CN113913890A - Integrated production method and production line of tempered bead wire - Google Patents
Integrated production method and production line of tempered bead wire Download PDFInfo
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- CN113913890A CN113913890A CN202111192122.1A CN202111192122A CN113913890A CN 113913890 A CN113913890 A CN 113913890A CN 202111192122 A CN202111192122 A CN 202111192122A CN 113913890 A CN113913890 A CN 113913890A
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- 239000011324 bead Substances 0.000 title claims abstract description 100
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 86
- 238000000034 method Methods 0.000 claims abstract description 78
- 238000005496 tempering Methods 0.000 claims abstract description 71
- 238000007747 plating Methods 0.000 claims abstract description 65
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 62
- 239000010959 steel Substances 0.000 claims abstract description 62
- 230000008569 process Effects 0.000 claims abstract description 57
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 46
- 238000000576 coating method Methods 0.000 claims abstract description 46
- 229910052802 copper Inorganic materials 0.000 claims abstract description 46
- 239000010949 copper Substances 0.000 claims abstract description 46
- 239000011248 coating agent Substances 0.000 claims abstract description 40
- 238000005554 pickling Methods 0.000 claims abstract description 32
- 238000005265 energy consumption Methods 0.000 claims abstract description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 64
- 238000005406 washing Methods 0.000 claims description 49
- 238000001816 cooling Methods 0.000 claims description 28
- 238000001035 drying Methods 0.000 claims description 28
- 230000006698 induction Effects 0.000 claims description 23
- 239000002253 acid Substances 0.000 claims description 15
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 10
- 229910052796 boron Inorganic materials 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 10
- 230000004913 activation Effects 0.000 claims description 7
- 238000005491 wire drawing Methods 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 4
- 230000001105 regulatory effect Effects 0.000 claims description 4
- 230000001276 controlling effect Effects 0.000 claims description 3
- 238000001514 detection method Methods 0.000 claims description 3
- 230000001050 lubricating effect Effects 0.000 claims description 2
- 230000010354 integration Effects 0.000 claims 1
- 239000000126 substance Substances 0.000 abstract description 8
- 238000003912 environmental pollution Methods 0.000 abstract description 3
- 238000004140 cleaning Methods 0.000 description 11
- 230000000694 effects Effects 0.000 description 7
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 229910000906 Bronze Inorganic materials 0.000 description 4
- 239000010974 bronze Substances 0.000 description 4
- KUNSUQLRTQLHQQ-UHFFFAOYSA-N copper tin Chemical compound [Cu].[Sn] KUNSUQLRTQLHQQ-UHFFFAOYSA-N 0.000 description 4
- 239000000463 material Substances 0.000 description 4
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- 230000001070 adhesive effect Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000000605 extraction Methods 0.000 description 2
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- 239000002184 metal Substances 0.000 description 2
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- 230000007306 turnover Effects 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- WIKSRXFQIZQFEH-UHFFFAOYSA-N [Cu].[Pb] Chemical compound [Cu].[Pb] WIKSRXFQIZQFEH-UHFFFAOYSA-N 0.000 description 1
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- 229910021538 borax Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 201000010099 disease Diseases 0.000 description 1
- 208000037265 diseases, disorders, signs and symptoms Diseases 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
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- 238000007493 shaping process Methods 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 238000005482 strain hardening Methods 0.000 description 1
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- 238000004381 surface treatment Methods 0.000 description 1
- 230000008719 thickening Effects 0.000 description 1
- 238000004073 vulcanization Methods 0.000 description 1
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D7/00—Electroplating characterised by the article coated
- C25D7/06—Wires; Strips; Foils
- C25D7/0607—Wires
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/34—Pretreatment of metallic surfaces to be electroplated
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25F—PROCESSES FOR THE ELECTROLYTIC REMOVAL OF MATERIALS FROM OBJECTS; APPARATUS THEREFOR
- C25F1/00—Electrolytic cleaning, degreasing, pickling or descaling
- C25F1/02—Pickling; Descaling
- C25F1/04—Pickling; Descaling in solution
- C25F1/06—Iron or steel
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Electroplating Methods And Accessories (AREA)
- Ropes Or Cables (AREA)
Abstract
The invention relates to an integrated production method and a production line of a tempered tire bead steel wire. The production method comprises a wire rod pretreatment procedure, a drawing procedure, a tempering procedure, a copper plating procedure and a coating procedure which are integrated and continuously operated, and single-wire single-control production from a tempered bead steel wire rod to a tempered bead steel wire finished product is realized; the wire rod pretreatment process adopts online electrolytic pickling, the tempering process adopts an online high-frequency tempering mode, and the copper plating process adopts an electrochemical plating mode. The integrated production method of the tempered bead wire provided by the invention reduces the traditional tempering and unfolded multi-wire chemical copper plating treatment processes, adopts on-line electro-pickling to replace concentrated pickling, replaces lead bath tempering with high-frequency tempering, replaces unfolded multi-wire chemical copper plating with single-wire electrochemical copper plating, reduces the environmental pollution point, improves the production efficiency, reduces the energy consumption, reduces the number of workers, and improves the reliability of the product quality through automatic intelligent production.
Description
Technical Field
The invention relates to the technical field of metal wire surface plating, in particular to an integrated production method and production line of a tempered bead wire.
Background
The tempered tin-plated bronze tire bead wire is a reinforcing material applied to a rubber framework in an automobile tire and is one of important raw materials for manufacturing the automobile tire. The tempered tin-plated bronze tire bead wire can improve the rubber adhesive force and the rubber aging resistance of the tire bead wire as a rubber framework material, and enhance the safety and the comfort of a tire. Existing tire bead steel wire copper plating toolThe process is mainly an unfolded multi-head copper plating process and comprises 4 procedures of rough drawing, medium wire heat treatment, medium drawing and copper plating. Specifically, 1) a first process:
wire rod → paying off → mechanical shelling → acid cleaning and rust removing → water cleaning → boron coating → drying → crude drawing → spool taking up. 2) The second procedure: paying off a spool → washing with water → chemical pickling → coating boron → drying → taking up the spool. 3) The third procedure: spool paying-off → middle pulling → spool taking-up. 4) A fourth procedure: spool paying-off → lead bath tempering → water cooling → electrolytic acid washing → water washing → copper plating → water washing → neutralization → water washing → hot water washing → drying → coating → take-up.
In the production process, the acid cleaning and rust removal, the chemical acid cleaning, the lead tempering, the electrolytic acid cleaning and the like have great pollution to the environment, for example, the acid cleaning and rust removal is mostly concentrated acid cleaning, a large amount of acid mist is generated, a factory building is polluted, the operating environment of workers is poor, and the health of a human body is damaged; and if copper-lead plating fire tempering can generate lead steam, the environment is polluted, the lead tempering adopts electric heating lead, the energy consumption is extremely high, the total installed capacity of a production line reaches 2000KW, and the like. The environmental protection cost required for treating the pollution points in actual production is usually high, the resource waste is serious, and the traditional copper plating method adopts a multi-head expansion method, so that the pollution is large, the environment is poor, the energy consumption is large, the occupied area is large, and the labor cost is high (one line generally needs 20 operators).
Disclosure of Invention
In order to overcome the defects, the invention provides an integrated production method and a production line of tempered bead wires.
The technical scheme adopted by the invention is as follows:
an integrated production method of a tempered bead wire comprises a wire rod pretreatment process, a drawing process, a straightening process, a tempering process, a copper plating process and a coating process which are integrated and continuously operated, and single-wire single-control production from a tempered bead wire rod to a tempered bead wire finished product is realized; the wire rod pretreatment process adopts online electrolytic pickling, the tempering process adopts an online high-frequency tempering mode, and the copper plating process adopts an electrochemical plating mode.
Further, the wire rod pretreatment process comprises the following sequential steps:
paying off the tempered bead wire rod;
mechanically peeling;
the on-line electrolytic pickling;
sequentially washing with high-pressure water and hot water to remove residual acid liquor on the surface to obtain the tire bead steel wire coil element; wherein the pressure range of the high-pressure water washing is 0.4-1.0 MPa; the water temperature range of the hot water washing is 60-100 ℃, and the treatment time of the hot water washing is 0.5-2s, preferably 1 s.
Further, the drawing process includes the steps of:
coating boron on the tire bead wire disc element on line;
then drying the moisture on the surface of the bead wire coil element by induction heating;
integrally drawing the bead wire coil element to a set wire diameter, wherein the wire diameter ranges from 0.78 mm to 1.65 mm;
and (5) dry wiping and removing drawing lubricating powder to obtain the tire bead steel wire blank.
Further, in the tempering process, the bead wire blank is tempered by high frequency, and then is cooled by air cooling and water to obtain the bead wire blank, wherein the temperature range set by the high frequency tempering is 450-550 ℃.
Further, the copper plating process comprises the steps of sequentially carrying out electrolytic pickling activation, electrochemical plating, water washing and induction drying on the tire bead steel wire blank, and then coating an antirust tackifying coating through the coating process to obtain the finished product of the tempered tire bead steel wire.
Further, the linear speed of the finished tempered bead wire is 11-20 m/s. In addition, the tempered bead wire rod, the bead wire coil element, the bead wire blank and the finished tempered bead wire are single tensioned wires which are only positioned in different process sections, and the wiring speed of the whole wire is consistent.
The invention also provides an integrated production line of the tempered bead wire, which comprises a wire rod pretreatment device, a drawing device, a straightening device, a tempering device, a copper plating device and a coating device which are sequentially arranged, wherein the wire rod pretreatment device is sequentially provided with a wire releasing device, a mechanical shucker, an online electrolytic pickling device and a water washing device, the tempering device adopts an online high-frequency tempering mode, the copper plating device adopts an electrochemical plating mode, a tempered bead steel wire rod is flatly and straightly passed through the mechanical husking machine, the online electrolytic pickling device, the water washing device and the drawing device after being paid off by the paying-off device, is regulated and tensioned by the straightening device and flatly passed through the tempering device, the copper plating device and the coating device, and finally is automatically and integrally formed to obtain a tempered bead steel wire finished product, so that the single-wire single-control production from the tempered bead steel wire rod to the tempered bead steel wire finished product is realized.
Further, the drawing device comprises an online boron coating device and a wire drawing unit; the straightening device comprises a group of tension brackets, one tension bracket is arranged between the tempering device and the drawing device, and the other tension bracket is integrated on the coating device and is positioned at the front end of the coating device; the tempering device sequentially comprises a tempering induction heating section, an air cooling section and a water cooling device; the copper plating device sequentially comprises an electrolytic pickling activation device, an electrochemical plating device, a copper plating post-washing device, an induction drying device and an air cooling device.
Furthermore, a tractor is arranged between the air cooling device and the coating device, and the traction speed is 11-20 m/s; and the tail end of the production line is provided with a take-up machine.
Furthermore, the production line is provided with a plurality of detection control modules for detecting energy consumption and regulating and controlling the running state, thereby realizing intelligent production.
Compared with the prior art, the integrated production method of the tempered bead wire provided by the invention reduces the traditional lead bath tempering and unfolded multi-wire chemical copper plating treatment processes, adopts on-line electro-pickling to replace concentrated pickling, replaces lead bath tempering with high-frequency tempering, replaces unfolded multi-wire chemical copper plating with single-wire electrochemical copper plating, reduces the environmental pollution point, improves the production efficiency, reduces the energy consumption, reduces the number of workers, and improves the reliability of the product quality through automatic intelligent production.
Drawings
Fig. 1 is a production flow chart of a tempered bead wire in an embodiment of the present invention.
Fig. 2 is a layout view of an integrated production line for tempered bead wires according to an embodiment of the present invention.
Fig. 3 is an integrated production line of the tempered bead wire shown in fig. 2.
Description of the main element symbols:
wire rod pretreatment apparatus 100
Upward drawing type pay-off rack 101
First high pressure water washing device 105
On-line electrolytic pickling device 107
Second high-pressure water washing apparatus 109a
Hot water washing apparatus 109b
Online boron coating device 201
First induction drying device 203
First air cooling device 205
Straightening device 300
Tempering apparatus 400
Tempering induction heating section 401
Electrolytic pickling activation device 501
Copper plating post-washing device 505
Second induction drying device 507
Second air-cooling device 509
Spool wire-rewinding machine 605
Detailed Description
In order that the above objects, features and advantages of the embodiments of the present invention can be more clearly understood, the present invention will be described below with reference to the accompanying drawings and detailed description. In addition, the features of the embodiments of the present application may be combined with each other without conflict.
In the following description, examples are set forth to provide a thorough understanding of the present invention, and the described embodiments are only a part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present invention without any creative effort belong to the protection scope of the embodiments of the present invention.
The high-frequency drying means that the steel wire directly enters and exits the inductor with the high-frequency induction magnetic field, the resistance in the eddy current induction steel wire is fed back to the control mechanism, and the drying power is automatically adjusted according to the production line speed requirement, so that the steel wire is heated instantly. Wherein the "high frequency" is only relative to the operating frequency of a conventional electric oven (e.g., 50Hz, etc.). In addition, the working principle of the high-frequency tempering is similar to that of the high-frequency drying, and the difference is that the temperature process curve is different.
The "H extraction force" herein means that both ends of a steel wire are embedded in two rubber blocks by a predetermined length, and the force required for extracting a single steel wire from a vulcanized rubber block is measured.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which embodiments of the present invention belong. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the embodiments of the invention.
The invention provides an integrated production method of a tempered tire bead steel wire, which is characterized by comprising the following steps of: the method comprises the integrated continuous operation of a wire rod pretreatment process, a drawing process, a straightening process, a tempering process, a copper plating process and a coating process, and realizes the single-wire single-control production from a tempered bead steel wire rod to a tempered bead steel wire finished product; the wire rod pretreatment process adopts online electrolytic pickling, the tempering process adopts an online high-frequency tempering mode, and the copper plating process adopts an electrochemical plating mode. The method has the advantages that the concentrated pickling is replaced by the on-line electrolytic pickling, the high-frequency tempering replaces the lead bath tempering, the subsequent pickling step is avoided, the pollution to the environment is effectively reduced, the energy consumption is reduced, the design of the integrated production method reduces the process steps, the artificial intelligent operation is realized, the labor intensity of workers is reduced, the manual participation is reduced, the product quality is further controlled in a standardized manner, and the performance is more excellent.
Referring to fig. 1, the integrated production method of the tempered bead wire provided by the invention comprises the following steps: the method comprises the following steps of wire rod pretreatment, drawing, straightening, tempering, copper plating and coating. The specific steps of an integrated production method of a tempered bead wire according to the present invention will be described herein below with reference to fig. 1.
First, in order to ensure the thickening effect of copper plating on rubber and thus to exert the effect of the bead wire in a tire, the steps of rust removal and descaling of a wire rod are indispensable, and the quality of the tempered bead wire is directly determined by the surface treatment effect. Considering the adverse effect of centralized acid cleaning on the environment, long treatment time, low efficiency and possibility of hydrogen embrittlement, the invention designs the combination of mechanical rust removal and an online electrolytic acid cleaning technology, on one hand, the pollution is reduced, the production efficiency is improved, on the other hand, the whole steel wire rod is continuously processed online after being unreeled, the effective treatment environment and the treatment time of the whole steel wire rod are controlled in a standardized way, and the removal effect is more uniform and more thorough.
S1: wire rod pretreatment process
S101: paying off: and paying off the tempered bead wire rod raw material.
S102: mechanical husking: the repeated bending machinery is peeled and derusted by a hydraulic oil cylinder, and oxide skin on the surface of the raw material is removed. In the step, in order to thoroughly remove impurities remained on the surface of the mechanical husking, a high-pressure water washing mode (such as the first high-pressure water washing step shown in fig. 1) can be adopted for washing and removing, especially large-particle solids; wherein the pressure range of the high-pressure water washing can be any value between 0.4 and 1.0 MPa.
S103: and (3) online electrolytic pickling: the novel on-line electrolytic acid production process is used for rapidly removing the oxide skin on the surface of the coil.
S104: high-pressure water washing: and (3) rapidly cleaning the residual acid liquor on the surface of the raw material by high-pressure water washing to obtain the tire bead steel wire coil element. In the embodiment shown in fig. 1, this step includes a high pressure water wash followed by a hot water wash. Generally, the hot water has higher solubility of substances, and the hot water washing is assisted to dissolve residual acid attached to the surface to a greater extent. In some embodiments, the pressure of the high pressure water wash may be selected from the range of 0.4 to 1.0Mpa, the temperature of the hot water wash may be in the range of 60 to 100 ℃, and the duration of the treatment may be in the range of 0.5 to 2s, preferably 1 s.
The bead wire coil element needs to be applied to a tire, needs high strength, high yield ratio and other characteristics and set wire diameter and shape, and needs to be subjected to multi-pass drawing treatment for plastic processing.
S2: drawing step
S201: and (3) online boron coating: the surface of the tire bead steel wire coil element is uniformly covered with a uniform borax layer by online boron coating, so that the subsequent high-speed drawing is facilitated.
S202: first induction drying: and (3) quickly drying the moisture on the surface of the bead wire coil element by high-frequency power supply induction heating. In the embodiment shown in fig. 1, the step includes induction drying and air cooling, and the induction drying and the air cooling are combined to achieve the purpose of rapid drying. Herein, induction drying is also called high-frequency drying, and compared with the ordinary hot air drying treatment, the induction drying treatment has the advantages of high treatment efficiency, greatly shortened drying area which is about 0.2m, small occupied area and contribution to the optimized configuration of an integrated production line.
S203: integral drawing (including rough drawing and middle drawing): the wire rod is drawn to the desired bead wire diameter (i.e., set wire diameter), which in particular embodiments is typically 0.78-1.65 mm.
S204: dry wiping: and (4) rapidly removing wire drawing powder (lubricant used for drawing) on the surface of the steel wire to obtain the tire bead steel wire blank. The step removes the wire drawing powder by mechanical treatment and a physical method, is beneficial to the layout of an automatic production line, does not need to introduce a special device for dissolving a lubricant, and saves the equipment cost; the invention adopts mechanical degreasing to replace alkaline washing, reduces the consumption of chemicals, lightens the environmental burden, is more environment-friendly, and also reduces the subsequent treatment processes, such as the process of removing a dissolving agent (alkali liquor) and the like.
S3: straightening: for correcting the linearity of the steel wire. As an integrated production line, the straightness and the residual torsion of the steel wire need to be strictly controlled, and basic solution needs to be obtained in the drawing process so as to avoid the quality defects of steel wire ring deformation, degumming, tire bead steel wire stabbing and the like caused by unqualified steel wire straightness or residual torsion. The alignment procedure, after its inception, also has a decisive influence on the uniformity of the tempering and coating treatment. The straightening control is realized by adopting a group of tension frames, and a front tension frame and a rear tension frame are arranged in the straightening device, wherein the front tension frame is arranged between the drawing device and the tempering device, and the rear tension frame is arranged before the rolling.
S4: and a tempering process, wherein the tempering is a process of performing structure recovery or local recrystallization on the cold deformation metal wire at a certain temperature, properly adjusting the dislocation density and reuniting partially broken crystal grains, and the tempering treatment generally basically keeps the work hardening of cold deformation, reduces the strength, reduces the twisting times, obviously improves the shaping, improves the total elongation at break and improves the elastic yield strength. The straightness is an important performance index of the tire bead steel wire, and the high-speed automatic production line can guarantee the straightness of the steel wire very stably. The traditional lead tempering is a press-in type, and has a certain angle, which can affect the stability of the linearity of the bead wire. The invention abandons the traditional lead bath tempering process and replaces the traditional lead bath tempering process with a high-frequency tempering technology, thereby reducing the environmental pollution and saving the energy consumption and the process steps.
S401: high-frequency tempering is used for heating the tire bead steel wire blank to obtain specific mechanical properties, and replaces the traditional lead tempering process. In the step, the tempering frequency is matched with the linear velocity of the steel wire, the resistance of the steel wire and the like, and is automatically adjusted. Wherein the temperature range set by the high-frequency tempering is 450-550 ℃.
S402: the air cooling section is the best heat treatment time and method to obtain ideal mechanical performance.
S403: and (3) water cooling, wherein the water temperature of cooling water is usually controlled to be about 50-90 ℃, and the wire enters from the air cooling section and passes through cooling circulating water to obtain the tire bead wire blank.
The sequence of the steps S402 and S403 can not be reversed, the tempering treatment effect is optimized through multiple cooling curve design, the internal stress is eliminated, and the condition that the steel wire performance is finally influenced due to the incomplete recrystallization degree in single treatment is avoided.
S5: and a copper plating process, which is used for covering a tin bronze plating layer with good surface copper plating bonding force on the surface of the tire bead steel wire blank at a high speed.
S501: copper plating: and sequentially carrying out electrolytic pickling activation and electrochemical plating on the tire bead steel wire blank. In a specific embodiment, the plating material is typically selected to be tin bronze. In the present embodiment, the moving speed of the bead wire blank is 11 to 20 m/s.
S502: and water washing, wherein the water washing is used for quickly cleaning the residual plating solution on the surface of the steel wire by multistage high-pressure water, and the pressure range of the high-pressure water washing can be set to be 0.4-1.0 MPa. In one embodiment, the wash is 5 passes. In other embodiments, the number of times of water washing may be two, three, four or more, and is not limited to the above embodiments; hot water washing may also be used in combination.
S503: and (3) second induction drying: and (5) quickly drying the water on the surface of the steel wire. In one embodiment, the oven dry length may be 1.2-2 m. In order to facilitate the subsequent operation and improve the production efficiency, air cooling can be arranged after drying, as shown in fig. 1.
S6: coating process
S601: and the traction machine is used for traction auxiliary wire take-up. In the embodiment, a 450-reel tractor is adopted to assist in drawing and winding up through a 450-reel traction wheel.
S602: post-tension frame + coating: and after passing through the tension bracket, coating a layer of antirust tackifying coating on the surface of the steel wire. In this embodiment, the integrated design is carried out with the coating device to back tension frame, avoids the alignment back steel wire to draw the distance of overlength to recoat, can hang once more and make the coating inhomogeneous, influences protection effect and performance.
S603: and (6) taking up the wire. In the embodiment, a spool wire-rewinding machine <760 type > is adopted, and the steel wire plated with copper is wound on a 760 type I-shaped wheel.
By adopting the process technology, the method has the following advantages:
A) the flatness performance of the bead wire is stably kept within 3000 x 200, and the flatness performance of the bead wire is kept within 3000 x 600 in the traditional process. The quality is improved.
B) By adopting the single-filament single-control process, the stability of the color of the product is very good, and the stability of the thickness of the plating layer can be kept within 5 percent.
C) The rubber adhesive force can adapt to the influence of rubber materials of most manufacturers in China on vulcanization, the H extraction force can be stably ensured to be larger than 1200N, and the rubber adhesive force meets the quality standard of each large tire manufacturer.
D) After high-frequency tempering, lead is not needed in steel wire production, and stubborn diseases of the traditional production line of hanging lead can not be generated.
The invention also provides a production line for implementing the production method, which comprises a wire rod pretreatment device 100, a drawing device 200, a straightening device 300, a tempering device 400, a copper plating device 500 and a coating device 600 which are sequentially arranged as shown in figure 2. Referring to fig. 3 in detail, the wire rod pretreatment device 100 is sequentially provided with a wire releasing device, a mechanical husking machine 103, an online electrolytic pickling device 107 and a water washing device 109, the tempering device 400 adopts an online high-frequency tempering mode, the copper plating device 500 adopts an electrochemical plating mode, a tempered bead steel wire rod is released by the wire releasing device and then passes through the mechanical husking machine 103, the online electrolytic pickling device 107, the water washing device 109 and the drawing device 200, the tempered bead steel wire rod is adjusted and tensioned by the straightening device 300 and then passes through the tempering device 400, the copper plating device 500 and the coating device 600, and finally, the tempered bead steel wire finished product is obtained through automatic integrated forming, so that single-wire single-control production from the tempered bead steel wire rod to the tempered bead steel wire finished product is realized.
With reference to the integrated production line of tempered bead wires shown in fig. 3, the tempered bead wire rod is passed through in sequence:
the wire rod pretreatment device 100 sequentially comprises an upward-drawing pay-off rack 101, a mechanical husking machine 103, a first high-pressure water washing device 105, an online electrolytic pickling device 107 and a water washing device 109, wherein the water washing device 109 is sequentially provided with a second high-pressure water washing device 109a and a hot water washing device 109 b.
The drawing device 200 sequentially comprises an online boron coating device 201, a first induction drying device 203, a first air cooling device 205, a wire drawing unit 207 and a dry wiping device 209.
The straightening device 300 comprises a front tension bracket 301 and a rear tension bracket 303, wherein the front tension bracket 301 is arranged between the dry wiping device 209 and the tempering device 400, and the rear tension bracket 303 is integrated on the coating device 600.
The tempering device 400 comprises a tempering induction heating section 401, an air cooling section 403 and a water cooling device 405 in sequence.
The copper plating apparatus 500 includes an electrolytic pickling activation apparatus 501, an electrochemical plating apparatus 503, a copper plating post-washing apparatus 505, a second induction drying apparatus 507, and a second air cooling apparatus 509 in this order.
The coating device 600 sequentially comprises a tractor 601, a rear tension frame 303, a coating unit 603 and a spool take-up machine 605, and integrally forms the tempered bead wire.
All the process equipment in the production line form integrated equipment through reasonable preparation, and the integrated equipment is a one-step finished product from the raw material feeding to the finished product discharging without intermediate transfer and discharging, and is also called an integrated machine.
In other embodiments, the first high-pressure water washing device 105, the hot water washing device 109b, the second air-cooling device 509, etc. may be omitted as appropriate, depending on the actual production. In a specific embodiment, the production line is provided with a plurality of detection control modules for detecting energy consumption and regulating and controlling the running state, so that intelligent production is realized.
The full-automatic production line is verified to be a high-speed tempered bead wire integrated production line, and the production speed is up to 11-20 m/s.
1) Firstly, the traditional production process is changed, the working procedures are reduced, the production running speed is increased, the running speed of the produced steel wire is increased from 3-4m/s to 11-20m/s, and the running speed is increased by 4-5 times.
2) Secondly, the traditional centralized pickling is replaced by the on-line electrolytic pickling treatment wire rod, the traditional lead bath tempering is replaced by the high-frequency tempering, the traditional unfolded copper plating operation line is replaced by the integrated high-speed copper plating, the whole production process is visualized, the material is formed at one time, no off-line turnover is generated in the middle, the manpower transportation and the equipment cost are saved, and only 1 person is needed to operate the production line; the production speed and the requirements of the process equipment are balanced through reasonable design of the equipment, so that the single-line production speed is high in efficiency, the occupied area of the equipment is effectively reduced, the multi-line layout can be realized, and the batch production capacity is improved.
3) And thirdly, the whole production line can adopt artificial intelligence operation, the labor intensity of workers is reduced, the labor efficiency is improved, and the product quality is more stably guaranteed.
4) Because single-line production is adopted, the production line can be opened at any time, and compared with an expanded production line, the problems of high cost (common equipment is used) and long turnover time consumption and the like during non-full-load production of the equipment do not exist. The single-wire starting is the ideal economic load, and the machine is stopped without load, so that the consumption is avoided. The power consumption of the integrated machine ton product is about 400KW.H/T (representing the specification of 1.65mm), and the power consumption of the traditional expanded wire ton product is about 700KW.H/T (representing the specification of 1.65 mm).
In conclusion, the invention provides a more environment-friendly and efficient integrated production process and production line for the tempered bead wire, which have the advantages of low labor cost, high intelligence degree and more reliable product quality.
The above are all preferred embodiments of the present invention, and the protection scope of the present invention is not limited thereby, so: all equivalent changes made according to the structure, shape and principle of the invention are covered by the protection scope of the invention.
Claims (10)
1. An integrated production method of a tempered bead wire is characterized in that: the method comprises the integrated continuous operation of a wire rod pretreatment process, a drawing process, a straightening process, a tempering process, a copper plating process and a coating process, and realizes the single-wire single-control production from a tempered bead steel wire rod to a tempered bead steel wire finished product; the wire rod pretreatment process adopts online electrolytic pickling, the tempering process adopts an online high-frequency tempering mode, and the copper plating process adopts an electrochemical plating mode.
2. An integrated production method of a tempered bead wire according to claim 1, wherein said wire rod pretreatment process comprises the following sequential steps:
paying off the tempered bead wire rod;
mechanically peeling;
the on-line electrolytic pickling;
sequentially washing with high-pressure water and hot water to remove residual acid liquor on the surface to obtain the tire bead steel wire coil element; wherein the pressure range of the high-pressure water washing is 0.4-1.0 MPa; the water temperature range of the hot water washing is 60-100 ℃.
3. The integrated production method of a tempered bead wire according to claim 2, wherein the drawing process comprises the steps of:
coating boron on the tire bead wire disc element on line;
then drying the moisture on the surface of the bead wire coil element by induction heating;
then integrally drawing the bead wire coil element to a set wire diameter;
and (5) dry wiping and removing drawing lubricating powder to obtain the tire bead steel wire blank.
4. The integrated production method of a tempered bead wire according to claim 3, characterized in that: in the tempering process, the bead wire blank is tempered in a high frequency mode, and then is cooled in an air cooling section and water to obtain the bead wire blank, wherein the temperature range set by the high frequency tempering is 450-550 ℃.
5. The integrated production method of a tempered bead wire according to claim 4, characterized in that: and the copper plating process comprises the steps of sequentially carrying out electrolytic pickling activation, electrochemical plating, water washing and induction drying on the tire bead steel wire blank, and then coating an antirust tackifying coating in the coating process to obtain the finished product of the tempered tire bead steel wire.
6. The integrated production method of a tempered bead wire according to claim 1, characterized in that: the linear speed of the finished tempered bead wire is 11-20 m/s.
7. The utility model provides an integration production line of tempering tire bead steel wire which characterized in that: the device comprises a wire rod pretreatment device, a drawing device, a straightening device, a tempering device, a copper plating device and a coating device which are sequentially arranged, wherein the wire rod pretreatment device is sequentially provided with a paying-off device, a mechanical husking machine, an online electrolytic pickling device and a water washing device, the tempering device adopts an online high-frequency tempering mode, the copper plating device adopts an electrochemical plating mode, a tempered bead steel wire rod passes through the mechanical husking machine, the online electrolytic pickling device, the water washing device and the drawing device after being paid off by the paying-off device, passes through the tempering device, the copper plating device and the coating device after being adjusted and tensioned by the straightening device, and finally, a tempered bead steel wire finished product is obtained through automatic integrated forming, so that single-wire single-control production from the bead steel wire rod to the tempered bead steel wire finished product is realized.
8. The integrated production line of tempered bead wires according to claim 7, characterized in that: the drawing device comprises an online boron coating device and a wire drawing unit; the straightening device comprises a group of tension brackets, one tension bracket is arranged between the tempering device and the drawing device, and the other tension bracket is integrated on the coating device and is positioned at the front end of the coating device; the tempering device sequentially comprises a tempering induction heating section, an air cooling section and a water cooling device; the copper plating device sequentially comprises an electrolytic pickling activation device, an electrochemical plating device, a copper plating post-washing device, an induction drying device and an air cooling device.
9. The integrated production line of tempered bead wires according to claim 8, characterized in that: a tractor is arranged between the air cooling device and the coating device, and the traction speed is 11-20 m/s; and the tail end of the production line is provided with a take-up machine.
10. The integrated production line of tempered bead wires according to claim 7, characterized in that: the production line is provided with a plurality of detection control modules for detecting energy consumption and regulating and controlling the running state, thereby realizing intelligent production.
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| CN202111192122.1A CN113913890A (en) | 2021-11-29 | 2021-11-29 | Integrated production method and production line of tempered bead wire |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2024152395A1 (en) * | 2023-01-18 | 2024-07-25 | 江苏兴达钢帘线股份有限公司 | Tire bead wire production line and production method |
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2021
- 2021-11-29 CN CN202111192122.1A patent/CN113913890A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2024152395A1 (en) * | 2023-01-18 | 2024-07-25 | 江苏兴达钢帘线股份有限公司 | Tire bead wire production line and production method |
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