A steel wire metering system and use method thereof

Abstract

The present invention discloses a wire meter counting system and a method for using the same, which are applied to a wire drawing machine. Each wire drawing machine is composed of a plurality of reels and a take-up wheel. The meter counting system is arranged on the last reel of the wire drawing machine, and includes a gearbox transmission mechanism, a gearbox pulley, a trigger device, a high-frequency pulse trigger, a frequency divider, a pulse receiver and a PLC controller. A gearbox transmission mechanism is arranged below the reel, and a gearbox pulley is arranged on one side of the gearbox transmission mechanism. A trigger device and a high-frequency pulse trigger are arranged on the gearbox pulley. The high-frequency pulse trigger is arranged at the input shaft of the gearbox, and the high-frequency pulse trigger is connected to the frequency divider, and the frequency divider is connected to the pulse receiver, and the pulse receiver is connected to the PLC controller. The present invention tracks and counts the fluctuation of meter counting; improves the wire drawing meter counting device to improve its meter counting accuracy; and improves the uniform matching of the length of the steel wires between the wire drawing platforms.

Description

Technical Field

[0001] The invention relates to the technical field of length measuring devices, in particular to a steel wire meter measuring system and a use method thereof. Background Art

[0002] In the prestressed steel strand industry, the accuracy of wire metering is a comprehensive indicator that can effectively reflect the company's technology, equipment and management level. The error in the metering of the wire produced between the wire drawing machines is relatively large, and the length of each reel of wire is different, resulting in a large amount of waste wire at the end of the I-spool in the stranding process, and even the phenomenon of "head escape" on the machine, affecting production efficiency and yield rate, and also increasing labor costs. It is a common problem among steel strand manufacturers.

[0003] In the field of wire drawing for metal products, there are two general metering methods: meter wheel metering and motor encoder metering. The meter wheel metering is equipped with a special meter wheel, and the metering is realized by recording the number of rotations of the meter wheel through a counter; the meter wheel is installed next to the last drum. After the steel wire fills the lower half of the last drum, it goes around the meter wheel and then around the upper half of the last drum, and finally around the take-up line. The meter wheel rotates one circle, and the meter proximity switch is triggered once. Problems: Since the steel wire drives the meter wheel to rotate, and the steel wire only goes around half a circle, there is an unstable slight slip between the steel wire and the meter wheel during operation, resulting in inaccurate metering, causing the remaining steel wires of each I-shaped wheel at the end of the strand to be of different lengths. The motor encoder metering uses a special encoder to record the speed of the last motor of the wire drawing machine to realize metering.

[0004] As the equipment ages, the meter wheel and motor pulley of the wire drawing machine wear to varying degrees, causing the meter wheel and motor pulley to slip, which leads to uncontrollable errors in the metering of the wire drawing machine, and the length of each coil of steel wire produced is different. Seven coils of steel wire are used in the production of stranded wire. After the production is completed, the remaining length of each coil of steel wire is different, resulting in serious waste and reducing the yield rate. Summary of the invention

[0005] In order to solve the above problems, the purpose of the present invention is to provide a steel wire metering system and a method of using the same, so as to improve the metering accuracy of the wire drawing machine and increase the yield rate of finished products.

[0006] The technical solution adopted by the present invention to solve the above-mentioned problem is: a steel wire meter counting system, which is applied to a wire drawing machine, each wire drawing machine is composed of multiple reels and a take-up wheel, and the meter counting system is arranged on the last reel of the wire drawing machine, and it includes a gear box transmission mechanism, a gear box pulley, a trigger device, a high-frequency pulse trigger, a divider, a pulse receiver and a PLC controller; a gear box transmission mechanism is arranged under the reel, and a gear box pulley is arranged on one side of the gear box transmission mechanism, and a trigger device and a high-frequency pulse trigger are arranged on the gear box pulley, and the high-frequency pulse trigger is arranged at the gear box input shaft, the high-frequency pulse trigger is connected to the divider, the divider is connected to the pulse receiver, and the pulse receiver is connected to the PLC controller.

[0007] A method for using a steel wire meter measuring system, comprising the following contents:

[0008] The above-mentioned steel wire metering system is installed on a single wire drawing machine, a high-frequency pulse trigger is installed at the input shaft of the last gearbox of the wire drawing machine, and each coil of steel wire produced by the single wire drawing machine is placed on the same stranding machine for operation, and the number of times the counter of each coil of fixed-length steel wire produced by each wire drawing machine is triggered is counted;

[0009] The above-mentioned wire metering system will be gradually installed on other wire drawing machines in the production line;

[0010] Two wire drawing machines are used to supply one stranded wire. The difference in the remaining wire reels of the two wire drawing reels is counted to adjust the meter counting coefficient. Then, by matching two or more wire drawing reels to the same stranded wire production machine, the error between the meter counts of different wire drawing machines is counted. By adjusting the wire drawing coefficient of each machine, it is ensured that the actual number of meters of steel wire produced by all wire drawing machines is the same.

[0011] Furthermore, track the working status of the wire drawing machine meter counter, track the number of remaining wire coils at the end of the stranding machine after equipment improvement and under different wire mixing conditions, regularly make statistics, summarize and analyze the fluctuations of the wire drawing meter counters of each machine; for machines with relatively large fluctuations, make gradual improvements and gradually reduce the fluctuation range.

[0012] Due to the application of the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0013] The invention tracks and counts the fluctuation of meter counting; improves the wire drawing meter counter to improve its meter counting accuracy; improves the uniform matching of the steel wire lengths between the wire drawing platforms; and tracks the remaining amount of steel wire on the tail drum of the I-shaped wheel in the stranding process in real time.

[0014] Since the gear box pulley and the wire drawing reel are connected by gears, that is, there is no error between the meter counter and the actual number of meters of the wire, the present invention can effectively improve the triggering stability of the wire drawing meter counter, and eliminate the inaccurate meter counting phenomenon caused by the slippage of the meter counter wheel and the motor pulley, so that the length of each reel of wire is uniform, the amount of waste wire is reduced, and the finished product yield is greatly improved.

[0015] The present invention effectively improves the metering accuracy of steel wire production and significantly improves the degree of refined management, so as to better and more accurately control the metering length of the steel strand production process. Currently, the metering error rate of wire drawing is less than 0.3%, which can reduce waste wire by about 170 tons per year. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the application of the device of the present invention.

[0017] Figure 2 It is a structural schematic diagram of the present invention.

[0018] Figure 3 This is a top view of the production process of the present invention on a stranding machine.

[0019] In the figure:

[0020] Reel 1, gear box transmission mechanism 2, gear box pulley 3, trigger device 4, high-frequency pulse trigger 5, frequency divider 6, pulse receiver 7, PLC controller 8, take-up wheel 9. DETAILED DESCRIPTION

[0021] The present invention is further described in detail below with reference to the accompanying drawings.

[0022] Embodiment 1:

[0023] See also Figure 1-3 , Figure 2 The drawing shows a structural schematic diagram of a steel wire metering system. As shown in the figure, the steel wire metering system of the present invention is applied to a wire drawing machine, each of which is composed of 8 reels and a take-up wheel 9. The metering system is installed on the eighth reel (i.e., the last reel 1), and includes a gear box transmission mechanism 2, a gear box pulley 3, a trigger device 4, a high-frequency pulse trigger 5, a frequency divider 6, a pulse receiver 7 and a PLC controller 8.

[0024] A gearbox transmission mechanism 2 is provided below the reel 1, and a gearbox pulley 3 is provided on one side of the gearbox transmission mechanism 2. A trigger device 4 and a high-frequency pulse trigger 5 are provided on the gearbox pulley 3. The high-frequency pulse trigger 5 is arranged at the input shaft of the gearbox, and the high-frequency pulse trigger 5 is connected to a divider 6, and the divider 6 is connected to a pulse receiver 7, and the pulse receiver 7 is connected to a PLC controller 8.

[0025] The trigger device 4 rotates synchronously with the rotation of the gear box pulley 3. The trigger probe of the trigger device 4 is fixedly installed by a bracket. The high-frequency pulse signal generated by the high-frequency pulse trigger 5 is reduced to a low-frequency pulse signal through a frequency divider 6. The low-frequency pulse signal is then input into the pulse receiver 7 to ensure accurate counting. The pulse receiver 7 transmits the detected low-frequency pulse signal to the PLC controller 8. Through the internal formula of the PLC, the PLC calculates the actual number of meters of steel wire based on the incoming counting signal and the transmission ratio of the eighth gear box of the wire drawing machine.

[0026] See also Figure 1-3 The present invention relates to a method for using a steel wire meter measuring system, comprising the following contents:

[0027] The above-mentioned wire metering system is installed on a single wire drawing machine, and each reel of wire produced by the single wire drawing machine is placed on the same stranding machine for operation, that is, a single machine with a single configuration. After eliminating the slippage of the metering system, the remaining tail reel of wire after the stranding production is completed is significantly reduced. The production situation of 15-20 sets of stranding reels is counted, and the number of meters of the tail reel of wire is basically controlled between 0-20 meters;

[0028] The above-mentioned steel wire meter counting system is gradually installed on other wire drawing machines. Due to the different models of wire drawing machines and the errors in the production fixed-length coefficients, there is still a certain difference in the number of wire reels produced by each wire drawing machine; two wire drawing machines are used to supply one strand of wire, and the remaining tail reels of the two wire drawing reels are counted to adjust the meter counting coefficient; and then the errors between the number of meters of different wire drawing machines are counted by matching two or more wire drawing machines to the same strand of wire for production. By adjusting the drawing coefficients of each machine, it is ensured that the actual number of meters of steel wire produced by all wire drawing machines is the same, which greatly reduces the amount of waste steel wire at the end of the strand of wire.

[0029] The application of a steel wire meter measuring system according to the present invention is as follows:

[0030] Track and count the remaining turns of the stranded wire, check the existing meter counting device for wire drawing, and find the following:

[0031] The No. 1 wire drawing meter wheel is slipping;

[0032] The wire drawing tension of No. 2 was too low, causing the meter wheel to slip;

[0033] Wear of the No. 3, 5, 6, 7, and 8 wire drawing meter wheels causes slippage;

[0034] The trigger device of the No. 4 wire drawing meter wheel is deformed and easily damaged, resulting in inaccurate metering;

[0035] The upper half of the last reel of the No. 9 and No. 10 wire drawing machines can only store one circle of wire, which causes slippage and cannot ensure the stability of the meter triggering.

[0036] The steel wire metering system of the present invention is adopted:

[0037] A high-frequency pulse trigger is installed at the input shaft of the last gearbox of the wire drawing machine to count the number of times the counter of each reel of fixed-length wire is triggered. Statistics show that there is uncertainty in the number of times the counter of each reel of fixed-length wire is triggered. On-site tracking shows that the meter wheels of each wire drawing machine slip to varying degrees, resulting in errors in meter counting. The number of remaining turns of the stranded wire is counted, and the existing meter counting devices for wire drawing are checked.

[0038] The wire drawing machines No. 3, 5, 6, 7 and 8 were equipped with the above-mentioned wire metering system and the effectiveness of the new metering system was verified by arranging single strands of wire.

[0039] Other wire drawing machines have improved the meter counting accuracy through targeted methods: For No. 2 wire drawing, the wire taking-up tension is appropriately increased to minimize the slippage of the meter wheel; for No. 4 wire drawing, the trigger device is redesigned to ensure the triggering stability and prevent it from being damaged easily; for No. 4, 9 and 10 wire drawing machines, an automatic wire pressing device is added at the wire taking-up point to increase the number of wire turns on the upper layer of the double-layer drum, minimize the slippage of the meter wheel and improve the triggering stability; for No. 1 wire drawing, a meter counting trigger device is added to the top of the last drum to improve the triggering stability.

[0040] Through mixing, the meter lengths of each wire drawing machine are matched; the lengths of wires No. 2, 3, 5, 6, 7 and 8 are well matched; for wire drawing machine No. 1, a meter trigger device is installed on the top of the last reel; the meter trigger device of wire drawing machine No. 4 is redesigned and improved, and an automatic wire pressing device is installed at the wire taking-up; automatic wire pressing devices are installed at the wire taking-up of No. 9 and 10, and the meter trigger device is replaced; through statistics on the remaining coils of steel wire and mixing with other machines on site, it is found that the number of remaining coils of steel wire at the end of the stranded wire is significantly reduced and uniform.

[0041] Track the working status of the wire drawing machine meter counter, track the number of remaining wire coils at the end of the stranding machine after equipment improvement and under different wire mixing conditions, regularly make statistics, summarize and analyze the fluctuations of the wire drawing meter counters of each machine; for machines with relatively large fluctuations, make gradual improvements to gradually reduce the fluctuation range.

[0042] Before installing the meter counting system of the present invention, the fluctuation of meter counting was tracked and counted, and the amount of remaining wire in the last reel of 7 reels of steel wire after the production of the stranded wire was completed was counted. Most of the remaining wire in the last reel was between 20-200 meters, and the waste wire in the last reel was extremely wasted. After installing the meter counting system of the present invention, the remaining wire in the last reel of steel wire after the production of the stranded wire was completed was significantly reduced. The production of 15-20 sets of stranded wire reels was counted, and the number of meters of the last reel of steel wire was basically controlled between 0-20 meters.

[0043] In addition to the above embodiments, the present invention also includes other implementation modes. Any technical solutions formed by equivalent transformation or equivalent replacement should fall within the protection scope of the claims of the present invention.

Claims

1. A method for using a steel wire metering system, characterized in that: The wire metering system is applied to a wire drawing machine, each of which is composed of a plurality of winding drums and a take-up wheel. The metering system is arranged on the last winding drum (1) of the wire drawing machine, and comprises a gearbox transmission mechanism (2), a gearbox pulley (3), a trigger device (4), a high-frequency pulse trigger (5), a frequency divider (6), a pulse receiver (7) and a PLC controller (8); a gearbox transmission mechanism (2) is arranged below the winding drum (1), a gearbox pulley (3) is arranged on one side of the gearbox transmission mechanism (2), a trigger device (4) and a high-frequency pulse trigger (5) are arranged on the gearbox pulley (3), the high-frequency pulse trigger (5) is arranged at the input shaft of the gearbox, the high-frequency pulse trigger (5) is connected to the frequency divider (6), the frequency divider (6) is connected to the pulse receiver (7), and the pulse receiver (7) is connected to the PLC controller (8); The usage includes the following: The above-mentioned steel wire metering system is installed on a single wire drawing machine, a high-frequency pulse trigger is installed at the input shaft of the last gearbox of the wire drawing machine, and each coil of steel wire produced by the single wire drawing machine is placed on the same stranding machine for operation, and the number of times the counter of each coil of fixed-length steel wire produced by each wire drawing machine is triggered is counted; The above-mentioned wire metering system will be gradually installed on other wire drawing machines in the production line; Two wire drawing machines are used to supply one stranded wire. The difference in the remaining wire reels of the two wire drawing reels is counted to adjust the meter counting coefficient. Then, by matching two or more wire drawing reels to the same stranded wire production machine, the error between the meter counts of different wire drawing machines is counted. By adjusting the wire drawing coefficient of each machine, it is ensured that the actual number of meters of steel wire produced by all wire drawing machines is the same.

2. The method for using the steel wire meter measuring system according to claim 1, characterized in that: Track the working status of the wire drawing machine meter counter, track the number of remaining wire coils at the end of the stranding machine after equipment improvement and under different wire mixing conditions, regularly make statistics, summarize and analyze the fluctuations of the wire drawing meter counters of each machine; for machines with relatively large fluctuations, make gradual improvements to gradually reduce the fluctuation range.

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