Steel wire ultrasonic phosphating unit

Abstract

This invention relates to an ultrasonic phosphating unit for steel wire, comprising a phosphating tank supported by a steel structure. Several wire-splitting devices and several wire-supporting devices are spaced apart within the phosphating tank to guide the phosphating steel wire. The key feature is that multiple ultrasonic devices are spaced apart below the phosphating steel wire within the phosphating tank. Each ultrasonic device includes an ultrasonic support, a damping plate, and a lower ultrasonic vibrating plate. The two ends of the ultrasonic support are mounted on the front and rear side walls of the phosphating tank. The damping plate is mounted on the upper surface of the ultrasonic support, and the lower ultrasonic vibrating plate is mounted on the damping plate, positioned below the phosphating steel wire. The phosphating steel wire enters the phosphating tank from one end, travels straight within the tank, and exits straight out from the other end. By incorporating ultrasonic devices within the phosphating tank, this invention can reduce the heating temperature of the phosphating solution to 70-75°C while maintaining the required phosphating amount, effectively reducing the generation of phosphate slag and improving production efficiency.

Description

Technical Field

[0001] This invention belongs to the technical field of steel wire heat treatment equipment, specifically relating to an ultrasonic phosphating unit for steel wire. Background Technology

[0002] In existing technologies, various heat treatments are typically required to improve the overall performance of steel wire. After cleaning, semi-finished steel wire needs to be coated or reacted to form a lubricating coating on its surface. This lubricating coating facilitates the smooth progress of the next drawing process.

[0003] Phosphating coating is a commonly used lubricating coating for steel wire. It has excellent rust resistance and good plasticity, maintaining continuity during deformation and exhibiting excellent adaptability and durability. Phosphating coating is produced through a phosphating treatment. Current steel wire phosphating technology typically involves passing the steel wire through a phosphating solution at temperatures above 80℃ to 85℃ for a certain period of time, forming a phosphating film on the wire surface. However, this phosphating process easily produces phosphorus slag, and the higher the heating temperature, the greater the amount of phosphorus slag produced. Phosphorus slag affects the quality of the steel wire, requiring frequent cleaning, which disrupts production, wastes raw materials and labor, and increases hazardous waste disposal costs. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a cleverly designed and reasonable ultrasonic phosphating unit for steel wire. By setting an ultrasonic device in the phosphating tank, the heating temperature of the phosphating liquid can be reduced to 70-75°C while meeting the required phosphorus content, thereby effectively reducing the generation of phosphorus slag and improving production efficiency.

[0005] According to the technical solution provided by this invention: a steel wire ultrasonic phosphating unit includes a phosphating tank supported by a steel structure. Several wire-splitting devices and several wire-supporting devices for guiding the phosphating steel wire are spaced apart within the phosphating tank. The unit is characterized in that: multiple ultrasonic devices are spaced apart below the phosphating steel wire within the phosphating tank. Each ultrasonic device includes an ultrasonic support, a damping plate, and a lower ultrasonic vibrating plate. The two ends of the ultrasonic support are mounted on the front and rear side walls of the phosphating tank. The damping plate is mounted on the upper surface of the ultrasonic support. The lower ultrasonic vibrating plate is mounted on the damping plate and is located below the phosphating steel wire. The phosphating steel wire enters straight into the phosphating tank from one end, travels straight within the phosphating tank, and exits straight out from the other end of the phosphating tank.

[0006] As a further improvement of the present invention, a phosphating liquid circulation system is provided on the side of the phosphating tank. The phosphating liquid circulation system includes an external circulation tank and a circulation down-pressure pump. The external circulation tank is arranged parallel to the side of the phosphating tank and is supported by a steel structure. A steam heating coil is installed inside the external circulation tank. Phosphating liquid overflow baffles are installed at both ends of the phosphating tank, thereby forming phosphating liquid overflow chambers at both ends of the phosphating tank. The side wall of the phosphating liquid overflow chamber adjacent to the external circulation tank has a phosphating liquid inlet that communicates with the external circulation tank. Two insert plates are symmetrically arranged in the middle of the phosphating tank, forming a phosphating liquid inflow chamber between the two insert plates. The side wall of the phosphating liquid inflow chamber adjacent to the external circulation tank has a phosphating liquid outlet that communicates with the external circulation tank. The circulation down-pressure pump is installed in the middle of the external circulation tank and pumps the phosphating liquid from top to bottom, so that the phosphating liquid enters the phosphating liquid inflow chamber from the phosphating liquid outlet.

[0007] As a further improvement of the present invention, the circulating down-pressure pump includes a motor, a rotating shaft and a blade. The motor is supported and mounted on a steel structure by a motor bracket. The output shaft of the motor is connected to the rotating shaft downward through a coupling. The blade is installed at the lower end of the rotating shaft. A phosphating liquid down-pressure output chamber is provided in the middle of the external circulation tank. A down-pressure conveying cylinder is provided at the top of the phosphating liquid down-pressure output chamber. The blade is arranged inside the down-pressure conveying cylinder.

[0008] As a further improvement of the present invention, both insert plates are inclined from bottom to top, and the distance between the two insert plates gradually increases from bottom to top.

[0009] As a further improvement of the present invention, a thermocouple tube and a float level gauge are installed in the external circulation tank.

[0010] As a further improvement of the present invention, there are two steam heating coils, which are respectively located at both ends of the external circulation tank.

[0011] As a further improvement of the present invention, the external circulation tank is equipped with a side cover plate.

[0012] As a further improvement of the present invention, the vertical distance between the ultrasonic lower vibrating plate and the phosphated steel wire is 4 to 8 cm.

[0013] As a further improvement of the present invention, the wire separating device includes a wire separating bracket and a wire separating roller. The two ends of the wire separating bracket are installed on the front and rear side walls of the phosphating tank, and the wire separating roller is installed on the top of the wire separating bracket. The wire supporting device includes a wire supporting bracket and a flat granite. The two ends of the wire supporting bracket are installed on the front and rear side walls of the phosphating tank, and the flat granite is installed on the top of the wire supporting bracket.

[0014] As a further improvement of the present invention, the phosphating tank is equipped with a cover plate assembly.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] 1) By installing an ultrasonic device in the phosphating tank, the present invention can reduce the heating temperature of the phosphating solution to 70-75°C while ensuring the phosphorus content meets the requirements. This effectively reduces the generation of phosphorus slag, and the phosphorus content is good and the efficiency is high. It also allows the length of the phosphating tank to be shortened by about half, saving plant space.

[0017] 2) By setting up a phosphating solution circulation system on the side of the phosphating tank, the present invention makes the circulation flow of the phosphating solution more reasonable, prevents blockage, and makes the temperature of the phosphating solution more stable during the production process. Attached Figure Description

[0018] Figure 1 This is a structural front view of an embodiment of the present invention.

[0019] Figure 2 This is a top view of the structure of an embodiment of the present invention.

[0020] Figure 3 This is a structural side view of an embodiment of the present invention.

[0021] Figure 4 For embodiments of the present invention along Figure 2 Cross-sectional view of the structure along the AA direction.

[0022] Figure 5 For embodiments of the present invention along Figure 1 Sectional view of the structure along the BB direction.

[0023] Figure 6 For embodiments of the present invention along Figure 2 Cross-sectional view of the structure along the CC direction.

[0024] Explanation of reference numerals in the attached drawings: 1-Steel structure, 2-Phosphating tank, 3-Separating device, 3.1-Separating bracket, 3.2-Separating roller, 4-Wire support device, 4.1-Wire support bracket, 4.2-Plain marble, 5-Ultrasonic device, 5.1-Ultrasonic support bracket, 5.2-Damping plate, 5.3-Ultrasonic lower vibrating plate, 6-Circulating lower pressure pump, 6.1-Motor, 6.2-Rotating shaft, 6.3-Blade, 6.4-Motor bracket, 7-Insertion plate, 8-Cover plate assembly, 9-Phosphating steel wire, 10-Side cover plate, 11-Float level gauge, 12-Thermocouple tube, 13-Steam heating coil, 14-External circulation tank, 15-Phosphating liquid overflow baffle, 16-Phosphating liquid overflow chamber, 17-Phosphating liquid inlet, 18-Phosphating liquid inflow chamber, 19-Phosphating liquid outlet, 20-Phosphating liquid lower pressure output chamber, 21-Lower pressure conveying cylinder. Detailed Implementation

[0025] The present invention will be further described below with reference to specific accompanying drawings and embodiments.

[0026] like Figures 1-6 As shown in the embodiment, an ultrasonic phosphating unit for steel wire is disclosed, which is mainly composed of steel structure 1, phosphating tank 2, wire distribution device 3, wire support device 4, ultrasonic device 5, circulating pressure pump 6, insert plate 7, cover plate assembly 8, side cover plate 10, float level gauge 11, thermocouple tube 12, steam heating coil 13, external circulation tank 14, phosphating liquid overflow baffle 15 and other components.

[0027] In this embodiment, the phosphating tank 2 is supported by a steel structure 1. Several wire-splitting devices 3 and several wire-supporting devices 4 are spaced apart within the phosphating tank 2 to guide the phosphated steel wires 9. Each wire-splitting device 3 includes a wire-splitting bracket 3.1 and a wire-splitting roller 3.2. The two ends of the wire-splitting bracket 3.1 are mounted on the front and rear side walls of the phosphating tank 2, and the wire-splitting roller 3.2 is mounted on top of the wire-splitting bracket 3.1. Each wire-supporting device 4 includes a wire-supporting bracket 4.1 and a flat granite 4.2. The two ends of the wire-supporting bracket 4.1 are mounted on the front and rear side walls of the phosphating tank 2, and the flat granite 4.2 is mounted on top of the wire-supporting bracket 4.1.

[0028] In this embodiment, multiple ultrasonic devices 5 are spaced apart below the phosphated steel wire 9 within the phosphated tank 2. These ultrasonic devices 5 can employ conventional designs and mainly include an ultrasonic support 5.1, a damping plate 5.2, and a lower ultrasonic vibrating plate 5.3. The ultrasonic support 5.1 is mounted on the front and rear side walls of the phosphated tank 2 at both ends. The damping plate 5.2 is mounted on the upper surface of the ultrasonic support 5.1, and the lower ultrasonic vibrating plate 5.3 is mounted on the damping plate 5.2 and located below the phosphated steel wire 9. With this configuration, the ultrasonic devices 5 are activated during the phosphated steel wire process, generating ultrasonic waves that act on the phosphated steel wire 9. This allows the phosphate coating on the phosphated steel wire 9 to meet requirements, while reducing the heating temperature of the phosphated solution to 70-75°C, effectively reducing the generation of phosphate slag. Actual factory operation has shown a reduction in phosphate slag generation of approximately two-thirds. Furthermore, due to the high phosphate coating efficiency, the overall length of the phosphated tank 2 can be shortened by about half, saving factory space. In addition, due to the small amount of phosphate slag produced, the phosphated steel wire 9 can enter straight from one end of the phosphated tank 2, travel straight inside the phosphated tank 2, and exit straight from the other end of the phosphated tank 2. Compared with the previous phosphated treatment equipment that required a wire pressing device, the phosphated steel wire 9 will not be pressed down and bent during the process, and the travel is smoother and more stable, without tangling.

[0029] In this embodiment, a phosphating solution circulation system is provided beside the phosphating tank 2. This system includes an external circulation tank 14 and a circulation pump 6. The external circulation tank 14 is arranged parallel to the side of the phosphating tank 2 and is supported by a steel structure 1. A steam heating coil 13 is installed inside the external circulation tank 14. Phosphating solution overflow baffles 15 are installed at both ends of the phosphating tank 2, thereby forming phosphating solution overflow chambers 16 at both ends of the phosphating tank 2. The phosphating solution overflow chambers 16 are adjacent to... The side wall of the external circulation tank 14 is provided with a phosphating liquid inlet 17 that connects to the external circulation tank 14; two insert plates 7 are symmetrically arranged in the middle of the phosphating tank 2, and the two insert plates 7 form a phosphating liquid inflow chamber 18. The side wall of the phosphating liquid inflow chamber 18 adjacent to the external circulation tank 14 is provided with a phosphating liquid outlet 19 that connects to the external circulation tank 14; the circulating pressure pump 6 is installed in the middle of the external circulation tank 14, and the circulating pressure pump 6 pushes the phosphating liquid from top to bottom, so that the phosphating liquid enters the phosphating liquid inflow chamber 18 from the phosphating liquid outlet 19.

[0030] In this embodiment, the circulating down-pressure pump 6 mainly consists of a motor 6.1, a rotating shaft 6.2, and a blade 6.3. The motor 6.1 is supported and mounted on the steel structure 1 by a motor bracket 6.4. The output shaft of the motor 6.1 is connected to the rotating shaft 6.2 downward through a coupling. The blade 6.3 is installed at the lower end of the rotating shaft 6.2. The outer circulation tank 14 is provided with a phosphating liquid down-pressure output chamber 20 in the middle. The top of the phosphating liquid down-pressure output chamber 20 is provided with a down-pressure conveying cylinder 21. The blade 6.3 is set inside the down-pressure conveying cylinder 21.

[0031] When the phosphating solution circulation system is working, the circulating pressure pump 6 pumps the phosphating solution in the external circulation tank 14 from top to bottom to the phosphating solution pressure output chamber 20. The phosphating solution then flows from the pressure output chamber 20 through the phosphating solution outlet 19 into the phosphating solution inflow chamber 18, and then flows from bottom to top, passing over the upper end of the baffle 7 and flowing to both ends of the phosphating tank 2. As the circulating pressure pump 6 continuously feeds the phosphating solution into the phosphating tank 2, the amount of phosphating solution in the phosphating tank 2 will increase. When the phosphating solution level in the phosphating tank 2 is higher than the phosphating solution overflow baffles 15 at both ends, the phosphating solution flows over the phosphating solution overflow baffles 15 into the phosphating solution overflow chamber 16, and then enters the external circulation tank 14 through the phosphating solution inlet 17. After being heated by the steam heating coil 13, it flows back to the circulating pressure pump 6, and so on. [See details] Figure 2 [As shown by the middle arrow]. Moreover, since the phosphating solution at the circulating pressure pump 6 is pumped from top to bottom, even if the phosphating solution contains phosphorus residue, blockage will not occur.

[0032] In this embodiment, both insert plates 7 are inclined from bottom to top, and the distance between the two insert plates 7 gradually increases from bottom to top. This arrangement ensures that the phosphating solution flows obliquely from bottom to top and outward in the phosphating solution inflow chamber 18. This effectively carries up the phosphate slag in the phosphating solution, allowing the phosphate slag to pass over the upper end of the insert plate 7 with the rapidly flowing phosphating solution. Meanwhile, the phosphating solution flows more slowly on the lower outer side of the insert plate 7, and the phosphate slag easily settles there after passing over the insert plate 7, facilitating centralized cleaning.

[0033] In this embodiment, a thermocouple tube 12 and a float level gauge 11 are installed in the external circulation tank 14, which facilitates the monitoring of the temperature and remaining amount of the phosphating solution for precise control.

[0034] In this embodiment, there are two steam heating coils 13, which are respectively located at both ends of the external circulation tank 14. This arrangement places the two steam heating coils 13 close to the two phosphating liquid inlets 17, making it easy to wash away any phosphate slag adhering to the coils 13, thus preventing slag buildup and ensuring good heat transfer performance. Furthermore, the phosphating liquid at the two inlets 17 is at its lowest temperature immediately after exiting the phosphating tank 2; placing the two steam heating coils 13 at this location allows for more efficient heating of the phosphating liquid, resulting in a more stable overall temperature. The steam heating coils 13 in this invention are preferably made of stainless steel.

[0035] In this embodiment, the vertical distance between the ultrasonic lower vibrating plate 5.3 and the phosphated steel wire 9 is 4-8 cm, which is adjusted according to the required amount of phosphate during the production process.

[0036] In this embodiment, a flat granite 4.2 is also installed on the top of the phosphating solution overflow baffle 15. This arrangement helps to keep the phosphating steel wire 9 stable at the point where the phosphating solution overflows.

[0037] In this invention, the phosphating tank 2 is equipped with a cover plate assembly 8, and the external circulation tank 14 is equipped with a side cover plate 10. This can keep the phosphating solution warm, prevent heat loss, and save energy.

[0038] The above description is merely a preferred embodiment of the present invention, and the specific embodiments described above are not intended to limit the present invention. Various modifications and variations can be made within the scope of the technical concept of the present invention. All refinements, modifications, or equivalent substitutions made by those skilled in the art based on the above description are within the scope of protection of the present invention.

Claims

1. A steel wire ultrasonic phosphating unit, comprising a phosphating tank (2) supported by a steel structure (1), wherein a plurality of wire-splitting devices (3) and a plurality of wire-supporting devices (4) for guiding phosphating steel wires (9) are arranged at intervals within the phosphating tank (2); wherein a plurality of ultrasonic devices (5) are arranged at intervals below the phosphating steel wires (9) within the phosphating tank (2), wherein each ultrasonic device (5) comprises an ultrasonic support (5.1), a damping plate (5.2), and an ultrasonic lower vibrating plate (5.3), wherein the two ends of the ultrasonic support (5.1) are mounted on the front and rear side walls of the phosphating tank (2), the damping plate (5.2) is mounted on the upper surface of the ultrasonic support (5.1), the ultrasonic lower vibrating plate (5.3) is mounted on the damping plate (5.2), and the ultrasonic lower vibrating plate (5.3) is located below the phosphating steel wires (9); characterized in that: A phosphating solution circulation system is provided on the side of the phosphating tank (2). The phosphating solution circulation system includes an external circulation tank (14) and a circulation pump (6). The external circulation tank (14) is arranged parallel to the side of the phosphating tank (2) and is supported by a steel structure (1). A steam heating coil (13) is installed in the external circulation tank (14). Phosphating solution overflow baffles (15) are installed at both ends of the phosphating tank (2), thereby forming phosphating solution overflow chambers (16) at both ends of the phosphating tank (2). The side wall of the phosphating solution overflow chamber (16) adjacent to the external circulation tank (14) is provided with a phosphating solution inlet that connects to the external circulation tank (14). The phosphating tank (2) has two symmetrically arranged insert plates (7) in the middle, and the two insert plates (7) form a phosphating liquid inflow chamber (18). The side wall of the phosphating liquid inflow chamber (18) adjacent to the external circulation tank (14) has a phosphating liquid outlet (19) that connects to the external circulation tank (14). The circulating pressure pump (6) is installed in the middle of the external circulation tank (14). The circulating pressure pump (6) pushes the phosphating liquid from top to bottom, so that the phosphating liquid enters the phosphating liquid inflow chamber (18) from the phosphating liquid outlet (19). The phosphating steel wire (9) enters straight from one end of the phosphating tank (2), runs straight in the phosphating tank (2), and exits straight from the other end of the phosphating tank (2).

2. The ultrasonic phosphating unit for steel wire as described in claim 1, characterized in that: The circulating down-pressure pump (6) includes a motor (6.1), a rotating shaft (6.2), and a blade (6.3). The motor (6.1) is supported and mounted on the steel structure (1) by a motor bracket (6.4). The output shaft of the motor (6.1) is connected to the rotating shaft (6.2) downward through a coupling. The blade (6.3) is installed at the lower end of the rotating shaft (6.2). The phosphating liquid down-pressure output chamber (20) is provided in the middle of the external circulation tank (14). The down-pressure conveying cylinder (21) is provided at the top of the phosphating liquid down-pressure output chamber (20). The blade (6.3) is set in the down-pressure conveying cylinder (21).

3. The ultrasonic phosphating unit for steel wire as described in claim 1, characterized in that: Both of the insert plates (7) are inclined from bottom to top, and the distance between the two insert plates (7) gradually increases from bottom to top.

4. The ultrasonic phosphating unit for steel wire as described in claim 1, characterized in that: The external circulation tank (14) is equipped with a thermocouple tube (12) and a float level gauge (11).

5. The ultrasonic phosphating unit for steel wire as described in claim 1, characterized in that: There are two steam heating coils (13), which are respectively located at both ends of the external circulation tank (14).

6. The ultrasonic phosphating unit for steel wire as described in claim 1, characterized in that: The external circulation tank (14) is equipped with a side cover plate (10).

7. The ultrasonic phosphating unit for steel wire as described in claim 1, characterized in that: The vertical distance between the ultrasonic lower vibrating plate (5.3) and the phosphated steel wire (9) is 4-8 cm.

8. The ultrasonic phosphating unit for steel wire as described in claim 1, characterized in that: The wire separating device (3) includes a wire separating bracket (3.1) and a wire separating roller (3.2). The two ends of the wire separating bracket (3.1) are installed on the front and rear side walls of the phosphate tank (2), and the wire separating roller (3.2) is installed on the top of the wire separating bracket (3.1). The wire support device (4) includes a wire support bracket (4.1) and a flat granite (4.2). The two ends of the wire support bracket (4.1) are installed on the front and rear side walls of the phosphate tank (2), and the flat granite (4.2) is installed on the top of the wire support bracket (4.1).

9. The ultrasonic phosphating unit for steel wire as described in claim 1, characterized in that: The phosphating tank (2) is equipped with a cover plate assembly (8).

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