Wire pickling and phosphating full-automatic production line

Abstract

The invention discloses a wire pickling and phosphating full-automatic production line which comprises a steel structure, a plurality of RGV trolleys used for transporting wires are installed above the steel structure, and a plurality of process tanks used for conducting a wire pickling and phosphating process are arranged below the RGV trolleys; a tunnel type closed room for reducing leakage of acid mist and harmful gas is arranged above the process tank, and is connected with an acid mist collecting and filtering device through a pipeline. And the automatic production line can greatly improve the acid pickling and phosphating treatment efficiency of the wire rod, and the production period is shortened. Energy consumption and environmental pollution are reduced, the energy consumption and harmful substance emission are reduced through optimal management of the intelligent control system on the production line, and green production is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of metal processing, in particular to a fully automatic production line for pickling and phosphating of wires. Background Art

[0002] Pickling and phosphating of wire is an important part of metal processing. It is used to remove oxides, oil stains and other impurities on the surface of the wire and form a phosphating film on its surface to improve the corrosion resistance of the wire and the adhesion of the coating. Traditional wire pickling and phosphating production lines mostly use manual or semi-automatic methods, which have problems such as low production efficiency, high energy consumption, and great environmental pollution. Therefore, it is of great significance to develop an efficient, energy-saving, and environmentally friendly fully automatic production line for wire pickling and phosphating.

[0003] Therefore, a fully automatic production line for wire pickling and phosphating is proposed. Summary of the invention

[0004] The purpose of the present invention is to provide a fully automatic production line for pickling and phosphating of wire rods, which fully considers the continuity and efficiency of the production line. The various devices are seamlessly connected through the RGV trolley to ensure the continuous and efficient processing of wire rods from raw materials to finished products. At the same time, by optimizing the production process, unnecessary waiting time and transportation links are reduced, and the overall efficiency of the production line is improved.

[0005] To achieve the above object, the present invention provides the following technical solution: a fully automatic production line for wire pickling and phosphating, comprising a steel structure, a plurality of RGV trolleys for transporting wires are installed above the steel structure, and a plurality of process tanks for wire pickling and phosphating are provided below the RGV trolleys;

[0006] A tunnel-type sealed room is installed above the process tank to reduce the leakage of acid mist and harmful gases, and the tunnel-type sealed room is connected to an acid mist collection and filtering device through a pipeline;

[0007] A flushing device for removing residual liquid on the surface of the wire material and a bulking device for dispersing the wire material are respectively installed in the plurality of process tanks.

[0008] Preferably, a track is installed above the steel structure, the RGV trolley is installed on the track, and a hook for hoisting wires is installed below the RGV trolley.

[0009] Preferably, the top of the tunnel-type closed room is provided with an opening along the track, and the opening is sealed with an acid-resistant flexible material.

[0010] Preferably, the acid mist collecting and filtering device cooperates with the tunnel-type closed room, adopts a micro-negative pressure method, and uses a fan to form and maintain a micro-negative pressure between the entire system and the outside world to prevent the escape of acid mist.

[0011] Preferably, a transfer machine is installed on the track to facilitate the RGV trolley to turn along the arrangement direction of the process tanks.

[0012] Preferably, each of the plurality of process tanks is equipped with a heat exchange coil for maintaining a suitable process temperature of the liquid.

[0013] Preferably, the plurality of process tanks are connected with a phosphating liquid filtering device for filtering and purifying the phosphating liquid and a process tank management device for monitoring and controlling the temperature, liquid level or pH value parameters in the process tank.

[0014] Preferably, the flushing device comprises a plurality of spray pipes located inside the process tank for spraying water.

[0015] Preferably, the bulking device comprises a plurality of bulking rollers installed inside the process pipe, and the bulking rollers are driven to rotate by a motor.

[0016] Preferably: a ground rail vehicle for loading and unloading materials is installed on one side of the process tank.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1. Improve production efficiency: The automated production line can greatly improve the processing efficiency of wire pickling and phosphating and shorten the production cycle.

[0019] 2. Reduce energy consumption and environmental pollution: Through the optimization management of the production line through the intelligent control system, energy consumption and harmful substance emissions can be reduced to achieve green production.

[0020] 3. Ensure product quality: The production line is equipped with a process tank management system and an intelligent control system, which can accurately control various parameters of the pickling and phosphating processes to ensure the consistency and stability of product quality.

[0021] 4. Reduce manual intervention: Automated production lines can significantly reduce manual intervention, reduce labor intensity and improve production safety. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic top view of the structure of the present invention;

[0023] Figure 2 It is a schematic diagram of the main structure of the present invention;

[0024] Figure 3 It is a schematic side view of the structure of the present invention;

[0025] Figure 4 It is a schematic diagram of the cutaway structure of the bulk material device of the present invention.

[0026] In the figure: 1. Steel structure; 2. Track; 3. RGV trolley; 4. Transfer machine; 5. Process tank; 6. Tunnel-type closed room; 7. Hook; 8. Ground rail car; 9. Phosphate solution filtration device; 10. Acid mist collection and filtration device; 11. Process tank management device; 12. Flushing device; 13. Bulk material device; 131. Bulk material roller; 14. Controller; 15. Water sealing tank. DETAILED DESCRIPTION

[0027] The technical solutions in the embodiments of the present invention will be described clearly and completely below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0028] See also Figure 1-4 The present invention provides a technical solution: a fully automatic production line for wire pickling and phosphating, including a steel structure 1, which serves as the main supporting structure of the production line, carrying components such as a process tank 5 and a tunnel-type closed room 6, to ensure the stability and safety of the production line.

[0029] A plurality of RGV trolleys 3 for transporting wires are installed above the steel structure 1. The RGV trolleys 3 run on the track 2 and are used to transfer the wires from one process tank 5 to another process tank 5, thereby realizing the automatic transportation of the wires. The production line uses a plurality of RGV trolleys 3 to form a basic logistics system, which runs in a cyclic operation mode and is automatically controlled by the controller 14. Each RGV trolley 3 runs along the guide direction of the track 2 and is automatically allocated to sequentially complete the processes of material grabbing, pickling, washing, phosphating, washing, saponification and discharging.

[0030] A plurality of process tanks 5 for pickling and phosphating of wires are provided below the RGV trolley 3. The number and configuration of the process tanks 5 can be adjusted according to actual needs and arranged in sequence on the production line. They are used to hold pickling solution, cleaning water, phosphating solution and saponifying solution, and to carry out pickling, immersion, flushing, phosphating and saponifying process treatments on the wires. A water sealing tank 15 is provided at the first process tank 5 to effectively prevent the escape of acid mist.

[0031] A tunnel-type closed room 6 is installed above the process tank 5 to reduce the leakage of acid mist and harmful gases. The top of the tunnel-type closed room 6 is provided with an opening along the direction of the track 2, and the opening is sealed with an acid-resistant flexible material. The tunnel-type closed room 6 is located above the process tank 5, and the pickling and phosphating processes are sealed in the tunnel-type space to reduce the emission of acid mist and harmful gases and ensure the safety of operators. A certain slope is designed on the top of the closed room to drain the droplets condensed on the upper part of the closed room to the side panels. An opening is provided on the top of the closed room along the direction of the RGV track, which is sealed with acid-resistant flexible materials to prevent leakage of acid mist.

[0032] The tunnel-type closed room 6 is connected with an acid mist collecting and filtering device 10 through a pipeline. The acid mist collecting and filtering device 10 is installed beside the production line to collect and process the acid mist and harmful gases generated by the production line, reduce environmental pollution, and protect the health of operators. The acid mist collection adopts a fully enclosed micro-negative pressure acid mist collection method, that is, the process tank 5 is sealed by acid-resistant materials to form a relatively closed acid mist collection system, and a blower is used to form and maintain a micro-negative pressure between the entire system and the outside world to prevent the escape of acid mist. At the same time, through the optimized arrangement of the exhaust port and the air inlet, the entire closed room forms a good collection flow state, and the acid mist is collected efficiently and quickly, and the dead angle is reduced. After collection, it is transported to the acid mist purification tower outside the closed room by the blower for absorption and treatment.

[0033] like Figure 1 , Figure 2 and Figure 3 As shown: a track 2 is installed above the steel structure 1, an RGV trolley 3 is installed on the track 2, and a hook 7 for hoisting wires is installed below the RGV trolley 3. The hook 7 is lifted by the RGV trolley 3 and circulates between various processes of the production line to hoist and fix the wires to ensure the stable operation of the wires on the production line. The number and configuration of the hooks 7 can be adjusted according to the scale of the production line and the specifications of the wires.

[0034] like Figure 1 As shown: a transfer machine 4 is installed on the track 2 to facilitate the RGV trolley 3 to turn along the arrangement direction of the process tank 5. The transfer machine 4 is arranged at the turning point of the track 2 to meet the horizontal turning of the RGV trolley 3. The rotating track and fixed track system of the transfer machine 4 can achieve precise alignment to ensure the smooth passage of the RGV trolley 3.

[0035] like Figure 1 and Figure 3 As shown: a plurality of process tanks 5 are equipped with heat exchange coils for maintaining a suitable process temperature of the liquid. The process tank 5 has a built-in coil heat exchange system for heating the pickling liquid, phosphating liquid, and saponifying liquid in the process tank 5 to maintain a suitable process temperature and improve the processing efficiency.

[0036] like Figure 1 As shown: a plurality of process tanks 5 are connected with a phosphating solution filtering device 9 for filtering and purifying the phosphating solution. The phosphating solution filtering device 9 is installed beside the production line, and includes a sedimentation filtering device and a plate and frame filter press, which is used to filter and purify the phosphating solution, remove impurities and particles therein, and extend the service life of the phosphating solution.

[0037] A process tank management device 11 for monitoring and controlling the temperature, liquid level or pH value parameters in the process tank 5. The process tank management device 11 is installed beside the production line, and includes a pump group and pipelines, connecting the process tanks 5 of each station, and is used to monitor and control the temperature, liquid level, pH value and other parameters in the process tank 5 to ensure the stability and consistency of the pickling and phosphating processes.

[0038] like Figure 1 As shown: the flushing device 12 includes a plurality of spray pipes located inside the process tank 5 for spraying water. It is installed in the process tank 5 of the flushing station of the production line to flush the wire and remove the residual pickling solution and phosphating solution on the surface of the wire, as well as other impurities. The flushing device 12 is divided into internal flushing and external flushing, and can move along a predetermined track in the process tank 5. The internal flushing is used for flushing the inside of the wire, and the external flushing is used for flushing the outside of the wire. In order to ensure the flushing effect, a rotating roller is installed at the bottom of the flushing process tank 5, which can rotate the wire while flushing, so that the inside and outside of the wire are thoroughly cleaned.

[0039] like Figure 1 and Figure 4 As shown: the bulking device 13 includes a plurality of bulking rollers 131 installed inside the process pipe, and the bulking rollers 131 are driven by a motor to rotate. It is installed in the process tank 5 of the bulking station of the production line, and a rotating bulking roller 131 is installed at the bottom. The RGV trolley 3 transfers the wire to the bulking station, lowers the hook 7, and the wire is placed on the bulking roller 131. The bulking roller 131 rotates synchronously to disperse the wire that has been pickled, change the wire bonding surface, and ensure the removal of the oxide scale on the wire surface for subsequent cleaning and processing. The purpose is to prevent the wires from sticking to each other and ensure the smooth progress of subsequent processing.

[0040] like Figure 1 and Figure 2 As shown: a ground rail vehicle 8 for loading and unloading is installed on one side of the process tank 5. It is used to transport the wire from the entrance of the production line to the specified position, or from the specified position to the exit of the production line, so as to realize automatic loading and unloading of the wire.

[0041] like Figure 3 As shown: a plank road is laid along the entire length of the track system for daily inspection and maintenance of the track system and the RGV trolley 3. The plank road system is provided with a ladder for going up and down the plank road.

[0042] like Figure 1 As shown: Storage tank: including new acid tank, waste acid tank, phosphating liquid guide tank, storing new acid, waste acid, phosphating liquid, connected with process tank 5 through process tank management device 11, can supply tank body and related equipment in time.

[0043] like Figure 1As shown: the controller 14 is installed in the main control room. As the core part of the production line, it is responsible for receiving instructions, processing information, and controlling the operation of the production line. The intelligent control system can automatically adjust the operating status of the production line according to actual needs, including speed, temperature, liquid level and other parameters, to achieve automatic and intelligent management of the production line.

[0044] Working principle: The main processes of the wire pickling and phosphating automatic production line of the present invention include: loading, water sealing, low-acid pickling, bulk material, high-acid pickling, immersion one, rinsing, immersion two, surface adjustment, phosphating, water washing one, water washing two, saponification, drying, unloading and other processes.

[0045] RGV trolley 3 No. 1 moves to the loading area, lowers the hook 7, and the ground rail car 8 moves to the loading position, and the hook 7 rises and grabs the wire. RGV trolley 3 moves through the water sealing tank 15, hangs the wire into the low-acid tank, removes the oxide scale on the surface of the workpiece, and exposes the iron matrix. RGV trolley 3 No. 1 returns to the loading area.

[0046] The second RGV trolley 3 moves to the low acid pool to grab the wire and bring it into the bulk material pool (that is, the process tank 5 where the bulk material device 13 is located). In order to make the pickling more thorough, the bulk material will be turned over to change the wire bonding surface. Then it is brought into the high acid pool and the wire is put down.

[0047] The No. 3 RGV trolley 3 goes to the high acid pool to grab the wire and send it to the immersion pool 1. The main purpose of immersion is to clean the pickling liquid adhering to the surface of the workpiece. The indexing machine 4 above the immersion station rotates 90° and moves to the flushing pool (that is, the process tank 5 where the flushing device 12 is located). After the indexing machine 4 rotates 90°, it lowers the hook 7 and starts flushing, using high-pressure water to flush the inside and outside of the wire.

[0048] RGV trolley No. 4 moves to the washing tank to grab the wire and hoist it into the immersion tank No. 2. After immersion, it continues to move to the surface conditioning tank. The purpose of surface conditioning is to increase the phosphating speed. Then it moves to the phosphating tank. The phosphating tank is used to deposit a phosphating film on the surface of the workpiece to improve the wear resistance, lubrication and corrosion resistance of the wire surface.

[0049] RGV trolley 3 No. 5 moves to the phosphating tank to grab the material, and sends the phosphated wire parts to the water washing tank 1 to clean the phosphating liquid adhering to the surface of the wire parts. Then it moves to the water washing tank 2. After the water washing, it continues to move to the saponification tank for saponification treatment of the workpiece surface to improve the lubricity and wear resistance of the workpiece.

[0050] RGV trolley 3 No. 6 moves to the saponification tank to grab the material, and then moves to the drying station. After the wire is dried in the drying station, it is discharged from the discharge door and enters the unloading area. The ground rail car 8 moves to the unloading position, the hook 7 descends to discharge the material, and the ground rail car 8 transfers the pickled and phosphated wire to the storage area. RGV trolley 3 places the empty hook 7 on the transfer bracket and then returns to the saponification tank.

[0051] The wire pickling and phosphating production line has been innovatively designed in terms of equipment layout, process optimization, and application of intelligent control systems. First, the equipment layout has been carefully planned to achieve smooth operation of the production line and reduce material handling and waiting time; second, an advanced intelligent control system has been introduced to achieve precise control and real-time monitoring of the production process, effectively improving production efficiency and capacity. The combined effect of these measures has enabled the production line described in this patent to significantly improve production efficiency and capacity while ensuring product quality.

[0052] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A fully automatic production line for pickling and phosphating of wire rods, comprising a steel structure (1), characterized in that: A plurality of RGV trolleys (3) for transporting wires are installed above the steel structure (1), and a plurality of process tanks (5) for performing a pickling and phosphating process on the wires are provided below the RGV trolleys (3); A tunnel-type sealed room (6) for reducing the leakage of acid mist and harmful gas is installed above the process tank (5), and the tunnel-type sealed room (6) is connected to an acid mist collecting and filtering device (10) through a pipeline; A flushing device (12) for removing residual liquid on the surface of the wire material and a bulking device (13) for dispersing the wire material are respectively installed in the plurality of process tanks (5).

2. The fully automatic wire pickling and phosphating production line according to claim 1 is characterized by: A track (2) is installed above the steel structure (1), the RGV trolley (3) is installed on the track (2), and a hook (7) for lifting wires is installed below the RGV trolley (3).

3. The fully automatic wire pickling and phosphating production line according to claim 1 is characterized by: The top of the tunnel-type closed room (6) is provided with an opening along the track (2), and the opening is sealed with an acid-resistant flexible material.

4. A fully automatic wire pickling and phosphating production line according to claim 3, characterized in that: The acid mist collecting and filtering device (10) cooperates with the tunnel-type closed room (6) to form and maintain a slight negative pressure between the entire system and the outside world by using a fan, thereby preventing the acid mist from escaping.

5. The fully automatic wire pickling and phosphating production line according to claim 1 is characterized by: A transfer machine (4) is installed on the track (2) to facilitate the RGV trolley (3) to turn along the arrangement direction of the process tanks (5).

6. The fully automatic wire pickling and phosphating production line according to claim 1 is characterized by: Each of the plurality of process tanks (5) is provided with a heat exchange coil for maintaining a suitable process temperature of the liquid.

7. The fully automatic wire pickling and phosphating production line according to claim 1 is characterized by: The plurality of process tanks (5) are connected to a phosphating liquid filtering device (9) for filtering and purifying the phosphating liquid and a process tank management device (11) for monitoring and controlling the temperature, liquid level or pH value parameters in the process tank (5).

8. The fully automatic wire pickling and phosphating production line according to claim 1 is characterized by: The flushing device (12) comprises a plurality of spray pipes located inside the process tank (5) and used for spraying water.

9. The fully automatic wire pickling and phosphating production line according to claim 1 is characterized by: The material dispersing device (13) comprises a plurality of material dispersing rollers (131) installed inside the process pipe, and the material dispersing rollers (131) are driven to rotate by a motor.

10. The fully automatic wire pickling and phosphating production line according to claim 1 is characterized by: A ground rail vehicle (8) for loading and unloading materials is installed on one side of the process tank (5).

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