An automatic feeding galvanizing system

Abstract

The application relates to the technical field of hot galvanization, in particular to an automatic feeding galvanization system, which comprises a rack, closed doors are rotatably installed on the short sides of the rack, a long through groove is formed in the rack, the long through groove is communicated with the two closed doors, an observation window is formed in one side of the rack, movable grooves are formed on the two sides of the observation window and located on the outer side walls of the rack, an observation baffle is movably installed on the movable grooves, a guide rail is fixedly installed on the side of the rack far from the observation baffle, a cross beam I is slidably installed on the guide rail, motors are fixedly installed on the two ends of the cross beam I, foldable plate bodies are installed on the motors, a zinc pool is fixedly installed at the bottom of the rack, and a beating device is installed in the middle of the rack. The beating device beats the machining elements rising from the zinc pool, the working efficiency is improved, and the safety hidden danger possibly generated when the machining elements are beaten manually is eliminated.

Description

Technical Field

[0001] This invention relates to the field of hot-dip galvanizing technology, specifically to an automatic feeding galvanizing system. Background Technology

[0002] Hot-dip galvanizing involves several steps, including pickling, washing, adding flux, drying, plating, cooling, passivation, cleaning, polishing, and finally, the hot-dip galvanizing process is complete. The hot-dip galvanizing industry has developed rapidly in recent decades, and many domestic and international companies have adopted automated galvanizing production lines, such as the new environmentally friendly automated hot-dip galvanizing production line of Xuzhou Ruima Intelligent Technology Co., Ltd. However, investigations have revealed that in the plating process of current automated hot-dip galvanizing production lines, an overhead crane uses ropes to hoist the workpiece into the zinc bath. Before the workpiece enters the zinc bath, the side plates need to be lowered to prevent zinc molten metal from splashing. After the workpiece is lifted from the zinc bath, operators need to raise the side plates, and then multiple operators need to manually strike the workpiece with tools to shake off any remaining zinc molten metal. Once the shaking of the workpiece has decreased, the overhead crane moves the workpiece to the next process. This manual striking process requires at least two workers, which, under typical two-shift production conditions, would take at least 40 man-hours per day. Furthermore, when operators strike processing components, the molten zinc that is shaken off may splash onto the operators, posing a certain threat to their personal safety.

[0003] To address this, an automated feeding galvanizing system is proposed, which uses mechanical devices to replace manual striking of processing components, thereby improving efficiency while ensuring the personal safety of operators. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic feeding galvanizing system. By installing a striking device inside the frame, the operator controls the striking device through a central control room to strike the processing elements rising from the zinc bath. This eliminates the need for raising and lowering the observation window and the plate when manually striking the processing elements, reducing labor costs, improving production efficiency, and eliminating potential safety hazards that may arise from manual striking of processing elements, thereby solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] An automatic feeding galvanizing system, comprising:

[0007] The frame has a closed door rotatably installed on one of its short sides. The frame has a long through slot for the movement of ropes on the crane. The long through slot connects the two closed doors. One side of the frame has an observation window for observing the processed components. Both sides of the observation window have movable slots, which are located on the outer wall of the frame. Observation baffles are movably installed on the movable slots.

[0008] A zinc bath is fixedly installed at the bottom of the frame;

[0009] A striking device is installed in the middle of the frame, and the striking device is used to strike the processing elements that have just come out of the zinc bath.

[0010] Preferably, the striking device includes a second crossbeam installed on the side of the frame away from the observation baffle. Fixing blocks are symmetrically installed on the long side wall of the frame near the observation baffle. Each fixing block is connected to the second crossbeam. Multiple high-temperature cylinders are uniformly fixed on each second crossbeam. The output end of each high-temperature cylinder on the second crossbeam is connected to an impact plate.

[0011] Before the processing component enters the frame, the control system opens the closed door. An overhead crane moves the component along a long through-slot to the inside of the frame via ropes. The closed door closes, and the overhead crane slowly lowers the component into the zinc bath by releasing the ropes. After galvanizing, the overhead crane retracts the ropes, gradually raising the component away from the zinc bath. The impact plate is positioned three meters above the zinc bath. When the operator observes through a monitoring camera in the central control room that the component and the impact plate are at the same height, the overhead crane stops retracting the ropes, and the component stops moving. The control system in the central control room then activates a high-temperature cylinder. This cylinder drives the impact plate in a reciprocating motion to strike the component. Since the temperature of the zinc bath is around 500℃ and the temperature inside the frame is around 100℃, the process is more efficient. Typical ambient temperature cylinders operate in environments between 5-70℃. If an ambient temperature cylinder is used above a zinc bath, the sealing ring may soften, resulting in insufficient sealing. High temperature cylinders, on the other hand, can operate at temperatures up to 800℃. Therefore, using a high temperature cylinder can avoid the leakage problem of an ambient temperature cylinder. It also shakes off the residual zinc liquid on the processing element. When the operator observes through a monitoring camera in the central control room that no more zinc droplets are being produced at the bottom of the processing element, the cylinder can be stopped. This device allows multiple people to manually strike the processing element, reducing the machine to be operated by a single person. It saves at least 20 man-hours per day, eliminates the need for the rising and falling of the side plates, reduces the time consumption by 30 seconds, improves production efficiency, and ensures the personal safety of the operator.

[0012] Preferably, the contact surface between the impact plate and the processing element is a rectangle with a width of at least 40 cm. Since different processing elements have different shapes, a rectangular impact plate with a certain width can increase the impact area and reduce the operational difficulty for the operator in the central control room. The given width of 40 cm can be adjusted according to the actual processing elements being produced. The cross-section of the impact plate is U-shaped, with the opening of the U-shaped plate facing towards the direction close to the second crossbeam. Since the function of the impact plate is to shake off excess molten zinc from the processing element by striking it, but the direction of the molten zinc falling is uncontrollable, the impact plate is made into a U-shape. The U-shaped plate is symmetrical. The two side walls shield the upper and lower sides of the cylinder, and the width of the side walls is greater than or equal to the extension length of the cylinder to prevent molten zinc from splashing onto the cylinder's extension rod and affecting the cylinder's operation. The outer side wall of the impact plate is curved, which prevents damage to the processing element when the impact plate strikes it. The impact plate is made of high manganese steel. Since the impact plate will not only receive impact when striking the processing element, but will also generate a certain amount of friction with the processing element, and high manganese steel is a wear-resistant and impact-resistant material, using high manganese steel as the material of the impact plate can increase the service life of the impact plate.

[0013] Preferably, the high-temperature cylinder is reinforced and mounted on the second crossbeam using spring washers.

[0014] Because the high-temperature cylinder generates a large impact when it drives the impact plate to strike the processing element, most high-temperature cylinders are connected by bolts. However, bolts can loosen after repeated impacts. Therefore, spring washers are used to increase the reliability of the high-temperature cylinder and ensure the striking quality of the striking device. The spring washers can be replaced with anti-loosening washers such as Lodile washers and Spiral washers.

[0015] Preferably, the top of the frame has two short through slots on the side away from the observation baffle, and each short through slot is perpendicularly connected to the long through slot. A turntable is installed at the junction of each through slot, and the turntable has a through slot. Electric slide rails are symmetrically installed on both sides of the inner wall of the frame away from the observation baffle. A slider is movably installed on the electric slide rail and the slider is connected to the second crossbeam. A guide rail is fixedly installed on the side of the frame away from the observation baffle, and a first crossbeam is slidably installed on the guide rail. A motor is fixedly installed at both ends of the first crossbeam, and a foldable plate is installed on the motor.

[0016] The turntable here is part of the rotating device of an overhead crane in the prior art. The upper part of the turntable is connected to the rotating device via a connector. When the rotating device rotates, the turntable rotates synchronously. The overhead crane moves forward, bringing the processing element into the machine frame. When the overhead crane moves to the rotating device and stops, it slowly lowers the processing element into the zinc bath. After the processing element is galvanized and lifted out of the zinc bath, the central control room can observe the galvanized processing element through monitoring. If damage or incomplete galvanization is found, the central control room can take action. The control room can control the rotating device to rotate the overhead crane 90 degrees, and the turntable also rotates 90 degrees. At this time, the through groove of the turntable is connected to the two short through grooves on the frame. The central control room then controls the first crossbeam and the slider to descend, and the plate gradually folds. The second crossbeam follows the slider to descend. The first crossbeam and the second crossbeam descend to the same height as the highest point of the side wall of the zinc bath and then stop. The overhead crane is then started to move, and the overhead crane moves the processing element away from the observation baffle. This device can separate defective galvanized products from the production line in a timely manner, reducing the waste of subsequent processing resources.

[0017] Preferably, a gravity sensor for detecting the weight of the second crossbeam is installed on the fixing block and slider at one end of the second crossbeam.

[0018] During production, the impact plate strikes the processing components that have just emerged from the zinc bath, shaking off excess zinc. However, the direction of the falling zinc droplets is uncontrollable, and some zinc inevitably splashes onto the second crossbeam and the impact plate. This zinc solidifies on the impact plate and the second crossbeam, gradually increasing their weight over time. Gravity sensors detect this increase in weight on the second crossbeam, and the control system analyzes the data transmitted back from the sensors. When the weight on the second crossbeam increases by 10 kg compared to the initial state, the control system alerts the operator to clean up the solidified zinc on the second crossbeam and the impact plate to prevent excessive weight from damaging the connectors.

[0019] Preferably, the striking device includes symmetrically opened square through holes on the long side wall of the frame, and the square through holes are located above the observation window. Fixing blocks are fixedly installed on both sides of the square through holes, and each fixing block is connected to a crossbeam II. Multiple room temperature cylinders are evenly fixedly installed on each crossbeam II. The room temperature cylinders are located outside the frame, and the output end of each room temperature cylinder on the crossbeam II is connected to an impact plate.

[0020] Since high-temperature cylinders are about 10 times more expensive than normal-temperature cylinders, and because they are installed inside the machine frame, their wiring and piping need to be high-temperature resistant, leading to excessive costs, a through-hole can be made in the side wall of the machine frame to install the cylinders outside the frame. The environment outside the machine frame is around 40°C, where normal-temperature cylinders can operate normally, and the wiring and piping can use European standards. Therefore, this solution can save a lot of costs. However, the premise of using all normal-temperature cylinders is to change the movable side plate to a fixed plate. The production line is only in one direction, so it lacks the function of timely separation of the processing components from the production line when the central control room detects damage or incomplete galvanization of the processing components.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0022] 1. The automatic feeding galvanizing system of the present invention uses a striking device installed on the frame. The striking device includes a cylinder installed in the middle of the frame and an impact plate connected to the output end of the cylinder. The cylinder drives the impact plate to strike the processing element that rises from the zinc bath, shaking off the residual zinc liquid on the processing element. This replaces the step of manually striking the processing element, reduces labor costs, and eliminates the safety hazards that may occur when manually striking the processing element.

[0023] 2. In the automatic feeding galvanizing system of the present invention, the impact plate installed at the output end of the cylinder is U-shaped. The two side walls of the U-shaped plate can prevent the zinc liquid from splashing onto the extension rod of the cylinder when the cylinder drives the impact plate to extend and retract, thus preventing the cylinder from running. The bend of the outer side wall of the impact plate is made into an arc shape, which can also prevent the impact plate from damaging the processing element when hitting the processing element.

[0024] 3. The automatic feeding galvanizing system of the present invention has a gravity sensor installed on the upper end of the electric slide rail. The gravity sensor can sense the increased weight on the entire crossbeam 2. During production, some molten zinc will inevitably splash onto the crossbeam 2 and the impact plate. The control system can analyze the data transmitted back by the gravity sensor. When the weight on the entire crossbeam 2 increases by 10kg compared to the initial state, the control system can remind the operator to clean up the solidified molten zinc on the crossbeam 2 and the impact plate to prevent the excessive weight of the crossbeam 2 and the impact plate from damaging the connecting parts. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of one side of the overall structure of the present invention;

[0026] Figure 2 This is a schematic diagram of the overall structure of the present invention from another side;

[0027] Figure 3This is a schematic diagram of the internal structure of Embodiment 1 of the present invention;

[0028] Figure 4 This is a front view of the internal structure of the present invention;

[0029] Figure 5 This is a cross-sectional view of the present invention;

[0030] Figure 6 This is a cross-sectional view of the impact plate of the present invention;

[0031] Figure 7 This is a schematic diagram of the internal structure of Embodiment 2 of the present invention;

[0032] Figure 8 for Figure 7 Enlarged view of a portion of point A in the middle.

[0033] In the diagram: 1. Frame; 2. Guide rail; 3. Motor; 4. Crossbeam 1; 5. Plate; 6. Enclosed door; 7. Observation baffle; 8. Movable groove; 9. Fixed block; 10. Impact plate; 11. Normal temperature cylinder; 12. Crossbeam 2; 13. Slider; 14. Turntable; 15. Electric slide rail; 16. Sensor; 17. Zinc tank; 18. Spring washer; 19. High temperature cylinder. Detailed Implementation

[0034] Please see Figures 1 to 8 This invention provides an automatic feeding galvanizing system, the technical solution of which is as follows:

[0035] Example 1, refer to Figures 1 to 6 ,include:

[0036] When processing sheet metal with a thickness of less than 2mm, before the sheet metal is placed into the frame 1, the control system opens the sealing door 6. The overhead crane moves the sheet metal into the frame 1 via a rope along the long through groove. The sealing door 6 closes, and the overhead crane slowly lowers the sheet metal into the zinc bath 17 by releasing the rope. According to the "Hot-dip Galvanizing Operation Procedure," the sheet metal is immersed in zinc for 3 minutes. After 3 minutes, galvanizing is completed. The overhead crane gradually raises the sheet metal away from the zinc bath 17 by retracting the rope. The impact plate 10 is located at a height of three meters above the zinc bath 17. When the operator observes through a monitoring camera in the central control room that the sheet metal and the impact plate 10 are at the same height, the overhead crane stops retracting the rope, the sheet metal stops moving, and the control system in the central control room starts the high-temperature cylinder 19. The high-temperature cylinder 19 drives the impact plate 10 to reciprocate and strike the sheet metal, shaking off any residual zinc liquid on the sheet metal. When the impact plate 10 strikes the sheet metal, the zinc liquid splashing towards the extension rod of the high-temperature cylinder 19 is blocked by the side walls of the impact plate 10.

[0037] When the operator observes through a monitoring camera in the central control room that no more zinc droplets are being produced at the bottom of the plate, the high-temperature cylinder 19 can be stopped. The plate will have essentially stopped shaking after 30 seconds. At this point, the control system controls the overhead crane to continue retracting the rope, and the plate continues to rise. After 5 seconds, the rope returns to its initial state, the closed door 6 on the other side opens, and the overhead crane continues to carry the galvanized plate away from the machine frame 1 along the long through-slot. By eliminating the rising and falling steps of the plates 5 on both sides, the plating process of this invention reduces the consumption of 30 seconds compared to the traditional manual plate-beating plating process, improving production efficiency while reducing labor costs. Furthermore, after multiple experiments, the average thickness of the galvanized layer on the plate was measured to be 80.2 μm, meeting the process requirement of 80 μm.

[0038] When the central control room detects through the monitoring camera that the galvanized components are damaged or incompletely galvanized after being lifted from the zinc bath 17, it can control the rotating device to rotate the overhead crane 90 degrees, and the turntable 14 will also rotate 90 degrees. At this time, the through groove of the turntable 14 is connected to the two short through grooves on the frame 1. The central control room then controls the motor 3 and the slider 13 to descend, and the plate 5 and the second crossbeam 12 also descend. After the plate 5 and the second crossbeam 12 have descended, the overhead crane is started to move, and the overhead crane moves the galvanized components away from the observation baffle 7, so as to separate the defective galvanized products from the production line in a timely manner.

[0039] Example 2, refer to Figures 6 to 7 ,include:

[0040] The operation process of Example 2 is basically the same as that of Example 1, except that the high-temperature cylinder 19 is replaced by the room-temperature cylinder 11. The plate material is also 2mm thick. After multiple experiments, the average zinc coating thickness of the plate material is 79.8μm, meeting the production process requirements. Since the cost of the room-temperature cylinder 11 is generally one-tenth that of the high-temperature cylinder 19, and the cost of the associated wiring and piping is also lower, using the room-temperature cylinder 11 can reduce costs. However, using the room-temperature cylinder 11 requires replacing the lifting plate 5 with the fixed plate 5. Therefore, Example 2 lacks the function of promptly separating defective zinc-plated products from the production line when the operator discovers them.

[0041] Working principle:

[0042] Before the processing component is placed into rack 1, the control system opens the sealing door 6. The overhead crane moves the component into rack 1 via a rope along the long through-slot. The sealing door 6 closes, and the overhead crane stops moving when it reaches the turntable 14. The crane then releases the rope to slowly lower the processing component into the zinc bath 17. According to the "Hot-Dip Tinning Operation Procedure," the zinc immersion time for the processing component is generally 2-5 minutes. After galvanizing, the overhead crane retracts the rope to gradually raise the processing component away from the zinc bath 17. The impact plate 10 is positioned three meters above the zinc bath 17. When the operator observes from the central control room via a monitoring camera that the processing component and the impact plate 10 are at the same height, the overhead crane stops retracting the rope, and the processing component stops moving. The operator starts the striking device in the central control room. The striking device has two forms: the driving component is a high-temperature cylinder 19 or the driving component is a normal-temperature cylinder 11. The driving component drives the impact plate 10 to reciprocate to strike the processing element, shaking off the residual zinc liquid on the processing element. When the operator observes through the monitoring camera in the central control room that no more zinc droplets are produced at the lower end of the processing element, the driving component can be stopped. After 30 seconds, the processing element has basically stopped shaking. At this time, the control system controls the crane to continue to retract the rope, and the processing element continues to rise. After 5 seconds, the rope is retracted to the initial state, the closed door 6 on the other side is opened, and the crane continues to carry the galvanized processing element away from the inside of the frame 1 along the long through groove.

Claims

1. An automatic feeding galvanizing system, comprising: The frame has a closed door rotatably installed on one of its short sides. The frame has a long through slot that connects the two closed doors. An observation window is provided on one side of the frame. Movable slots are provided on both sides of the observation window and are located on the outer wall of the frame. An observation baffle is movably installed on the movable slot. A zinc bath is fixedly installed at the bottom of the frame; Its characteristic is that it further includes: A striking device is installed in the middle of the frame, and the striking device is used to strike the sheet metal that has just come out of the zinc bath; The striking device includes a second crossbeam installed on the side of the frame away from the observation baffle. Two fixing blocks are symmetrically installed on the long side wall of the frame near the observation baffle. The other end of each fixing block is connected to the second crossbeam. Multiple high-temperature cylinders are uniformly fixed on each second crossbeam. The output end of each high-temperature cylinder on the second crossbeam is connected to an impact plate. The impact plate has a U-shaped cross-section, with the opening of the U-shaped plate facing towards the direction close to the second crossbeam, and the width of the two side walls of the U-shaped plate is greater than or equal to the extension length of the high-temperature cylinder. The high-temperature cylinder drives the impact plate to reciprocate and strike the plate, shaking off the residual zinc liquid on the plate. When the impact plate strikes the plate, the zinc liquid splashing towards the extension rod of the high-temperature cylinder is blocked by the side walls of the impact plate. The striking device includes symmetrically opened square through holes on the long side wall of the frame, and the square through holes are located above the observation window. Fixing blocks are fixedly installed on both sides of the square through holes. Each fixing block is connected to a crossbeam II. Multiple room temperature cylinders are evenly fixedly installed on each crossbeam II. The room temperature cylinders are located outside the frame. The output end of each room temperature cylinder on the crossbeam II is connected to an impact plate.

2. The automatic feeding galvanizing system according to claim 1, characterized in that: The outer wall of the impact plate is curved.

3. The automatic feeding galvanizing system according to claim 1, characterized in that: All the high-temperature cylinders are reinforced with spring washers when installed on the second crossbeam.

4. The automatic feeding galvanizing system according to claim 1, characterized in that: Two short through slots are formed on the top of the frame away from the observation baffle, and each short through slot is perpendicularly connected to the long through slot. A turntable is installed at the junction of each through slot, and the turntable has a through slot. Electric slide rails are symmetrically installed on both sides of the inner wall of the frame away from the observation baffle. A slider is movably installed on the electric slide rail and is connected to the second crossbeam. A guide rail is fixedly installed on the outer wall of the frame away from the observation baffle. A first crossbeam is slidably installed on the guide rail. Motors are fixedly installed at both ends of the first crossbeam near the guide rail. A foldable plate is installed on the motor.

5. The automatic feeding galvanizing system according to claim 1, characterized in that: Gravity sensors for detecting the weight of the second crossbeam are installed on both the fixing block and the slider at one end of the second crossbeam.

6. The automatic feeding galvanizing system according to claim 1, characterized in that: Each of the two crossbeams is equipped with a gravity sensor on a fixed block at one end for detecting the weight of the crossbeam.

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