WO2021047681A1 - Npr钢筋盘圆的加工工艺 - Google Patents

Npr钢筋盘圆的加工工艺 Download PDF

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Publication number
WO2021047681A1
WO2021047681A1 PCT/CN2020/118266 CN2020118266W WO2021047681A1 WO 2021047681 A1 WO2021047681 A1 WO 2021047681A1 CN 2020118266 W CN2020118266 W CN 2020118266W WO 2021047681 A1 WO2021047681 A1 WO 2021047681A1
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Prior art keywords
steel bar
npr
procedure
steel
steel bars
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PCT/CN2020/118266
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English (en)
French (fr)
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何满潮
夏敏
郭洪燕
李洪超
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何满潮
夏敏
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Application filed by 何满潮, 夏敏 filed Critical 何满潮
Priority to JP2022516225A priority Critical patent/JP2023535656A/ja
Priority to GB2201623.2A priority patent/GB2600856B/en
Priority to US17/640,223 priority patent/US11679429B2/en
Publication of WO2021047681A1 publication Critical patent/WO2021047681A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/16—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling wire rods, bars, merchant bars, rounds wire or material of like small cross-section
    • B21B1/163—Rolling or cold-forming of concrete reinforcement bars or wire ; Rolls therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
    • B21H7/00—Making articles not provided for in the preceding groups, e.g. agricultural tools, dinner forks, knives, spoons
    • B21H7/18—Making articles not provided for in the preceding groups, e.g. agricultural tools, dinner forks, knives, spoons grooved pins; Rolling grooves, e.g. oil grooves, in articles
    • B21H7/187—Rolling helical or rectilinear grooves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
    • B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
    • B21C37/045—Manufacture of wire or bars with particular section or properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
    • B21C1/003—Drawing materials of special alloys so far as the composition of the alloy requires or permits special drawing methods or sequences
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F1/00—Bending wire other than coiling; Straightening wire
    • B21F1/02—Straightening
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F15/00—Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire
    • B21F15/02—Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire
    • B21F15/06—Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material
    • B21F15/08—Connecting wire to wire or other metallic material or objects; Connecting parts by means of wire wire with wire with additional connecting elements or material making use of soldering or welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21F—WORKING OR PROCESSING OF METAL WIRE
    • B21F45/00—Wire-working in the manufacture of other particular articles
    • B21F45/006—Wire-working in the manufacture of other particular articles of concrete reinforcement fibres

Definitions

  • the invention relates to the technical field of steel production, in particular, to a processing technology of NPR steel bar coils.
  • the new NPR material overcomes the local deformation and fracture of ordinary rebar and prestressed steel, and achieves both high strength and high toughness, with a yield strength of up to 900 MPa and a maximum force elongation of more than 20%; automatic intelligent NPR cold
  • the rolled (cold drawn) steel bar coil production line is mainly used for cold processing of new NPR materials.
  • the products are mainly NPR steel bars with a diameter of less than 14 mm, NPR cold-rolled spiral steel bars, and NPR prestressed steel bars.
  • the existing ordinary steel bar cold processing production line adopts cannon-type rack or rotating pay-off reel to pay off, adopts disc-type wire drawing machine for traction and wire drawing, adopts rolling tip and cold drawing through wire drawing die, and then adjusts Straight and cut can not be directly applied to the processing of NPR steel bars.
  • the existing gun-type uncoiler can only be used for low-carbon, small-diameter steel bars, and cannot be used for high-carbon steel bars or large-diameter high-carbon steel bars, especially NPR steel bars that produce resistance due to external forces.
  • the disc-type unwinding rack cannot be used for the unwinding of high-strength steel bars.
  • the above two pay-off methods a) Can not achieve continuous production without stopping, b) Can not meet the requirements of high-strength steel bars.
  • the existing steel welding machine can only weld low-carbon or ordinary high-carbon steel wire welding requirements. a) Cannot meet the welding requirements of large diameter, high strength, austenitic steel bars; b) Cannot complete the automatic thorn removal function; c) Cannot complete the digital operation.
  • the existing process adopts wire drawing dies to reduce the diameter.
  • the service life of the wire drawing dies is very short.
  • the service life of the die is only 2-3 tons, and the cost of the die is extremely high, which accounts for its processing.
  • the embodiment of the present invention provides a processing technology for the round of NPR steel bars to meet the requirements of fully automatic and intelligent production of NPR steel bars, NPR cold-rolled spiral steel bars, and NPR prestressed steel bars.
  • the present invention provides a process for processing NPR steel bars.
  • the NPR steel bars are cold-worked and have a diameter of less than 14 mm.
  • the NPR steel bars have a yield strength of 800MPa-950MPa, a tensile strength of 900MPa-1100MPa, and a maximum Force elongation ⁇ 20%;
  • the steps of the processing technology include: one-line unwinding process L20: one end of the unwinding rack is fixed, and the end of the steel bar is welded, and the front end of the steel bar is welded without stopping;
  • the uncoiling process L30 According to the travel direction of the steel bar, provide traction power to the in-line decoiler and initially level the steel bar, synchronize the steel bar with the wire drawing machine through intelligent industrial control equipment, and deliver the steel bar synchronously for the subsequent process; leveling process L40: adopt the steel wheel rolling leveling method , To make the steel bars repeatedly bend to cause the steel bars to lose stress
  • butt welding process L60 use PLC numerical control technology to control the current size to match the diameter of the steel bar, weld the steel bar according to the time required for steel welding and the welding current, and automatically remove the burrs on the welding surface of the steel bar after the welding is completed; hydraulic push Head process L70: Push the steel bar head to the smooth mold, and make it pass through the smooth mold in sequence.
  • the length of the steel bar head after the mold can be set; cold drawing smooth surface process L80: Perform NPR rebar Diameter modification and finishing, so that the busbar diameter rules are unified; sandblasting process L90: uses intelligent numerical control technology to communicate with the master control equipment, and automatically adjusts the diameter of the steel bars to be processed and the surface requirements of the steel bars.
  • Intelligent master control process L01 The intelligent master control system is connected to a remote computer server through an optical fiber network cable, through the server to realize remote one-key automatic start and stop, and view the production line equipment through the server Operating status and production information.
  • the processing technology of the NPR rebar coil of the present invention replaces the pickling step in the prior art through the sandblasting process L90, which meets the national green environmental protection requirements, and can be digitally produced online; through the one-line unwinding process L20 and the uncoiling process L30 replaces the application of cannon-type uncoiling racks in the prior art, does not stop production and avoids surface scratches and bends in the traction process of steel bars, and meets the requirements of high-strength steel bars; and other processes can achieve full intelligence It can meet the processing requirements of NPR rebar coils and the automatic and intelligent production requirements of NPR rebars, NPR cold-rolled spiral rebars, and NPR prestressed rebars.
  • Fig. 1 is a schematic flow chart of the processing technology of the NPR rebar coil according to the embodiment of the present invention.
  • Fig. 2 is a schematic diagram of a specific process flow of the processing technology of the NPR rebar coil in an embodiment of the present invention.
  • Figure 3 is a schematic diagram of an interface of the intelligent master control system of the fully automatic and intelligent NPR cold-rolled (cold-drawn) steel bar coil production line.
  • Figure 4 is a schematic diagram of another interface of the intelligent master control system of the fully automatic and intelligent NPR cold-rolled (cold-drawn) steel bar coil production line.
  • Fig. 5 is a photograph of the spiral rib of the NPR rebar obtained by the NPR rebar coil processing process according to the embodiment of the present invention.
  • FIG. 6 is a schematic diagram of an experimental curve of tensile test of NPR steel bars obtained by the processing technology of NPR steel bars in an embodiment of the present invention.
  • a process for processing NPR rebar coils is provided, which is processed by a fully automatic and intelligent NPR cold-rolled (cold drawn) rebar coil production line.
  • the NPR rebars are cold processed.
  • the NPR steel bar has a yield strength of 800MPa-950MPa, a tensile strength of 900MPa-1100MPa, and a maximum force elongation ⁇ 20%; the processing steps include:
  • Intelligent master control process L10 The intelligent master control system is connected to a remote computer server through an optical fiber network cable, and realizes remote one-key automatic start and stop through the server. View the operating status and production information of the production line equipment through the server; through the control panel, buttons, PLC module, power supply module, contactor and other necessary electrical devices of each equipment, it can be used for automatic and manual control operations. You can view equipment related parameters such as the equipment name, operating status, and steel production information of the equipment. As shown in Fig. 3 and Fig. 4, the interface schematic diagram of the intelligent master control system of the automatic and intelligent NPR cold-rolled (cold drawn) steel bar coiling production line is shown.
  • One-line unwinding process L20 One end of the unwinding rack is fixed, and the steel bar is welded at the end and the end of the steel bar.
  • the front end of the steel bar can realize non-stop welding.
  • the rotating end of the flat frame performs rotating breaking force, so that the steel bar can be wound according to the normal way of the raw material, and flattened and laid out in the opposite direction of the raw material rotation direction, so that the steel bar will not produce axial direction when the flat line is laid.
  • Torsion the end of the steel bar is fixed during the laying-out process, which can realize the head and tail welding without stopping, so that the normal production of the steel bar without stopping the machine can be realized.
  • Uncoiling process L30 According to the traveling direction of the steel bar, provide traction power to the in-line decoiler and initially level the steel bar, synchronize the steel bar with the wire drawing machine through intelligent industrial control equipment, and deliver the steel bar synchronously for the subsequent process; make the steel bar can be conveyed straight and at the same speed
  • the subsequent leveling, sandblasting and other devices can avoid the surface scratches and bends of the steel bars during the traction process.
  • Leveling process L40 Using the steel wheel rolling and leveling method, the steel bars are repeatedly bent to cause the steel bars to lose stress, so that the straight surface of the steel bars is not scratched; it can be used in the form of a straight line to enter the subsequent sandblasting or wire wheel removal. Rust equipment.
  • Tip-rolling process L50 The tip-rolling process is used to correct or remove the surface shape defects such as "waterline” or “ellipse” of the steel bar head wire during each production line start-up process, which effectively saves the rebar head in the process.
  • Butt welding process L60 Use PLC numerical control technology to control the current size to match the diameter of the steel bar. Weld the steel bar according to the time required for steel bar welding and the welding current. After the welding is completed, the burr on the surface of the steel bar welding is automatically removed; the welder can weld high-carbon steel wire , Low-carbon steel wire, austenitic steel bar, NPR steel bar, after welding, it can automatically remove the burrs on the welding surface of the steel bar, and can communicate with the main control equipment to complete the online welding task or the initial raw material storage welding task.
  • Hydraulic push head process L70 Push the steel bar head to the smooth mold, and make it pass through the smooth mold in sequence.
  • the length of the steel head after the mold can be set; avoiding the sharpening of the steel bar when it is over-molded Or the tip rolling causes a lot of waste of steel bars, reduces the labor intensity and time waste of workers, and is a key process to realize automation.
  • Cold-drawn smoothing process L80 Perform diameter modification and finishing of NPR steel bars, grind the wood with irregular diameters, and make the busbar diameter uniform after the cold-drawn smoothing process.
  • Sandblasting process L90 use intelligent numerical control technology to communicate with the master control equipment, automatically adjust the diameter of the steel bars to be processed and the surface requirements of the steel bars, and the sand output of the steel grit to detect the oxide skin and surface defects on the surface of the NPR hot-rolled steel bars And the lubricating powder of the smooth mold is processed online; in order to replace the original pickling process, intelligent numerical control technology is used to communicate with the master control equipment, and the steel grit is automatically adjusted according to the diameter of the steel bar to be processed and the surface of the steel bar. The amount of sand is used to process the oxide scale, surface defects and the lubricating powder of the smooth mold on the surface of the NPR hot-rolled steel bar. The maximum processing speed can reach 80 m/min.
  • the surface is bright oxide scale, surface defects and smooth mold.
  • Lubricant powder Avoid huge smoke and dust during online annealing in the next step; when the speed of steel grit production, the steel bar stops moving, and the steel bar surface is not completely processed, it will automatically alarm and stop and transmit the information to the central control.
  • In-situ online annealing process L10 Use intermediate frequency heating method to perform in-situ online heating and annealing of the steel bars. During the heating and annealing process, the maximum temperature is 1100 degrees Celsius and the fastest walking speed is 80 m/s.
  • Air-cooled buffer process L11 Use air-cooling to cool the high-temperature steel wire on-line;
  • Closing circle process L12 The NPR with residual temperature or residual heat is subjected to high-speed automatic feeding, chuck, automatic head and tail cutting, and automatic unloading of the NPR.
  • Unwinding process L13 unwinding the coiled steel bars after shaping and annealing heat treatment and cooling.
  • Leveling process L14 using multi-wheel cross 360-degree curve rolling and straightening to eliminate the internal stress of the steel bars, and the spiral ribs of the steel bars will not be damaged during the pre-straightening process; see Figure 5, which shows the present invention Photographs of spiral ribs of NPR steel bars obtained by the processing technology of the NPR steel bars in the embodiment.
  • Cold-drawn spiral process L15 The production of spiral steel bars is carried out by cold rolling with a roll die, that is, multiple roll dies are uniformly arranged in the circumferential direction through which the base material passes in a special rotating device.
  • a roll die that is, multiple roll dies are uniformly arranged in the circumferential direction through which the base material passes in a special rotating device.
  • the base material is drawn by the wire drawing machine through the rotation
  • a plurality of roll molds process spiral grooves on the surface of the base material through rolling friction.
  • Pre-straightening process L16 Multi-wheeled cross 360-degree curve rolling and straightening is used to eliminate the internal stress of the steel bars, and the spiral ribs of the steel bars will not be damaged during the pre-straightening process; and it is connected to the central processing unit.
  • Closing round process L17 The equipment in this process consists of a hydraulic shear system, two steel pipes, and two reel-type winding machines to realize online production and non-stop closing and bundling.
  • the processing technology of the NPR rebar coil of the present invention replaces the pickling step in the prior art through the sandblasting process L90, which meets the national green environmental protection requirements, and can be digitally produced online; through the one-line unwinding process L20 and the uncoiling process L30 replaces the application of cannon-type uncoiling racks in the prior art, does not stop production and avoids surface scratches and bends in the traction process of steel bars, and meets the requirements of high-strength steel bars; and other processes can achieve full intelligence It can meet the processing requirements of NPR rebar coils and the automatic and intelligent production requirements of NPR rebars, NPR cold-rolled spiral rebars, and NPR prestressed rebars.
  • Figure 2 provided by the present invention shows a specific process.
  • the above-mentioned cold-drawn screw process L15 is carried out by a cold-drawn screw machine, and the production of spiral steel bars is carried out by means of roll die cold rolling, that is, multiple roll dies are uniformly arranged in the circumferential direction through which the base material passes in a special rotating device.
  • roll die cold rolling that is, multiple roll dies are uniformly arranged in the circumferential direction through which the base material passes in a special rotating device.
  • the base material is drawn by the wire drawing machine through the rotating device, multiple roll molds process spiral grooves on the surface of the base material through rolling friction.
  • the drawing machine traction Doubled the service life of the mold can reach 3000-5000 tons of processed steel bars.
  • the extension of the life of the mold eliminates the need for frequent replacement of the mold, which can save more than 90% of the mold cost, and there is no need to use grease and lubrication during the processing.
  • Powder or lubricating oil which greatly reduces production costs and labor intensity, and improves production efficiency.
  • it saves more than 20% of manpower, saves more than 60% of electricity, and increases production capacity by more than 20%, saving each production line every year 3 million-5 million.
  • the above-mentioned NPR cold-rolled (cold-drawn) steel bar coil processing technology has the advantages of low pollution, low energy consumption, intelligence, and high degree of automation, and the quality control is stable and the production cost is low. In particular, it solves a series of problems that exist in the cold processing of ordinary steel bars, such as environmental protection, low automation, large mold loss, high energy consumption, and the inability to directly process NPR steel bars.
  • the raw materials of NPR steel bars are processed by the fully automatic and intelligent NPR cold-rolled (cold-drawn) steel bar coil production line, achieving both high strength and high toughness, with a yield strength of up to 900 MPa and a maximum force elongation of more than 20%.

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  • Life Sciences & Earth Sciences (AREA)
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Abstract

一种NPR钢筋盘圆的加工工艺，所述NPR钢筋为冷加工态，直径小于14毫米，所述NPR钢筋屈服强度800MPa‑950MPa、抗拉强度900MPa‑1100MPa、最大力延伸率≥20％；所述加工工艺的步骤包括：一字放料工序L20；开卷工序L30；校平工序L40；轧尖工序L50；对焊工序L60；液压推头工序L70；冷拔光面工序L80；喷砂工序L90；原位在线退火工序L10；风冷缓冲工序L11；收盘圆工序L12；放料工序L13；校平工序L14；冷拔螺旋工序L15；调直工序L16；收盘圆工序L17。NPR钢筋盘圆的加工工艺可以实现全程智能化，满足NPR钢筋盘圆的加工要求，满足NPR钢筋、NPR冷轧螺旋钢筋、NPR预应力钢筋全自动智能化的生产要求。

Description

NPR钢筋盘圆的加工工艺 技术领域
本发明涉及钢材生产技术领域，具体而言，涉及一种NPR钢筋盘圆的加工工艺。
背景技术
现有技术中，NPR新材料克服了普通螺纹钢和预应力钢筋局部变形断裂的情况，实现了既高强又高韧，屈服强度高达900MPa，最大力延伸率20％以上；全自动智能化NPR冷轧(冷拉)钢筋盘圆生产线主要用于NPR新材料的冷加工，产品主要为直径小于14毫米的NPR钢筋、NPR冷轧螺旋钢筋、NPR预应力钢筋。
全自动智能化NPR冷轧(冷拉)钢筋盘圆生产通过首尾焊接、钢筋除锈、钢丝轮或抛丸喷砂除锈、开卷、校平、轧尖或液压推头、钢筋冷拔修形、钢筋调直、钢筋回火、冷却加热后钢筋、回火后的钢筋集打捆、钢筋头轧细、校平钢筋、钢筋收尾焊接、钢筋初步调直、螺旋带肋、钢筋矫直、两个打捆机切换时切断钢筋用、收成品钢筋。
现有普通钢筋冷加工生产线通过酸洗、磷化后，采用炮式料架或旋转放线盘放线，采用圆盘式拉丝机进行牵引拉丝，采用轧尖、通过拉丝模具进行冷拉，后调直、切断，不能直接应用于NPR钢筋的加工。
现有普通钢筋冷加工生产线的技术弊端：
1)现有氧化皮清洗工艺采用酸洗、磷化不能满足国家绿色环保要求，不能完成在线数字化生产。
2)现有炮式开卷料架只能用于低碳、小直径钢筋的应用，不能用于高碳钢筋或大直径高碳钢筋的使用，特别是NPR钢筋这种因外力产生抵抗力钢筋的应用，圆盘式放料架，不能用于高强钢筋的放线。以上二种放线方式。a)不能做到连续生产不停机，b)不能满足高强钢筋的放线要求。
3)现有钢筋焊接机只能焊接低碳或普通高碳钢丝的焊接要求。a) 不能满足大直径高强、奥氏体钢筋的焊接要求；b)不能完成自动祛刺功能；c)不能完成数字化操作。
4)现有钢筋采用轧尖或削尖方式进行穿头，造成工人劳动强度较大，操作过程中存在安全危险，钢筋轧头长度过长，轧尖部分在实际应用中，无法使用，只能做废品处理，造成极大的原材料浪费。
5)现有工艺采用拉丝模具减径成型，在高强钢丝或奥氏体钢筋加工过程中拉丝模具的使用寿命非常短，模具的使用寿命只有2-3吨，模具使用费用极高，占其加工费用成本的60％左右，需要更换模具，更换模具时工人劳动强度大，耗时耗力，反复穿丝造成钢筋原材料极大浪费，需采用润滑脂润滑，增加了钢筋的加工成本。
6)现有普通钢筋冷加工生产线不能完成自动化生产，不能做到远程监控，生产的钢筋不能做到追踪溯源，无法做到从原材料到加工到智能化仓储，无法实现全程智能化监控。
综上所述，现有普通钢筋冷加工生产线以及加工工艺，无法满足NPR钢筋、NPR冷轧螺旋钢筋、NPR预应力钢筋全自动智能化的生产要求。
发明内容
本发明实施例中提供一种NPR钢筋盘圆的加工工艺，以满足NPR钢筋、NPR冷轧螺旋钢筋、NPR预应力钢筋全自动智能化的生产要求。
为实现上述目的，本发明提供了一种NPR钢筋盘圆的加工工艺，所述NPR钢筋为冷加工态，直径小于14毫米，所述NPR钢筋屈服强度800MPa-950MPa、抗拉强度900MPa-1100MPa、最大力延伸率≥20％；所述加工工艺的步骤包括：一字放料工序L20：放料架的一端固定，进行钢筋的首尾焊接，钢筋的前端头部，不停机头尾焊接；开卷工序L30：按照钢筋行进方向，给一字开卷机提供牵引动力并将钢筋初步调平，通过智能工控设备与拉丝机同步，为后续的工序同步输送钢筋；校平工序L40：采用钢筋轮滚动校平方式，使其钢筋进行反复弯曲致使钢筋失去应力，使钢筋平直表面无划伤；轧尖工序L50：采用轧尖工艺，在每次生产线启动穿头过程中，对钢筋头部线材的表面形状缺陷进行修正或者去除；对焊工序L60：采用PLC数控技术控制电流大小与钢 筋直径相匹配，按照钢筋焊接所需时间以及焊接电流对钢筋进行焊接，焊接完成后自动祛除钢筋焊接表面的毛刺；液压推头工序L70：将钢筋头部推送至光面模具，使其顺序通过光面模具，根据拉丝机的要求可设定过模后钢筋头部的长短；冷拔光面工序L80：将NPR钢筋进行直径修形整理，使母线直径规则统一；喷砂工序L90：采用智能数控技术与总控设备联网通讯，根据所需加工钢筋的直径及钢筋表面要求进行自动调整、钢砂的出砂量来对NPR热轧钢筋表面的氧化皮、表面缺陷以及光面模的润滑粉进行处理；原位在线退火工序L10：对钢筋进行原位在线加热退火；风冷缓冲工序L11：采用风冷对高温的钢筋线材进行在线冷却；收盘圆工序L12：将带有余温或余热的钢筋进行高速收卷，并进行自动送料、夹头、自动头尾剪切、自动卸料；放料工序L13：将整形以及退火热处理冷却后的盘圆钢筋进行开卷放线料；校平工序L14：采用多轮式十字交叉360度曲线滚压调直，使钢筋消除内在应力；冷拔螺旋工序L15：采用辊模冷轧的方式进行螺旋钢筋的生产；调直工序L16：采用多轮十字或水平调直，在校平的基础上进行精调；收盘圆工序L17：在线生产不停车收盘打捆。
进一步地，在一字放料工序L20之前还包括：智能化总控工序L01：智能化总控系统通过光纤网线连接到远程计算机服务器，通过服务器实现远程一键自动启动停止，通过服务器查看生产线设备的运行状态及生产信息。
本发明的NPR钢筋盘圆的加工工艺，通过喷砂工序L90代替了现有技术中的酸洗步骤，满足了国家绿色环保要求，而且可以在线数字化生产；通过一字放料工序L20和开卷工序L30代替了现有技术中炮式开卷料架的应用，不停机生产而且避免了钢筋在牵引过程中表面划伤、弯曲等现象，满足了高强钢筋的放线要求；而且其他工序可以实现全程智能化，满足NPR钢筋盘圆的加工要求，满足NPR钢筋、NPR冷轧螺旋钢筋、NPR预应力钢筋全自动智能化的生产要求。
附图说明
图1是本发明实施例的NPR钢筋盘圆的加工工艺的流程示意图。
图2是本发明实施例的NPR钢筋盘圆的加工工艺的具体流程示意 图。
图3是全自动智能化NPR冷轧(冷拉)钢筋盘圆生产线的智能化总控系统一个界面的示意图。
图4是全自动智能化NPR冷轧(冷拉)钢筋盘圆生产线的智能化总控系统另一个界面的示意图。
图5是本发明实施例的NPR钢筋盘圆的加工工艺制得的NPR钢筋的螺旋肋照片。
图6是本发明实施例的NPR钢筋盘圆的加工工艺制得的NPR钢筋拉伸的实验曲线示意图。
具体实施方式
下面结合附图和具体实施例对本发明作进一步详细描述，但不作为对本发明的限定。
参见图1所示，根据本发明的实施例，提供了一种NPR钢筋盘圆的加工工艺，通过全自动智能化NPR冷轧(冷拉)钢筋盘圆生产线进行加工，所述NPR钢筋为冷加工态，所述NPR钢筋屈服强度800MPa-950MPa、抗拉强度900MPa-1100MPa、最大力延伸率≥20％；所述加工工艺的步骤包括：
智能化总控工序L10：智能化总控系统通过光纤网线连接到远程计算机服务器，通过服务器实现远程一键自动启动停止。通过服务器查看生产线设备的运行状态及生产信息；可通过每台设备的控制面板、按钮、PLC模块、电源模块、接触器等其它必需的电气装置，可用作自动和手动控制操作。可查看设备的设备名称、运行状态、钢筋产量信息等设备相关参数。如图3和图4所示，示出了全自动智能化NPR冷轧(冷拉)钢筋盘圆生产线的智能化总控系统的界面示意图。
一字放料工序L20：放料架的一端固定，进行钢筋的首尾焊接，钢筋的前端头部，实现不停机头尾焊接；通过括充、开卷、进入一字放料架中心在钢筋牵引放线时，一字架旋转端进行旋转破力，使其钢筋能按照原材料的缠绕方式正常，按照原材料的旋转方向反方向开平、放线，使其钢筋在开平放线时，不会产生轴向、扭力，在放线过程中钢筋尾部固定不动，可以实现不停机头尾焊接，这样可以实现钢筋的 不停机正常生产。
开卷工序L30：按照钢筋行进方向，给一字开卷机提供牵引动力并将钢筋初步调平，通过智能工控设备与拉丝机同步，为后续的工序同步输送钢筋；使钢筋能平直、同速输送给后续调平喷砂等装置，避免了钢筋在牵引过程中表面划伤、弯曲等现象。
校平工序L40：采用钢筋轮滚动校平方式，使其钢筋进行反复弯曲致使钢筋失去应力，使钢筋平直表面无划伤；能以直线的形式，很好的进入后续喷砂或钢丝轮除锈设备。
轧尖工序L50：采用轧尖工艺，在每次生产线启动穿头过程中，对钢筋头部线材“水线”或“椭圆”等表面形状缺陷进行修正或者去除，有效的节约了钢筋头部在冷轧过程中不能使用的头部钢筋问题。
对焊工序L60：采用PLC数控技术控制电流大小与钢筋直径相匹配，按照钢筋焊接所需时间以及焊接电流对钢筋进行焊接，焊接完成后自动祛除钢筋焊接表面的毛刺；焊机能够焊接高碳钢丝、低碳钢丝、奥氏体钢筋、NPR钢筋，焊接完成后可以自动祛除钢筋焊接表面的毛刺，并能与总控设备联网通讯，可以完成在线焊接任务或初使原材料储存焊接任务。
液压推头工序L70：将钢筋头部推送至光面模具，使其顺序通过光面模具，根据拉丝机的要求可设定过模后钢筋头部的长短；避免了钢筋过模时通过削尖或轧尖造成钢筋大量的浪费、减少了工人的劳动强度、时间上的浪费，是实现自动化的关键工艺。
冷拔光面工序L80：将NPR钢筋进行直径修形整理，将直径有偏差不规则的木材磨面，冷拔光面工序修形以后使母线直径规则统一。
喷砂工序L90：用智能数控技术与总控设备联网通讯，根据所需加工钢筋的直径及钢筋表面要求进行自动调整、钢砂的出砂量来对NPR热轧钢筋表面的氧化皮、表面缺陷以及光面模的润滑粉进行在线处理；为了代替原有的酸洗工艺，采用智能数控技术与总控设备联网通讯，根据所需加工钢筋的直径及钢筋表面要求进行自动调整、钢砂的出砂量，来对NPR热轧钢筋表面的氧化皮、表面缺陷以及光面模的润滑粉进行在线处理，处理最大速度可达80米/分钟，处理后表面光亮氧化皮、表面缺陷以及光面模的润滑粉。避免下一步工序在线退火时极大的烟 和粉尘；在钢砂的出砂速度、钢筋停止行进时、钢筋表面未完全处理时自动报警停车并把信息传递给中央总控。
原位在线退火工序L10：采用中频加热方式，对钢筋进行原位在线加热退火，钢筋加热退火过程中，最大温度1100摄氏度，最快行走速度80米/秒。
风冷缓冲工序L11：采用风冷对高温的钢筋线材进行在线冷却；
收盘圆工序L12：将带有余温或余热的NPR进行高速收卷自动送料、夹头、自动头尾剪切、自动卸料。
放料工序L13：将整形以及退火热处理冷却后的盘圆钢筋进行开卷放线料。
校平工序L14：采用多轮式十字交叉360度曲线滚压调直，使钢筋消除内在应力，钢筋在预调直过程中螺旋肋不会受到损伤；参见图5，图5示出了本发明实施例的NPR钢筋盘圆的加工工艺制得的NPR钢筋的螺旋肋照片。
冷拔螺旋工序L15：采用辊模冷轧的方式进行螺旋钢筋的生产，即在一个专用旋转装置中母材通过的圆周方向上均匀设置有多个辊模，当母材被拉丝机牵引通过旋转装置时，多个辊模通过滚动摩擦对母材表面加工出螺旋槽。
预调直工序L16：采用多轮式十字交叉360度曲线滚压调直，使钢筋消除内在应力，钢筋在预调直过程中螺旋肋不会受到损伤；且与中央处理器相连。
收盘圆工序L17：本工序设备由液压剪切系统、两个钢筋导管、两个盘式收线机组成，实现在线生产不停车收盘打捆。
本发明的NPR钢筋盘圆的加工工艺，通过喷砂工序L90代替了现有技术中的酸洗步骤，满足了国家绿色环保要求，而且可以在线数字化生产；通过一字放料工序L20和开卷工序L30代替了现有技术中炮式开卷料架的应用，不停机生产而且避免了钢筋在牵引过程中表面划伤、弯曲等现象，满足了高强钢筋的放线要求；而且其他工序可以实现全程智能化，满足NPR钢筋盘圆的加工要求，满足NPR钢筋、NPR冷轧螺旋钢筋、NPR预应力钢筋全自动智能化的生产要求。
优选地，本发明提供的图2给出了具体流程。上述的冷拔螺旋工 序L15通过冷拔螺旋机进行，采用辊模冷轧的方式进行螺旋钢筋的生产，即在一个专用旋转装置中母材通过的圆周方向上均匀设置有多个辊模，当母材被拉丝机牵引通过旋转装置时，多个辊模通过滚动摩擦对母材表面加工出螺旋槽，与冷拔加工方式对比，采用辊模冷轧的方式进行螺旋钢筋加工时，拉丝机牵引力降低一倍，模具的使用寿命可以达到加工钢筋3000-5000吨，模具寿命的延长使得不需人工频繁的更换模具，可以节约模具费用90％以上，并且在加工过程中不需要使用润滑脂、润滑粉或润滑油，大大降低了生产成本和人工劳动强度，提高了生产效率，与现有技术相比，节省人力20％以上，节省电力60％以上，提高产能20％以上，每年每条生产线节省300万-500万。
参见图5和图6，上述的化NPR冷轧(冷拉)钢筋盘圆的加工工艺，具有污染小、能耗低、智能化、自动化程度高的优点，而且质量控制稳定，生产成本低。尤其是解决了普通钢筋冷加工存在的环保、自动化低、模具损耗大，能耗高，以及不能直接加工NPR钢筋等一系列问题。NPR钢筋原材料通过全自动智能化NPR冷轧(冷拉)钢筋盘圆生产线的加工，实现了既高强又高韧，屈服强度高达900MPa，最大力延伸率20％以上。
需要注意的是，这里所使用的术语仅是为了描述具体实施方式，而非意图限制根据本申请的示例性实施方式。如在这里所使用的，除非上下文另外明确指出，否则单数形式也意图包括复数形式，此外，还应当理解的是，当在本说明书中使用术语“包含”和/或“包括”时，其指明存在特征、步骤、工作、器件、组件和/或它们的组合。
需要说明的是，本申请的说明书和权利要求书及上述附图中的术语“第一”、“第二”等是用于区别类似的对象，而不必用于描述特定的顺序或先后次序。应该理解这样使用的数据在适当情况下可以互换，以便这里描述的本申请的实施方式能够以除了在这里图示或描述的那些以外的顺序实施。
当然，以上是本发明的优选实施方式。应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明基本原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也视为本发明的保护范围。

Claims (2)

  1. 一种NPR钢筋盘圆的加工工艺，其特征在于，所述NPR钢筋为冷加工态，直径小于14毫米，所述NPR钢筋屈服强度800MPa-950MPa、抗拉强度900MPa-1100MPa、最大力延伸率≥20％；所述加工工艺的步骤包括：
    一字放料工序L20：放料架的一端固定，进行钢筋的首尾焊接，钢筋的前端头部，不停机头尾焊接；
    开卷工序L30：按照钢筋行进方向，给一字开卷机提供牵引动力并将钢筋初步调平，通过智能工控设备与拉丝机同步，为后续的工序同步输送钢筋；
    校平工序L40：采用钢筋轮滚动校平方式，使其钢筋进行反复弯曲致使钢筋失去应力，使钢筋平直表面无划伤；
    轧尖工序L50：采用轧尖工艺，在每次生产线启动穿头过程中，对钢筋头部线材的表面形状缺陷进行修正或者去除；
    对焊工序L60：采用PLC数控技术控制电流大小与钢筋直径相匹配，按照钢筋焊接所需时间以及焊接电流对钢筋进行焊接，焊接完成后自动祛除钢筋焊接表面的毛刺；
    液压推头工序L70：将钢筋头部推送至光面模具，使其顺序通过光面模具，根据拉丝机的要求可设定过模后钢筋头部的长短；
    冷拔光面工序L80：将NPR钢筋进行直径修形整理，使母线直径规则统一；
    喷砂工序L90：采用智能数控技术与总控设备联网通讯，根据所需加工钢筋的直径及钢筋表面要求进行自动调整、钢砂的出砂量来对NPR热轧钢筋表面的氧化皮、表面缺陷以及光面模的润滑粉进行处理；
    原位在线退火工序L10：对钢筋进行原位在线加热退火；
    风冷缓冲工序L11：采用风冷对高温的钢筋线材进行在线冷却；
    收盘圆工序L12：将带有余温或余热的钢筋进行高速收卷，并进行自动送料、夹头、自动头尾剪切、自动卸料；
    放料工序L13：将整形以及退火热处理冷却后的盘圆钢筋进行开卷放线料；
    校平工序L14：采用多轮式十字交叉360度曲线滚压调直，使钢筋消除内在应力；
    冷拔螺旋工序L15：采用辊模冷轧的方式进行螺旋钢筋的生产；
    调直工序L16：采用多轮十字或水平调直，在校平的基础上进行精调；
    收盘圆工序L17：在线生产不停车收盘打捆。
  2. 根据权利要求1所述的加工工艺，其特征在于，在一字放料工序L20之前还包括：
    智能化总控工序L01：智能化总控系统通过光纤网线连接到远程计算机服务器，通过服务器实现远程一键自动启动停止，通过服务器查看生产线设备的运行状态及生产信息。
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