Multi-stage step countercurrent electroplating wire wastewater zero-discharge production line

Abstract

The present invention discloses a multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line, comprising a sequentially arranged loading unit, an electroplating unit, a vibration isolation unit, a multi-stage step-by-step countercurrent rinsing unit, a drying unit, and a discharge unit; the vibration isolation unit comprises a vibration drying tank and 2 to 5 sets of passive vibration drying devices arranged in series within the vibration drying tank; the multi-stage step-by-step countercurrent rinsing unit comprises at least two cleaning tanks arranged in series, each of which is provided with an axial flow air knife at the end; the airflow ejection direction of the axial flow air knife coincides with the axial direction of the electroplating wire and is opposite to the direction of travel of the electroplating wire. The present invention is characterized by saving water, electricity, and electroplating chemicals, and having an output higher than the input. Using the production line provided by the present invention not only does not increase the production cost of electroplating wire, but actually reduces it, making it a practical scientific and technological achievement suitable for promotion in the low-profit electroplating wire industry.

Description

Technical Field

[0001] The invention relates to a wire electroplating production line, in particular to a multi-stage step-by-step countercurrent type wire electroplating wastewater zero-discharge production line. Background Art

[0002] The current process flow for galvanizing wire at domestic and international manufacturers can be described as follows: 1. Raw black iron wire is loaded (loading unit); 2. The black iron wire enters the electroplating tank for zinc plating, resulting in a shiny galvanized wire (electroplating unit); 3. The wire enters the deposition tank, where the highly concentrated plating solution adheres to the shiny wire surface and is recovered (deposition unit); 4. The wire enters the cleaning unit, where the remaining plating solution is rinsed with clean water (cleaning unit); 5. After cleaning, the water on the wire surface is dried (drying unit); 6. The finished wire is removed from the assembly line (unloading unit). The process flow for electroplating other metal wires, such as copper, nickel, and chromium, is similar to the aforementioned process flow for galvanizing wire.

[0003] The reason why the electroplating wire production line generates a large amount of electroplating solution cleaning wastewater is that after the wire passes through the electroplating tank, a large amount of high-concentration electroplating solution will adhere to the surface. Only a small part of these highly adhesive electroplating solutions can be deposited and recovered in the sedimentation tank, and most of the rest is brought into the cleaning tank of the cleaning unit and has to be rinsed with a large amount of clean water in the cleaning tank.

[0004] To address wastewater pollution from electroplating wire production lines, China is promoting the use of electroplating wastewater treatment systems on production lines. However, existing electroplating wastewater treatment systems suffer from a fatal flaw: extremely high operating costs. From a cost accounting perspective, using electroplating wastewater treatment systems is not worth the cost. Therefore, even if manufacturers install electroplating wastewater treatment equipment on their production lines, they cannot afford the treatment costs. As a result, it is a common phenomenon in the industry that the purchased electroplating wastewater treatment equipment remains idle.

[0005] In addition to installing electroplating wastewater treatment systems on the production line, some manufacturers also choose to use isolation devices to minimize the amount of electroplated workpieces carried over from the plating tank, thereby reducing the use of clean rinse water and fundamentally reducing the amount of electroplating rinse wastewater generated. Currently, there are three main types of isolation devices used in electroplating wire production lines: 1. High-pressure runoff air knife (purge isolation); 2. Brush (drainage isolation); 3. Cotton yarn (adsorption isolation).

[0006] ① Regarding high-pressure runoff air knives: Using a high-pressure runoff air knife for purge isolation is a relatively mature and effective isolation solution. It is primarily used for pretreatment of electroplated wire prior to drying, specifically between the cleaning tank at the tail end of the cleaning unit and the drying unit. For example, the pneumatic drying device for electroplated wire disclosed in Authorization Announcement No. CN202881431U.

[0007] The specific arrangement of the high pressure radial air knife B1 is usually as follows Figure 1 As shown, it is located at the end of the cleaning tank at the tail end of the cleaning unit. During operation, the electroplated wire 7 from the previous cleaning tank passes through the left-side guide wear-resistant sleeve B2 and enters the cleaning water for immersion and cleaning. After cleaning, the electroplated wire 7 passes through the high-pressure runoff air knife B1, then passes through the right-side guide wear-resistant sleeve B2 and enters the drying unit. At the high-pressure runoff air knife B1, high-pressure air (5MPa) is ejected from the bottom micropores, forming a high-speed turbulent flow, sweeping away the adhered plating solution from above the electroplated wire 7 and causing it to fall into the cleaning tank of this level. Because the sweeping airflow direction is basically consistent with the radial direction of the electroplated wire 7, it is called a high-pressure runoff air knife B1.

[0008] The aforementioned high-pressure runoff air knife can only be used in the final rinse tank of an electroplating wire production line, to dry the water on the surface of the electroplated wire. During operation, fresh water must be continuously injected into the final rinse tank to maintain a purity close to that of pure water. Otherwise, the air knife will not function. This is because while the turbulent flow created by the high-pressure runoff air knife can clear debris from the surface of the electroplated wire, the debris that falls off the wire ultimately forms a highly dispersed, low-particle smoke, rather than easily sinking droplets. If this air knife is used to remove highly concentrated electroplating rinse water, a significant portion of the water will become smoke and dissipate directly into the air, directly impacting the health of the operator.

[0009] In addition, the above-mentioned high-pressure radial air knife has the following disadvantages:

[0010] One is high operating costs. The direction of the purge airflow coincides with the radial direction of the electroplating wire. To sweep away the debris on the lower half of the electroplating wire, the purge airflow must form high-speed turbulence. The air source that can form high-speed turbulence must be compressed air with a pressure of at least 5MPa. However, the energy efficiency of equipment that produces compressed air is generally very low. This high-energy solution increases user costs and reduces product profits, resulting in low end-user enthusiasm for use.

[0011] The second problem is a high failure rate. The nozzle of the high-pressure radial air knife is a row of microscopic holes that are almost invisible to the naked eye. They can easily become clogged by oil or dust in the air supply, causing failures. Furthermore, such localized failures are difficult for operators to detect, which can easily lead to quality problems in the electroplating wire. This equipment has a high failure rate and requires frequent maintenance.

[0012] ② About Brush B3: Brush B3 drainage isolation solution is usually used in sedimentation units, such as Figure 2As shown, the brushes B3 are generally arranged in groups in the plating solution deposition tank of the deposition unit and contact the passing electroplating wire 7. During operation, the plating liquid adhered to the electroplating wire 7 is absorbed by the fibers on the brushes B3 and then drained and settled into the plating solution deposition tank below.

[0013] However, because the brush fibers have little ability to absorb the plating solution adhering to the bottom and top of the plated wire (they mainly drain the plating solution adhering to the left and right sides), the isolation effect of this solution is very limited, generally less than 40%. In addition, the brush is constantly worn by the plated wire and is quickly consumed. Generally, a new brush needs to be replaced every month, and the large amount of plating solution crystals adhering to the old brush will cause secondary contamination.

[0014] ③ About cotton yarn: Replacing the above-mentioned brush with cotton yarn (including textiles such as cotton cloth) will form a typical cotton yarn adsorption and isolation device.

[0015] Compared to brush drainage isolation solutions, cotton yarn has a strong adsorption effect but poor downward drainage, resulting in even poorer isolation than brush drainage. Furthermore, once the plating solution reaches saturation, the cotton yarn must be replaced. Like brush drainage, the replaced cotton yarn cannot be treated with contaminants. Furthermore, cotton yarn can easily get stuck in the plating wire connectors on the production line, causing malfunctions, making it much more troublesome to use than brush drainage.

[0016] The following chart compares the advantages and disadvantages of the three isolation devices mentioned above:

[0017]

[0018] It can be seen that the above three isolation devices that can be used in electroplating wire production lines are unable to effectively isolate low-concentration electroplating solution cleaning water and high-concentration electroplating solution. Summary of the Invention

[0019] The present invention provides a multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line, which realizes the infinite recycling of electroplating wastewater, has extremely low equipment investment and operation costs, and achieves true theoretical zero discharge of electroplating wastewater.

[0020] The theoretical zero emission described in the present invention does not mean that not a drop of wastewater is discharged in the true sense, but it means that not a drop of wastewater is discharged under the premise of ignoring trace emissions caused by accidental equipment failures, human errors and normal volatilization during the production process.

[0021] To achieve the above-mentioned object, the technical solution adopted by the present invention is as follows: a multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line, comprising a loading unit, an electroplating unit, a vibration isolation unit, a multi-stage step-by-step countercurrent rinsing unit, a drying unit and a unloading unit arranged in sequence;

[0022] The vibration isolation unit includes a vibration drying tank and 2 to 5 sets of passive vibration drying devices arranged in series in the vibration drying tank. The passive vibration drying device is an eccentric groove wheel rotatably arranged in the vibration drying tank and having a wrap angle with the electroplating wire.

[0023] The multi-stage step-by-step countercurrent rinsing unit includes at least two cleaning tanks arranged in series. At every interval of T hours, the cleaning water in the cleaning tanks is stepped one tank away from the rear end to the front end. The cleaning water in the front end cleaning tank is returned to the electroplating unit, and the rear end cleaning tank is replenished with pure cleaning water.

[0024] Each cleaning tank is equipped with a changing roller for pressing the electroplating wire into the cleaning water, and an axial flow air knife is provided at the end of each cleaning tank; the air flow direction of the axial flow air knife coincides with the axial direction of the electroplating wire and is opposite to the running direction of the electroplating wire.

[0025] As a limitation of the present invention, a passive vibration drying device is arranged at the end of the tail plating tank of the electroplating unit.

[0026] As another limitation of the present invention, a V-shaped groove is provided on the circumferential curved surface of the eccentric sheave, the bottom of the V-shaped groove is an arc, and the radius of the arc is 2 to 3 times the radius of the electroplated wire.

[0027] As a further limitation of the present invention, the eccentric sheave has any of the following structures:

[0028] a. an eccentric shaft and a sheave assembled on the eccentric shaft, the sheave having at least one V-shaped groove;

[0029] b. A long core shaft and an eccentric sheave with an eccentric hole assembled on the long core shaft, wherein the eccentric sheave has at least one V-shaped groove.

[0030] As a further limitation of the present invention, the axial flow air knife includes an air duct connected to an air pump at one end and an air knife module assembled on the air duct, the air knife module having an air inlet hole connected to the air duct, and the air knife module having a wire hole for allowing the plating wire to pass through;

[0031] The air inlet hole is a tapered oblique blind hole pointing to the wire inlet end of the wire hole, or the air inlet hole is a vertical through hole close to the wire inlet end of the wire hole.

[0032] As a further limitation of the present invention, one end or both ends of the wire passing hole are inlaid with a wear-resistant guide sleeve, and the wear-resistant guide sleeve has an inner hole chamfer pointing to the wire inlet end of the wire passing hole.

[0033] As a further limitation of the present invention, the wire hole is a tapered hole with a small diameter of the wire inlet port and a large diameter of the wire outlet port.

[0034] As a further limitation of the present invention, the upper side of the air duct is pre-processed with a flat surface, and a mounting hole communicating with the inner cavity of the air duct is drilled on the flat surface;

[0035] The wind knife module includes an integrally formed rectangular portion and a protruding shoulder, the protruding shoulder is located below the rectangular portion and is glued and fixed in the mounting hole; the wire hole is provided on the rectangular portion, perpendicular to the axial direction of the air duct; the air inlet hole extends from the bottom of the protruding shoulder to connect to the wire hole, and is a tapered oblique blind hole with a larger bottom and a smaller top.

[0036] As a further limitation of the present invention, both sides of the air duct are pre-machined with flat surfaces, and mounting holes are drilled radially on the air duct, with both ends of the mounting holes located on the two side flat surfaces of the air duct respectively;

[0037] The air knife module includes a main blowing sleeve and an auxiliary blowing sleeve that are detachably connected. The main blowing sleeve and the auxiliary blowing sleeve each include a protruding shoulder and a cylindrical portion. The wire hole is arranged along the axis of the main blowing sleeve and the auxiliary blowing sleeve. The air inlet is arranged on the cylindrical portion of the main blowing sleeve and is a vertical through hole close to the wire inlet end of the wire hole.

[0038] The cylindrical part of the main blow-drying sleeve extends into the mounting hole from the left side of the air duct, and the protruding shoulder fits on the left plane of the air duct; the cylindrical part of the auxiliary blow-drying sleeve extends into the mounting hole from the right side of the air duct, and is detachably connected to the cylindrical part of the main blow-drying sleeve, and the protruding shoulder of the auxiliary blow-drying sleeve fits on the right plane of the air duct.

[0039] As a further limitation of the present invention, both sides of the air duct are pre-machined with flat surfaces, and mounting holes are drilled radially on the air duct, with both ends of the mounting holes located on the two side flat surfaces of the air duct respectively;

[0040] The air knife module includes a one-way blowing sleeve and a locking nut threadedly connected to the one-way blowing sleeve, wherein the one-way blowing sleeve includes an integrally formed protruding shoulder and a cylindrical portion; the wire hole is opened on the axis of the one-way blowing sleeve; the air inlet hole is provided on the upper side of the cylindrical portion of the one-way blowing sleeve, and is a tapered oblique blind hole with a larger upper portion and a smaller lower portion;

[0041] The cylindrical part of the one-way blowing sleeve extends into the mounting hole from the left side of the air duct and extends from the right side to be connected with the locking nut; wherein, the protruding shoulder of the one-way blowing sleeve fits on the left plane of the air duct, and the locking nut fits on the right plane of the air duct.

[0042] Due to the adoption of the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0043] (1) The present invention adds necessary isolation devices within (or between) the electroplating unit, rinsing unit, and drying unit: a vibration isolation unit and an axial flow air knife. Furthermore, a multi-stage step-by-step countercurrent rinsing unit is employed to achieve unlimited recycling of electroplating wire cleaning water back to the electroplating tank. This invention achieves true theoretical zero discharge of electroplating wastewater without the use of electroplating wastewater treatment equipment.

[0044] (2) The core components of the present invention are the vibration isolation unit and the axial flow air knife. Both are extremely low energy devices, with the former even being considered to have zero operating energy consumption. Furthermore, these two isolation devices are low cost and highly reliable, ensuring long-term trouble-free operation.

[0045] (3) The passive vibration drying device provided by the present invention can achieve an isolation rate of over 90% when used in series with three stages. This device can intercept the vast majority of high-concentration electroplating solution before the rinsing unit, ensuring to the greatest extent possible that high-concentration electroplating solution in the electroplating tank is not carried into the cleaning tank. This lays a solid foundation for the reliable unlimited recycling of cleaning water in electroplating wire production lines. This passive vibration drying isolation device has the advantages of low one-time investment cost, virtually no consumption in long-term use, and excellent isolation effect.

[0046] (4) The through-type axial flow air knife provided by the present invention has a structure that shortens the distance between the air knife nozzle and the electroplating wire to the maximum extent, which can minimize the energy loss of the air knife. Therefore, when a single-stage vortex air pump is used as the low-pressure air source of the air knife, the overall working effect can be basically similar to that of the existing high-pressure runoff air knife. The axial flow air knife uses a low-pressure air source to provide a smooth, stable and controllable working airflow, which can completely avoid the atomization phenomenon during the operation of the air knife, thereby overcoming the defect of high-pressure runoff air knife that causes serious atomization and causes wastewater to be discharged into the air; in addition, the use of a low-pressure air source increases the energy utilization rate by nearly 3 times compared with the high-pressure air pump that generates compressed air, making the energy consumption extremely low.

[0047] In summary, the present invention has the characteristics of saving water, electricity, and chemical preparations for electroplating, and the output is higher than the input. The use of the production line provided by the present invention will not only not increase the production cost of electroplating wire, but will reduce its production cost. It has the advantage of eliminating electroplating wastewater treatment equipment with high usage costs and immature technology. It is a practical scientific and technological achievement suitable for promotion in the low-profit electroplating wire industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The present invention will be described in further detail below with reference to the accompanying drawings and specific embodiments.

[0049] Figure 1 This is a schematic diagram of the arrangement structure of the high-pressure radial air knife in the tail end cleaning tank of the background technology of the present invention;

[0050] Figure 2 A schematic diagram of the arrangement structure of brushes in a plating solution deposition tank according to the background technology of the present invention;

[0051] Figure 3 Schematic diagram of the structural relationship of Example 1 of the present invention; wherein, Figure 3 a is a side view of Example 1, Figure 3 b is a front view of Example 1;

[0052] Figure 4 This is another structural diagram of Example 1 of the present invention;

[0053] Figure 5 This is a schematic structural diagram of Example 2 of the present invention;

[0054] Figure 6 This is a cross-sectional view of the structure of Example 3 of the present invention;

[0055] Figure 7 This is a cross-sectional view of the structural relationship of Example 4 of the present invention;

[0056] Figure 8 This is a cross-sectional view of the structure of Example 5 of the present invention;

[0057] Figure 9 This is a schematic structural diagram of a cleaning tank in Example 6 of the present invention;

[0058] Figure 10 This is a structural diagram of Example 7 of the present invention.

[0059] In the figure: 1. Loading unit; 2. Electroplating unit; 3. Vibration isolation unit; 4. Multi-stage step-by-step countercurrent rinsing unit; 5. Drying unit; 6. Unloading unit; 7. Electroplating wire;

[0060] 101, eccentric shaft; 102, sheave; 103, V-groove;

[0061] 201. Vibration drying tank; 202. Passive vibration drying device; 203. Pressing roller;

[0062] 301, air duct; 302, main blowing sleeve; 303, auxiliary blowing sleeve; 304, wear-resistant guide sleeve; 305, air inlet; 306, wire hole; 307, rectangular portion; 308, one-way blowing sleeve; 309, locking nut;

[0063] 401, cleaning tank; 402, direction-changing roller; 403, axial-flow air knife;

[0064] B1. High-pressure radial air knife; B2. Guide wear-resistant sleeve; B3. Brush. DETAILED DESCRIPTION

[0065] The preferred embodiments of the present invention are described below in conjunction with the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and understand the present invention and are not intended to limit the present invention.

[0066] It should be noted in advance that the amount of liquid adhering to the wire during the electroplating process is called carry-out and carry-in in industry terms. The amount of liquid adhering to the wire that enters the next level tank is called carry-in, and the opposite is called carry-out.

[0067] The front end (or head end) mentioned in the present invention refers to the end close to the loading unit, and the rear end (or end, tail end) refers to the end close to the unloading unit.

[0068] Example 1 A passive vibration drying device

[0069] like Figure 3 As shown, this embodiment is an eccentric sheave, comprising an eccentric shaft 101 and a sheave 102 assembled on the eccentric shaft 101 , and at least one V-shaped groove 103 is provided on the circumferential curved surface of the sheave 102 .

[0070] The working principle is as follows: the lower half of the electroplating wire 7 relies on tension to always adhere to point A of the V-shaped groove 103, driving the groove wheel 102 to rotate. Because the plating liquid attached to the electroplating wire 7 is mainly concentrated in the lower half of the circle, after the electroplating wire 7 passes through the V-shaped groove 103, point A of the V-shaped groove 103 absorbs the plating liquid. As the groove wheel 102 rotates, when point A separates from the electroplating wire 7 and rotates toward the lowest point, the plating liquid attached to point A quickly leaves point A under the dual effects of centrifugal force and gravity and flows along the inner side walls of the V-shaped groove 103 toward point B on the outer edge of the wheel, until it accumulates into droplets and is thrown out. When point A returns to the highest point again, the plating liquid attached to point A has been basically emptied, which means it is ready for re-adsorption and drying in the next cycle. Because the centrifugal force on the outer edge of the circle at point B is greater, as long as the groove wheel 102 maintains an appropriate rotation speed, the droplets thrown to point B will not be able to return to point A.

[0071] Under the action of the eccentric shaft 101, the sheave 102 undergoes a periodic vibration with each rotation, which in turn drives the electroplating wire 7 to vibrate, thereby causing the plating liquid adhering to the electroplating wire 7 to gather toward the lower half of the electroplating wire 7, thus providing favorable conditions for the above-mentioned operation. The vibration frequency of the sheave 102 is equal to its rotational speed, and the maximum amplitude is twice the eccentricity. In this embodiment, the eccentricity of the sheave 102 is slightly larger than the radius of the electroplating wire 7.

[0072] It should be emphasized that, theoretically, a sharp-angled bottom of the V-shaped groove 103 of the sheave 102 is most conducive to drainage and drying. However, after a period of use, sharp-angled grooves can wear out and frequently cause wire biting problems. To avoid such problems, the bottom of the V-shaped groove 103 in this embodiment is a circular arc, and the radius of the arc is 2 to 3 times the radius of the electroplating wire 7. In addition, to improve the adsorption of the electroplating solution, the sheave 102 should preferably be made of a hydrophilic material, such as chrome steel or carbon steel with an aluminized surface.

[0073] Since a production line usually electroplates 15 to 60 electroplated wires 7 at the same time, in practice, the circumferential surface of the groove wheel 102 usually has a plurality of V-shaped grooves 103 (such as Figure 4 As shown), each corresponding to a plating wire 7.

[0074] Finally, this embodiment can also be another variant structure, that is, the eccentric shaft 101 is changed into a long core shaft, and the groove wheel 102 is changed into an eccentric groove wheel with an eccentric hole, and then an eccentric groove wheel with multiple V-shaped grooves 103 is assembled on the long core shaft, or multiple eccentric groove wheels with one V-shaped groove 103 are assembled side by side on the long core shaft.

[0075] Example 2: A vibration isolation unit

[0076] like Figure 5 As shown, this embodiment includes a vibrating drying tank 201 and two to five sets of passive vibrating drying devices 202, as described in Example 1, arranged in series within the vibrating drying tank 201. The greater the number of passive vibrating drying devices 202 arranged in series, the better the isolation effect and the smaller the carryover from the vibrating drying tank 201. In principle, the number of sets selected in series should ensure that the carryover from the vibrating drying tank 201 is no greater than the carryover from the head-end cleaning tank 401, otherwise overflow from the head-end cleaning tank 401 will occur.

[0077] This embodiment uses three groups of passive vibration drying devices 202 working in series. In order to improve the isolation effect, the distance between the multiple groups of passive vibration drying devices 202 is greater than the circumference of the V-shaped groove 103, so that the high-concentration electroplating solution adhering to the electroplating wire 7 has a certain amount of time to be deposited on the lower half of the electroplating wire 7.

[0078] like Figure 5 As shown, a pressing roller 203 is provided between each two adjacent sets of passive vibration drying devices 202 to ensure that the electroplated wire 7 and the V-shaped groove 103 of the groove wheel 102 maintain an appropriate wrap angle.

[0079] Example 3 Axial Flow Air Knife (1st Generation)

[0080] like Figure 6As shown, this embodiment includes an air duct 301 and an air knife module assembled on the air duct 301. The air knife module has an air inlet 305 connected to the air duct 301 and a wire hole 306 for allowing the electroplating wire 7 to pass through.

[0081] Specifically, one end of the air duct 301 is connected to the air pump, and low-pressure air of no more than 40KPa from the air pump is always injected into the duct during operation. Figure 6 As shown, both sides of the air duct 301 are pre-processed with planes, and mounting holes are drilled radially on the air duct 301, with both ends of the mounting holes located on the planes on the left and right sides of the air duct 301 respectively.

[0082] The air knife module includes a main blowing sleeve 302 and an auxiliary blowing sleeve 303 which are detachably connected. Figure 6 As shown, both the main blow-drying sleeve 302 and the auxiliary blow-drying sleeve 303 include a protruding shoulder and a cylindrical portion. The cylindrical portion of the main blow-drying sleeve 302 is provided with an external thread, while the cylindrical portion of the auxiliary blow-drying sleeve 303 is provided with an internal thread that matches the external thread. During installation, the cylindrical portion of the main blow-drying sleeve 302 extends into the mounting hole from the left side of the air duct 301, with the protruding shoulder abutting the left flat surface of the air duct 301. The cylindrical portion of the auxiliary blow-drying sleeve 303 extends into the mounting hole from the right side of the air duct 301 and is detachably connected to the cylindrical portion of the main blow-drying sleeve 302 via threads. The protruding shoulder of the auxiliary blow-drying sleeve 303 abuts the right flat surface of the air duct 301.

[0083] The wire hole 306 is arranged along the axis of the main blowing sleeve 302 and the auxiliary blowing sleeve 303 after they are connected, and both ends of the wire hole 306 are inlaid with wear-resistant guide sleeves 304. Figure 6 As shown, the inner chamfers on the wear-resistant guide sleeve 304 all point to the wire inlet end of the wire hole 306, so as to facilitate the smooth passage of the electroplated wire 7.

[0084] Air inlet 305 is located on the cylindrical portion of the main blower sleeve 302 and is a vertical through-hole located near the inlet end of the cable hole 306. Through air inlet 305, low-pressure air from the air duct 301 is drawn into cable hole 306 and then ejected at high speed from the inlet and outlet ends of cable hole 306. Because air inlet 305 is closer to the inlet end of cable hole 306, the high-speed air ejected from the inlet end of cable hole 306 has a higher flow rate and velocity than that from the outlet end.

[0085] The specific working principle is as follows: High-speed air ejected from the inlet end of the wire hole 306 almost completely surrounds the electroplating wire 7, continuously blocking the plating liquid on the surface of the electroplating wire 7 at a distance of 10 to 50 mm from the inlet end. The liquid accumulates until it forms droplets that drip from the electroplating wire 7. In theory, as long as the air flow rate at the inlet end is slightly greater than the running speed of the electroplating wire 7, a good cleaning effect can be maintained.

[0086] Since a production line usually electroplates 15 to 60 electroplating wires 7 at the same time, in practice, a plurality of air knife modules are usually installed side by side on the air duct 301 so that each of the air knife modules can pass through one electroplating wire 7 respectively.

[0087] Example 4 Axial Flow Air Knife (2nd Generation)

[0088] like Figure 7 As shown, this embodiment includes an air duct 301 and an air knife module assembled on the air duct 301. The air knife module has an air inlet 305 connected to the air duct 301 and a wire hole 306 for allowing the electroplating wire 7 to pass through.

[0089] Specifically, one end of the air duct 301 is connected to the air pump, and the low-pressure air from the air pump is always injected into the duct during operation. Figure 7 As shown, a plane is pre-processed on the upper side of the air duct 301, and a mounting hole communicating with the inner cavity of the air duct 301 is drilled on the plane.

[0090] The air knife module includes a rectangular portion 307 and a protruding shoulder formed by integral injection molding. The shape of the protruding shoulder is adapted to the above-mentioned mounting hole. During installation, the protruding shoulder is placed in the mounting hole and glued in place. To increase the strength of the connection between the air knife module and the air duct 301, threaded holes can also be opened on the rectangular portion 307 of the air knife module and on the plane of the air duct 301. At the same time, a long pressure plate can be placed above the rectangular portion 307 of the air knife module. The long pressure plate, air knife module, and air duct 301 can then be fixed together using bolts.

[0091] The wire hole 306 is provided on the rectangular portion 307, perpendicular to the axial direction of the air duct 301, and one or both ends of the wire hole 306 are inlaid with a wear-resistant guide sleeve 304. Figure 7 As shown, the chamfered inner hole of the wear-resistant guide sleeve 304 points toward the inlet end of the wire hole 306, facilitating smooth passage of the electroplated wire 7. In this embodiment, the wire hole 306 is a tapered hole with a small inlet diameter and a large outlet diameter. This tapered hole arrangement not only facilitates the smooth passage of the electroplated wire 7, but also prevents the connector on the electroplated wire 7 from becoming stuck in the middle of the wire hole 306, potentially causing a malfunction.

[0092] The air inlet 305 is provided on the above-mentioned protruding shoulder, extending from the bottom of the protruding shoulder until it is connected to the wire hole 306. It is a tapered oblique blind hole pointing to the wire inlet end of the wire hole 306, with a larger bottom and a smaller top.

[0093] Working principle: The low-pressure air in the air duct 301 is guided by the tapered oblique blind hole and blows toward the wire inlet end of the wire hole 306. Before the electroplated wire 7 with liquid adhered to its surface enters the wire inlet end of the wire hole 306, it is swept by the ejected high-speed airflow, thereby isolating the liquid adhered to the surface of the electroplated wire 7 on the electroplated wire 7 outside the wire inlet end and continuously gathering until large liquid droplets are formed and fall down.

[0094] Compared with Example 3, this embodiment can guide almost all of the low-pressure air in the air duct 301 into the side of the line inlet end of the line hole 306, and has a better cleaning effect and higher energy efficiency.

[0095] Of course, assembling the air knife module on the lower side of the air duct 301 is also a variant of this embodiment. However, since the air knife module is covered by the air duct 301 above, it is not convenient for the operator to observe and operate the threading. Therefore, in practice, the air knife module should be installed on the upper side.

[0096] Since a production line usually electroplates 15 to 60 electroplating wires 7 at the same time, in practice, a plurality of air knife modules are usually installed side by side on the air duct 301 so that each of the air knife modules can pass through one electroplating wire 7 respectively.

[0097] Example 5 Axial Flow Air Knife (3rd Generation)

[0098] like Figure 8 As shown, this embodiment includes an air duct 301 and an air knife module assembled on the air duct 301. The air knife module has an air inlet 305 connected to the air duct 301 and a wire hole 306 for allowing the electroplating wire 7 to pass through.

[0099] Specifically, one end of the air duct 301 is connected to the air pump, and the low-pressure air from the air pump is always injected into the duct during operation. Figure 8 As shown, both sides of the air duct 301 are pre-processed with planes, and mounting holes are drilled radially on the air duct 301, with both ends of the mounting holes located on the planes on the left and right sides of the air duct 301 respectively.

[0100] The air knife module includes a one-way blowing sleeve 308 and a locking nut 309 that is threadedly connected to one end of the one-way blowing sleeve 308. The one-way blowing sleeve 308 includes an integrally formed protruding shoulder and a cylindrical portion. During installation, the cylindrical portion extends from the left side of the air duct 301 into the mounting hole, then extends from the right side and connects to the locking nut 309. The protruding shoulder of the one-way blowing sleeve 308 is affixed to the left plane of the air duct 301, and the locking nut 309 is affixed to the right plane of the air duct 301.

[0101] The wire hole 306 is formed on the axis of the one-way blowing sleeve 308, and one or both ends of the wire hole 306 are inlaid with a wear-resistant guide sleeve 304. Figure 8As shown, the chamfered inner hole of the wear-resistant guide sleeve 304 points toward the inlet end of the wire hole 306, facilitating smooth passage of the electroplated wire 7. In this embodiment, the wire hole 306 is a tapered hole with a small inlet diameter and a large outlet diameter. This tapered hole arrangement not only facilitates the smooth passage of the electroplated wire 7, but also prevents the connector on the electroplated wire 7 from becoming stuck in the middle of the wire hole 306, potentially causing a malfunction.

[0102] The air inlet hole 305 is provided on the upper side of the cylindrical portion, and is a tapered oblique blind hole pointing to the inlet end of the wire passing hole 306 , with a larger top and a smaller bottom.

[0103] This embodiment is a variation of Embodiment 3 and Embodiment 4, with similar principles and structures. The advantage of this embodiment is that the air inlet 305 can always be located at the top, which reduces the chance of blockage due to crystallization of the plating solution when isolating high-concentration plating solution.

[0104] Example 6 A multi-stage step-by-step countercurrent rinsing unit

[0105] This embodiment includes at least two cleaning tanks 401 with a capacity of L and a length of S, which are connected end to end (i.e., in series), and the amount of water carried out of the cleaning tank 401 at the head end is substantially equal to the amount of water carried out of the cleaning tank 401 at the tail end. Assuming that the time for the cleaning water in the cleaning tank 401 at the tail end to become turbid and unusable is T, then every T hours, the cleaning water in each cleaning tank 401 is stepped from the tail end to the head end by a distance of one tank position, starting from the cleaning tank 401 at the head end. The high-concentration cleaning water of the cleaning tank 401 at the head end flows back to the electroplating tank of the electroplating unit 2. After the stepping is completed, pure cleaning water is added to the cleaning tank 401 vacant at the tail end. The above-mentioned stepping process is completed by pumping with a water pump, which is a prior art.

[0106] The prerequisite for achieving zero discharge of cleaning water for the electroplating wire 7 in this embodiment is that when the electroplating production line is in normal production, the plating solution will heat up and evaporate. The evaporation loss of the plating solution in the electroplating tank is the basic process condition for the cleaning water to be able to be recycled.

[0107] The necessary and sufficient conditions for achieving zero discharge of cleaning water for the electroplating wire 7 in this embodiment are: the total amount of plating liquid evaporated in the electroplating tank within T hours ≥ L + (the amount of electroplating liquid brought into the head-end cleaning tank 401 from the electroplating tank - the amount of electroplating wire 7 brought out of the tail-end cleaning tank 401). It is not difficult to see that L is a constant in the aforementioned inequality, and the amount of electroplating wire 7 brought out of the tail-end cleaning tank 401 can only take a minimum value, otherwise it will increase the energy consumption of the subsequent drying unit 5. Therefore, in order to make the aforementioned inequality valid, efforts must be made in two aspects: 1. Reduce the amount of electroplating wire 7 brought into the head-end cleaning tank 401 from the electroplating tank; 2. Increase the T value so that the evaporation of plating liquid in the electroplating tank per unit time is greater than the amount of cleaning water produced in the cleaning tank.

[0108] To achieve point 1 above, the technical means disclosed in Example 2 are employed. To achieve point 2 above, this embodiment, while maintaining multi-stage rinsing (connecting multiple cleaning tanks 401 in series), adds multi-stage isolation and improves the performance of the isolation device. Specifically, axial-flow air knives 403 are added to adjacent cleaning tanks 401 to isolate the vast majority of the contaminants removed from each cleaning tank 401 by the electroplated wire 7 within that cleaning tank 401, thereby extending the service life of the cleaning water in the terminal cleaning tank 401.

[0109] When the T value is high enough and the evaporation volume of the plating tank within T hours is greater than the volume L of the single-stage cleaning tank 401, the cleaning water can be infinitely recycled and zero emissions can be achieved.

[0110] Generally speaking, adding 2 to 3 levels of step-by-step countercurrent rinsing after the vibration isolation unit 3 disclosed in Example 2 can ensure that the production line does not discharge wastewater.

[0111] Specifically, in this embodiment, three cleaning tanks 401 are arranged in series. Figure 9 As shown, each cleaning tank 401 is provided with a changing roller 402 for pressing the electroplating wire 7 into the cleaning water, and an axial flow air knife 403 is provided at the end of each cleaning tank 401. The air flow ejection direction of the axial flow air knife 403 coincides with the axial direction of the electroplating wire 7 and is opposite to the running direction of the electroplating wire 7.

[0112] The above-mentioned axial flow air knife 403 can be any one of embodiments 3-5.

[0113] It should be noted that the axial flow air knife 403 set at the end of the tail end cleaning tank 401 not only plays an isolation role, but also can be used as a drying pretreatment device to minimize the energy consumption of the drying unit 5 by reducing the amount of electroplated wire 7 carried out from the tail end cleaning tank 401.

[0114] Example 7 A multi-stage step-by-step countercurrent electroplating wire wastewater zero discharge production line

[0115] like Figure 10 As shown, this embodiment includes a loading unit 1, an electroplating unit 2, a vibration isolation unit 3, a multi-stage step countercurrent rinsing unit 4, a drying unit 5 and a unloading unit 6 which are arranged in sequence.

[0116] The feeding unit 1 is an existing structure, which adopts the current typical "I" wheel pay-off device.

[0117] The electroplating unit 2 includes two to four electroplating tanks arranged in series, all of which are conventional structures. In this embodiment, a passive vibration drying device 202 as described in Example 1 is arranged at the end of the tail electroplating tank to isolate the high-concentration electroplating solution adhering to the electroplating wire 7 in the electroplating tank.

[0118] The vibration isolation unit 3 is used to retain as much high-concentration electroplating solution brought out from the electroplating tank as possible in the unit. The vibration isolation unit 3 adopts the structure described in the second embodiment.

[0119] The multi-stage step-by-step countercurrent rinsing unit 4 is used to clean the electroplating solution adhered to the surface of the electroplating wire 7. The multi-stage step-by-step countercurrent rinsing unit 4 adopts the structure described in Example 6.

[0120] The drying unit 5 adopts a plate-type electric drying furnace in the prior art. The finished electroplated wire 7 with a certain amount of moisture on the surface will be dried by being heated by the upper arc plate on the plate-type electric drying furnace.

[0121] The unloading unit 6 is also called the finished product take-up unit of the electroplated wire 7. In this embodiment, an "I" wheel is used.

[0122] It should be noted that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art may still modify the technical solutions described in the above embodiments or replace some of the technical features therein with equivalents. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line, characterized by: It includes a loading unit, an electroplating unit, a vibration isolation unit, a multi-stage step-by-step countercurrent rinsing unit, a drying unit and an unloading unit which are arranged in sequence; The vibration isolation unit includes a vibration drying tank and 2 to 5 sets of passive vibration drying devices arranged in series in the vibration drying tank. The passive vibration drying device is an eccentric sheave rotatably arranged in the vibration drying tank and having a wrap angle with the electroplated wire. The eccentric sheave can be any of the following structures: a. an eccentric shaft and a sheave assembled on the eccentric shaft, the sheave having at least one V-shaped groove; b. a long mandrel and an eccentric sheave with an eccentric hole mounted on the long mandrel, the eccentric sheave having at least one V-shaped groove; The multi-stage step-by-step countercurrent rinsing unit includes at least two cleaning tanks arranged in series. At every interval of T hours, the cleaning water in the cleaning tanks is stepped one tank away from the rear end to the front end. The cleaning water in the front end cleaning tank is returned to the electroplating unit, and the rear end cleaning tank is replenished with pure cleaning water. Each cleaning tank is provided with a changing roller for pressing the electroplating wire into the cleaning water, and an axial flow air knife is provided at the end of each cleaning tank; the air flow ejection direction of the axial flow air knife coincides with the axial direction of the electroplating wire and is opposite to the running direction of the electroplating wire; the axial flow air knife includes an air duct connected to the air pump at one end and a wind knife module assembled on the air duct, the wind knife module has an air inlet hole connected to the air duct, and the wind knife module has a wire hole for allowing the electroplating wire to pass through; the air inlet hole is a tapered oblique blind hole pointing to the wire inlet end of the wire hole, or the air inlet hole is a vertical through hole close to the wire inlet end of the wire hole.

2. The multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line according to claim 1 is characterized by: A passive vibration drying device is arranged at the end of the electroplating tank at the tail end of the electroplating unit.

3. The multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line according to claim 1 or 2, characterized in that: A V-shaped groove is provided on the circumferential curved surface of the eccentric groove wheel. The bottom of the V-shaped groove is an arc, and the radius of the arc is 2 to 3 times the radius of the electroplated wire.

4. The multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line according to claim 3 is characterized by: One end or both ends of the wire hole are inlaid with a wear-resistant guide sleeve, and the wear-resistant guide sleeve has an inner hole chamfer pointing to the wire inlet end of the wire hole.

5. The multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line according to claim 4 is characterized in that: The wire hole is a tapered hole with a small diameter for the wire inlet and a large diameter for the wire outlet.

6. The multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line according to any one of claims 1, 2, 4, and 5, characterized in that: The upper side of the air duct is pre-processed with a flat surface, and a mounting hole communicating with the inner cavity of the air duct is drilled on the flat surface; The wind knife module includes an integrally formed rectangular portion and a protruding shoulder, the protruding shoulder is located below the rectangular portion and is glued and fixed in the mounting hole; the wire hole is provided on the rectangular portion, perpendicular to the axial direction of the air duct; the air inlet hole extends from the bottom of the protruding shoulder to connect to the wire hole, and is a tapered oblique blind hole with a larger bottom and a smaller top.

7. The multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line according to any one of claims 1, 2, 4, and 5, characterized in that: Both sides of the air duct are pre-processed with flat surfaces, and mounting holes are drilled radially on the air duct, with both ends of the mounting holes located on the two side planes of the air duct respectively; The air knife module includes a main blowing sleeve and an auxiliary blowing sleeve that are detachably connected. The main blowing sleeve and the auxiliary blowing sleeve each include a protruding shoulder and a cylindrical portion. The wire hole is arranged along the axis of the main blowing sleeve and the auxiliary blowing sleeve. The air inlet is arranged on the cylindrical portion of the main blowing sleeve and is a vertical through hole close to the wire inlet end of the wire hole. The cylindrical part of the main blow-drying sleeve extends into the mounting hole from the left side of the air duct, and the protruding shoulder fits on the left plane of the air duct; the cylindrical part of the auxiliary blow-drying sleeve extends into the mounting hole from the right side of the air duct, and is detachably connected to the cylindrical part of the main blow-drying sleeve, and the protruding shoulder of the auxiliary blow-drying sleeve fits on the right plane of the air duct.

8. The multi-stage step-by-step countercurrent electroplating wire wastewater zero-discharge production line according to any one of claims 1, 2, 4, and 5, characterized in that: Both sides of the air duct are pre-processed with flat surfaces, and mounting holes are drilled radially on the air duct, with both ends of the mounting holes located on the two side planes of the air duct respectively; The air knife module includes a one-way blowing sleeve and a locking nut threadedly connected to the one-way blowing sleeve, wherein the one-way blowing sleeve includes an integrally formed protruding shoulder and a cylindrical portion; the wire hole is opened on the axis of the one-way blowing sleeve; the air inlet hole is provided on the upper side of the cylindrical portion of the one-way blowing sleeve, and is a tapered oblique blind hole with a larger upper portion and a smaller lower portion; The cylindrical part of the one-way blowing sleeve extends into the mounting hole from the left side of the air duct and extends from the right side to be connected with the locking nut; wherein, the protruding shoulder of the one-way blowing sleeve fits on the left plane of the air duct, and the locking nut fits on the right plane of the air duct.

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