≤v＜100m/min；
当2.0mm≤t≤3.0mm时，3mm＜h≤5mm，30m/min≤v＜60m/min；
10KN＜F1＜35KN；
① 当t＜0.8mm时，ρtg＜F1*{|h|/（h2+L12）1/2}；
② 当t≥0.8mm时，ρtg＞F1*{|h|/（h2+L12）1/2}；
其中，t为带钢厚度，h为下涂敷辊（9）中心距离托辊（6）中心的垂直距离，v为带钢移动速度，L1为下涂敷辊（9）中心距离托辊（6）中心的水平距离，L2为下涂敷辊（9）中心距离固化段入口的水平距离，F1为带钢单位张力，ρ为钢板密度，g为重力加速度；
所述卧式辊涂机采用S型辊涂机，包括上涂敷段、下涂敷段和托辊（6）；所述下涂敷段包括下涂敷辊（9）、下取料辊（10）和下接液盘（11），所述下取料辊（10）的下端面位于下接液盘（11）内，所述下涂敷辊（9）的表面与下取料辊（10）的表面接触；所述上涂敷段和下涂敷段之间设有升降机构（8），所述托辊（6）设置在升降机构上；
所述上涂敷段包括上接液盘（1）、上取料辊（2）、上涂敷辊（3）和转向辊（4）；所述上取料辊（2）的下端面位于上接液盘（1）内，所述上涂敷辊（3）的表面与上取料辊（2）的表面接触，所述转向辊（4）安装在位于上取料辊（2）侧边的转向辊支架（5）上；
定义下涂敷辊（9）的转速为v1，0.7≤v1/v≤1.5；
定义下取料辊（10）的转速为v2，0.25≤v2/v≤0.9；
定义下涂敷辊（9）与下取料辊（10）之间的压力为F2，1.5KN≤F2≤4KN；
下涂敷辊（9）的硬度为50~60HS；
定义下涂敷辊（9）的粗糙度为Ra1、下取料辊（10）的粗糙度为Ra2，Ra1-Ra2≤0.7μm，且0.6μm≤Ra2≤0.9μm。
2.根据权利要求1所述的一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，其特征在于：定义固化段（12）的带钢固化温度为T1，70℃＜T1＜130℃。
3.根据权利要求1所述的一种提高卧式辊涂机带钢下表面钝化膜重均匀性的方法，其特征在于：定义带钢出冷却段（13）出口的温度为T2，T2＜50℃。
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