Rectangular galvanized steel wire continuous production line and production method thereof

Abstract

The invention discloses a rectangular galvanized steel wire continuous production line and a production method thereof, and belongs to the technical field of steel wire production, and the production method comprises the following steps: paying off a steel wire through a paying-off unit, and carrying out tension adjustment and straightening treatment; the steel wire subjected to tension adjustment and straightening treatment is pretreated, and mechanical dust removal, hot water cleaning, cold water flushing and electrolytic pickling are sequentially conducted; zinc plating is conducted on the pretreated steel wire in an electrogalvanizing tank, and residual plating liquid is cleaned through a series-connection washing tank; the galvanized steel wire is rolled into a rectangular section through a rolling mill, and then steam cleaning, straightening, wire diameter detection and take-up are conducted; wherein the method further comprises a linkage control process which is used for dynamically adjusting the power supply output current of the electrolytic pickling and the electrogalvanizing according to the state of the whole machine; the production process is reduced, galvanized steel wires do not need to be transferred and stored, the occupied area of equipment is shortened, the production and operation cost is reduced, and the production efficiency and quality are improved.

Description

Technical Field

[0001] The invention relates to a rectangular galvanized steel wire continuous production line and a production method thereof, belonging to the technical field of steel wire production. Background Art

[0002] The existing rectangular galvanized steel wire production mainly uses galvanized steel wire for rolling production. The whole production is divided into two steps. The first step is galvanized steel wire production: the steel wire is produced through the process stages of wire laying, dust removal, cleaning, hydrochloric acid washing, galvanizing, water washing, and wire winding; the second step is rectangular steel wire production: the galvanized steel wire is produced through the process stages of wire laying, rectangular steel wire rolling mill, steam cleaning, wire diameter detection, and wire winding.

[0003] Existing galvanized steel wires are generally produced in a continuous, low-speed, unfolded manner, which is incompatible with the high-speed, intermittent production of a single rectangular steel wire. Separate production leads to lengthy production processes. Storage and transportation of galvanized steel wires between different processes are prone to surface contamination, damage and oxidation, which reduces product quality and requires more equipment, space, manpower and material investment, resulting in high energy consumption and low production efficiency. In addition, in order to ensure that the steel wire coating is qualified, the existing galvanized production line requires the steel wires in the production start and stop sections to be scrapped, and wire breakage must be handled in a timely manner to avoid affecting the coating of other steel wires or wire jumpers, which can easily cause a lot of waste in the production process. Summary of the invention

[0004] The purpose of the present invention is to overcome the deficiencies in the prior art and provide a rectangular galvanized steel wire continuous production line and a production method thereof, so that the land occupation, manpower and material input of the production equipment can be reduced, the material and energy consumption can be reduced, the product quality can be improved, and the overall efficiency can be improved.

[0005] To achieve the above object, the present invention is implemented by adopting the following technical solutions: In a first aspect, the present invention provides a rectangular galvanized steel wire continuous production line, comprising a pay-off unit, a pretreatment unit, an electrogalvanizing unit and a rolling mill unit arranged in sequence, wherein: The wire-paying unit comprises a wire-paying machine, a tension adjusting device and a straightener arranged in sequence, and is used to stabilize and straighten the transmission of the steel wire; The pretreatment unit includes a mechanical plastering device, a hot water cleaning and rinsing tank and an electrolytic pickling tank arranged in sequence, which are used to remove impurities on the surface of the steel wire and activate the surface of the steel wire; The electrogalvanizing unit comprises an electrogalvanizing tank and a series-connected water washing tank arranged in sequence, which are used to uniformly galvanize the surface of the steel wire and clean the residual plating solution; The rolling mill unit comprises a rolling mill, a steam cleaning tank, a straightener, a wire diameter detection device and a wire take-up machine which are arranged in sequence and are used for rolling the galvanized steel wire into a rectangle and collecting it.

[0006] Furthermore, the tension adjustment device includes a tension detection sensor and a tension controller. The actual tension value fed back by the tension detection sensor is compared with the preset tension value, and after the tension difference is calculated, the speed of the pay-off motor is adjusted by the tension controller.

[0007] Furthermore, the mechanical plastering device in the pretreatment unit is used to remove most of the lubricating powder and oxide layer on the surface of the steel wire, and is equipped with a collection device; the hot water cleaning and rinsing tank is divided into two sections, wherein: The first section is equipped with a first lifting pump, a first liquid wiping device and an automatic temperature control and water replenishment system. The first lifting pump is placed on the upper surface of the tank body of the hot water cleaning and rinsing tank, and is used to lift the solution at the bottom of the tank body. The first liquid wiping device is a linear air knife, suspended above the steel wire, and is used to blow the steel wire and remove the residual liquid on the surface of the steel wire. The automatic temperature control and water replenishment system includes a temperature detection feedback device, an electric heater, a liquid level detection sensor and a pneumatic water replenishment valve, which are placed on the surface or inside of the tank body. The PLC controls the electric heater and the pneumatic water replenishment valve according to the preset temperature, the actual temperature fed back by the temperature detection feedback device and the feedback value of the liquid level detection sensor to ensure that the hot water temperature and water volume meet the standards; The second section is equipped with a first circulation pump, a water replenishment device and a first purging device; the first circulation pump is placed outside the tank body, and the inlet and outlet are connected to the tank body by a pipeline, which is used to form high-pressure water to flush the steel wire. The water replenishment device is arranged inside the tank body, and the water replenishment is determined by a mechanical float. The first purging device is placed at the steel wire outlet end of the tank body, which is used to remove residual liquid on the surface of the steel wire; The electrolytic pickling tank is used for cleaning steel wire with sulfuric acid, and is equipped with at least 3 first overflow plates. An insoluble electrode body is arranged in the first overflow plate, and the positive and negative electrodes of the electrolytic pickling power supply are alternately connected. The second lifting pump, the second wiping device, the second purging device, the first liquid level control equipment and the first acid mist purification treatment equipment are also arranged. The installation method of the second lifting pump, the second wiping device and the second purging device is the same as the installation method of the first lifting pump, the first wiping device and the first purging device in the hot water cleaning and rinsing tank. The first liquid level control equipment includes a liquid level detector and a pneumatic acid replenishing valve. The liquid level fed back by the liquid level detector is used to determine whether the amount of acid liquid meets the standard, and the pneumatic acid replenishing valve is controlled by PLC to replenish acid. The first acid mist purification treatment equipment is connected to the pipeline above the tank body, and is used to treat the gas generated by the steel wire reaction and the volatilization of the solution.

[0008] Furthermore, the electrogalvanizing tank in the electrogalvanizing unit is equipped with left and right cathode rollers, which are connected to the negative electrode of the electrogalvanizing power supply, and an upper and lower second overflow disk is arranged between the two cathode rollers. An insoluble electrode body is arranged in the second overflow disk, which is connected to the positive electrode of the electrogalvanizing power supply. The steel wire is wound around the left and right cathode rollers to form two sections of steel wire in the lower second overflow disk and one section of steel wire in the upper second overflow disk, and is equipped with a second circulation pump, a filtering device, a plating solution reaction circulation tank, a third wiping device, a third purge device, a second liquid level control device and a second acid mist Purification equipment; the plating solution reaction circulation tank is a separate tank body, which is used to store the galvanizing solution, and is connected to the electro-galvanizing tank pipeline through the second circulation pump and the filtering device; the installation method of the second circulation pump, the third liquid wiping device, and the third purge device is the same as the installation method of the first circulation pump, the first liquid wiping device, and the first purge device in the hot water cleaning and rinsing tank; the installation method of the second liquid level control device and the second acid mist purification treatment device is the same as the installation method of the first liquid level control device and the first acid mist purification treatment device in the electrolytic pickling tank; The series water washing tank is used to clean the residual plating solution of the steel wire, and is equipped with at least 3 sections of water washing tanks, and is equipped with a third lifting pump, a fourth liquid wiping device, a fourth purge device and a PH detection automatic water replenishment control device. The PH detection automatic water replenishment control facility includes a pneumatic water replenishment valve and a PH detection feedback device, which are placed in the last section of water washing. The pneumatic water replenishment valve is controlled to replenish water according to the feedback value and the preset value of the PH detection feedback device to adjust the solution in the water washing tank to be neutral; the installation method of the third lifting pump, the fourth liquid wiping device and the fourth purge device is the same as the installation method of the first lifting pump, the first liquid wiping device and the first purge device in the hot water washing and rinsing tank.

[0009] In a second aspect, the present invention provides a method for continuously producing rectangular galvanized steel wire, which is applicable to any of the above-mentioned continuous production lines for rectangular galvanized steel wire, comprising: The steel wire is paid out through the pay-out unit and goes through tension adjustment and straightening treatment; Pre-treatment of the tension-adjusted and straightened steel wire includes mechanical dust removal, hot water cleaning, cold water rinsing and electrolytic pickling in sequence; The pretreated steel wire is galvanized in an electrogalvanizing tank, and the residual plating solution is cleaned through a series of water washing tanks; The galvanized steel wire is rolled into a rectangular section by a rolling mill, followed by steam cleaning, straightening, wire diameter detection and wire winding; Wherein, the method also includes a linkage control process for dynamically adjusting the power supply output current of electrolytic pickling and electrogalvanizing according to the state of the whole machine.

[0010] Furthermore, a sulfuric acid solution with a concentration of 160-200 g / L is used in the electrolytic pickling step, and a zinc sulfate solution with a concentration of 200-350 g / L is used in the zinc plating step.

[0011] Furthermore, the whole machine state includes a preparation stage, a pre-startup stage, a startup stage, an acceleration stage, a constant speed stage, a deceleration stage and a stop stage.

[0012] Furthermore, in the linkage control process: Stop phase: The equipment in production is in the stop phase, the output current in the electrolytic pickling tank and the electrogalvanizing tank is 0, the purge, lifting pump and circulation pump in the hot water cleaning and rinsing tank, the electrolytic pickling tank, the electrogalvanizing tank and the series water washing tank are turned off, the solution drops, the wiping device is turned on, and the steam in the steam cleaning tank is turned off; Preparation stage: After the start button is pressed, the equipment enters the preparation stage, the hot water cleaning and rinsing tank, electrolytic pickling tank, electrogalvanizing tank and tandem water washing tank are closed, the lifting pump and circulation pump are turned on, and the solution rises; Pre-startup stage: After the liquid level in the electro-galvanizing tank rises to the preset time, the pre-startup stage begins. The power in the electrolytic pickling tank and the electro-galvanizing tank is turned on, and the preset starting current is output. The purge devices in the hot water cleaning and rinsing tank, the electrolytic pickling tank, the electro-galvanizing tank and the series water washing tank are turned on, and the steam in the steam cleaning tank is turned on. Just-starting stage: After the pre-starting stage is maintained for a preset time, it enters the just-starting stage, the whole machine is running, each process is continuously operated, the electrolytic pickling tank outputs the preset starting current, the electro-galvanizing tank outputs the starting compensation current, and the starting compensation time is continued; Acceleration stage: The whole machine is running, the wire speed is V, and it is first in the uniform acceleration stage. After the start-up compensation time, the output current of the electrolytic pickling tank is the pickling current coefficient multiplied by V, and the output current of the electrogalvanizing tank is the galvanizing current coefficient multiplied by V plus the acceleration compensation current; Uniform speed stage: The steel wire runs continuously at the set speed, and the output current of the electrogalvanizing tank is the galvanizing current coefficient multiplied by V; Speed ​​reduction stage: When the equipment presses the stop button or reaches a fixed length, it enters the speed reduction stage. The output current of the electro-galvanizing tank is the galvanizing current coefficient multiplied by V plus the deceleration compensation current, and the output current of the electro-galvanizing tank is not less than the preset minimum effective output current; Stop phase: After completely stopping, the wire speed is 0, the output current of the electrolytic pickling tank and the electro-galvanizing tank is 0, and it re-enters the stop phase.

[0013] Furthermore, the pickling current coefficient is 0.22, the galvanizing current coefficient is 0.82, the starting compensation current is 18 A and the duration is 2 seconds, the acceleration compensation current is 10 A, and the deceleration compensation current is -12 A.

[0014] Furthermore, the steel wire production speed is 0-350 m / min, the acceleration is 6 m / s², the deceleration is 10 m / s², and the mass of the galvanized layer is 0.51-0.61 g / Kg.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention provides a rectangular galvanized steel wire continuous production line and a production method thereof, which reduces the production process, eliminates the need for transfer and storage of galvanized steel wire, shortens the equipment footprint, reduces production and operation costs, and improves production efficiency and quality.

[0016] 2. In the present invention, the galvanized layer of the steel wire is qualified in the start-stop section of the equipment, and the single retractable wire does not affect other operating lines, thereby reducing a lot of waste. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a flow chart of a method for continuously producing rectangular galvanized steel wire provided by an embodiment of the present invention; Figure 2 is a schematic diagram of a linkage control process provided by an embodiment of the present invention; Figure 3 This is a test data diagram of rectangular galvanized steel wire samples produced according to an embodiment of the present invention. DETAILED DESCRIPTION

[0018] The present invention will be further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and cannot be used to limit the protection scope of the present invention.

[0019] Embodiment 1: This embodiment introduces a rectangular galvanized steel wire continuous production line, comprising: a wire-laying unit, a pretreatment unit, an electrogalvanizing unit and a rolling mill unit arranged in sequence.

[0020] The pay-off unit includes a pay-off machine, a tension adjustment device and a straightener arranged in sequence. The tension adjustment device automatically adjusts to ensure that the steel wire is transmitted smoothly without jumping during the entire continuous production process. The tension adjustment device includes a tension controller and a tension detection sensor. It compares the preset tension value with the actual tension value fed back, and adjusts the pay-off motor speed by calculating the tension difference.

[0021] The pretreatment unit includes a mechanical plastering device, a hot water cleaning and rinsing tank and an electrolytic pickling tank arranged in sequence. The mechanical plastering device is used to remove lubricating powder and oxide layer, and is equipped with a collection device. The hot water cleaning and rinsing tank is used for cleaning and is divided into two sections. The first section is equipped with a first lifting pump, a first wiping device and an automatic temperature control and water supply system; all lifting pumps are placed on the upper surface of the tank body to lift the solution at the bottom of the tank body. The first wiping device is a linear air knife suspended above the steel wire, and the cathode roller of the galvanizing tank is a ring-shaped air knife, which is used to blow the steel wire when the equipment stops, remove the residual liquid on the surface of the steel wire, and prevent or slow down the corrosion of the steel wire surface. The automatic temperature control and water supply system includes a temperature detection feedback device, an electric heater, a liquid level detection sensor and a pneumatic water supply valve, which are placed on the surface or inside the tank body. The electric heater and the pneumatic water supply valve are controlled by the PLC according to the preset temperature, the actual temperature and the feedback value of the liquid level detection sensor to ensure that the hot water temperature and water volume meet the standards. The second section is equipped with a first circulation pump, a water supply device and a first purge device. The first circulation pump is placed outside the tank, and the inlet and outlet are connected to the tank by a pipeline to form high-pressure water to flush the steel wire. The water replenishment device is arranged inside the tank, and the water replenishment is determined by a mechanical float. All first purge devices are placed at the steel wire outlet of the tank to remove residual liquid on the surface of the steel wire. The electrolytic pickling tank is used for cleaning steel wire with sulfuric acid, and is equipped with at least 3 first overflow plates. An insoluble electrode body is provided in the first overflow plate, and the positive and negative electrodes of the electrolytic pickling power supply are alternately connected. The second lifting pump, the second wiping device, the second purging device, the first liquid level control equipment and the first acid mist purification treatment equipment are also provided. The installation method of the second lifting pump, the second wiping device and the second purging device is the same as the installation method of the first lifting pump, the first wiping device and the first purging device in the hot water cleaning and rinsing tank. The first liquid level control equipment includes a liquid level detector and a pneumatic acid replenishing valve. The liquid level fed back by the liquid level detector is used to determine whether the amount of acid liquid meets the standard, and the pneumatic acid replenishing valve is controlled by PLC to replenish acid. The first acid mist purification treatment equipment is connected to the pipeline above the tank body, and is used to treat the gas generated by the steel wire reaction and the volatilization of the solution.

[0022] The electrogalvanizing unit includes an electrogalvanizing tank and a series washing tank arranged in sequence. The electrogalvanizing tank is used for steel wire galvanizing, and is equipped with left and right cathode rollers, which are connected to the negative electrode of the electrogalvanizing power supply. The upper and lower second overflow trays are arranged between the two cathode rollers. The second overflow tray is provided with an insoluble electrode body, which is connected to the positive electrode of the electrogalvanizing power supply. The steel wire is wound back through the left and right cathode rollers to form two sections of steel wire in the lower second overflow tray and one section of steel wire in the upper second overflow tray. It is equipped with a second circulation pump, a filter device, a plating solution reaction circulation tank, a third liquid wiping device, a third purge device, a second liquid level control device and a second acid mist purification treatment device. The plating solution reaction circulation tank has a separate tank body, which is used to store the galvanizing solution and is connected to the electrogalvanizing tank pipeline through the second circulation pump and the filter device. The liquid level control is the same as above, which is used to replenish water, and the concentration of the galvanizing solution is manually tested regularly. The installation method of the second circulation pump, the third liquid wiping device, and the third purge device is the same as the installation method of the first circulation pump, the first liquid wiping device, and the first purge device in the hot water cleaning and rinsing tank; the installation method of the second liquid level control device and the second acid mist purification treatment device is the same as the installation method of the first liquid level control device and the first acid mist purification treatment device in the electrolytic pickling tank. The series water washing tank is used to clean the residual plating solution of the steel wire, at least 3 sections of water washing, and is equipped with a third lifting pump, a fourth liquid wiping device, a fourth purge device, and a PH detection automatic water replenishment control device. The PH detection automatic water replenishment control device includes a pneumatic water replenishment valve and a PH detection feedback device, which are placed in the last section of water washing. The PLC controls the pneumatic water replenishment according to the PH feedback value and the preset value to adjust the water washing tank solution to be neutral; the installation method of the third lifting pump, the fourth liquid wiping device, and the fourth purge device is the same as the installation method of the first lifting pump, the first liquid wiping device, and the first purge device in the hot water cleaning and rinsing tank.

[0023] The rolling mill unit includes a rolling mill, a steam cleaning tank, a straightener, a wire diameter detection device and a wire take-up machine which are arranged in sequence. The rolling mill is used for rectangular rolling of steel wires, and the steam cleaning tank is used for removing residual oil stains.

[0024] like Figure 1 As shown in the figure, the production process includes the continuous wire laying process, pretreatment process, galvanizing process and rolling mill process. The specific steps are as follows: P1. Paying off the wire: Paying off the wire from the pay-off machine.

[0025] P2. Tension adjustment: stabilize the operation of the steel wire and ensure smooth transmission of the steel wire without jitter.

[0026] P3. Straightening: restore the steel wire to a straight state to ensure the galvanizing and rolling mill processing requirements.

[0027] P4. Mechanical plastering: remove most of the lubricating powder and oxide layer on the surface of the steel wire.

[0028] P5. Wash and rinse with hot water: clean the dirt on the surface of the steel wire and further remove the lubricating powder on the surface of the steel wire.

[0029] P6. Electrolytic pickling: further remove the oxide layer on the surface of the steel wire and activate the surface of the steel wire to obtain a good coating.

[0030] P7, Electrogalvanizing: The surface of the steel wire is evenly coated with zinc.

[0031] P8. Series water washing: clean the residual plating solution on the surface of the steel wire to make the surface of the steel wire nearly neutral.

[0032] P9. Rolling mill: The galvanized steel wire is rolled through a rolling mill to produce rectangular galvanized steel wire.

[0033] P10. Steam cleaning: remove oil stains on the surface of steel wire.

[0034] P11. Straightening: Improve the dimensional accuracy and consistency of rectangular steel wire.

[0035] P12, Wire diameter detection: Ensure the dimensional accuracy and consistency of rectangular steel wire.

[0036] P13, Wire collection: Collect rectangular galvanized steel wire.

[0037] like Figure 2 As shown, the linkage control process includes whole machine status determination, action and power supply output current adjustment, which is specifically implemented as follows: L1, stop stage: the equipment in production is in the stop stage, the output current in steps P6 and P7 is 0; the purge, lift pump and circulation pump in P5, P6, P7 and P8 are turned off, the solution drops, and the wipe liquid is turned on; the steam in P10 is turned off.

[0038] L2, preparation stage: After the start button is pressed, the equipment enters the preparation stage, the wiping liquid in P5, P6, P7 and P8 is turned off, the lifting pump and circulation pump are turned on, and the solution rises.

[0039] L3, pre-starting stage: 3 seconds before the liquid level in P7 rises to the right position, the pre-starting stage begins, the power supplies in P6 and P7 are turned on, and the output current is 10A (the measured starting response time of the rectifier power supply configured for pickling and galvanizing is about 2.7 seconds, and the minimum effective output current is 10A), the purge in P5, P6, P7 and P8 is turned on, and the steam in P10 is turned on.

[0040] L4, just-starting stage: L3 is maintained for 3 seconds before entering the just-starting stage, the whole machine is running, P1-P13 works continuously, P6 outputs a current of 10A, considering that there is a certain lag in the whole system communication and speed calculation, P7 outputs a current of "starting compensation current", and the duration is "starting compensation time". The "starting compensation current" and "starting compensation time" shall be subject to actual measurements based on the coating requirements.

[0041] L5, acceleration stage: the whole machine is running, the wire speed is V, it is first in the uniform acceleration stage, after the "start-up compensation time", P6 output current = "pickling current coefficient" * V, considering that there is a certain lag in system speed calculation and rectifier power supply response, P7 output current = "galvanizing current coefficient" * V + "acceleration compensation current", "pickling current coefficient", "galvanizing current coefficient" and "acceleration compensation current" shall be based on actual measurement according to coating requirements.

[0042] L6, uniform speed stage: the steel wire runs continuously at the set speed, P7 output current = "galvanizing current coefficient" * V L7, deceleration stage: the equipment presses the stop button or reaches a fixed length and enters the deceleration stage. Considering the hysteresis of system speed calculation and rectifier power supply response and the minimum effective output current of 10A, P7 output current = "galvanizing current coefficient" * V + "deceleration compensation current", and P7 output current ≥ 10A, "deceleration compensation current" shall be based on actual measurement according to coating requirements.

[0043] L1, stop stage: After completely stopping, the wire speed is 0, the output current of P6 and P7 is 0, and it re-enters the production stop stage.

[0044] Rectangular galvanized steel wire is produced using 2.1mm steel wire, the steel wire coating is 0.51-0.61g / Kg, the steel wire production speed is V (0-350m / min), the steel wire acceleration is 6m / s, and the deceleration is 10m / s. Based on the above process requirements, the concentration of sulfuric acid solution in P6 is 160-200g / L, and the concentration of zinc sulfate solution in P7 is 200-350g / L; the "startup compensation current" in L4 is tested and regulated to be 18A, and the "startup compensation time" is 2S; the "pickling current coefficient" in L5 is tested and regulated to be 0.22, the "galvanizing current coefficient" is 0.82, and the "acceleration compensation current" is 10A; the "deceleration compensation current" in L7 is tested and regulated to be -12A.

[0045] Based on the above process and parameters, rectangular galvanized steel wire is produced. Taking the production speed of 180m / min and 240m / min as an example, the sample preparation and test data are as follows Figure 3 As shown. Figure 3 It can be seen that the steel wire coating is qualified in the acceleration section, the uniform speed section and the deceleration section with small fluctuation, which meets the high quality requirements of customers. The present invention can realize the continuous high-speed production of rectangular galvanized steel wire, and the coating of the produced steel wire is qualified in all sections.

[0046] Embodiment 2: This embodiment provides a method for continuously producing rectangular galvanized steel wire, which is applicable to the rectangular galvanized steel wire continuous production line described in any one of Embodiment 1, comprising: The steel wire is paid out through the pay-out unit and goes through tension adjustment and straightening treatment; Pre-treatment of the tension-adjusted and straightened steel wire includes mechanical dust removal, hot water cleaning, cold water rinsing and electrolytic pickling in sequence; The pretreated steel wire is galvanized in an electrogalvanizing tank, and the residual plating solution is cleaned through a series of water washing tanks; The galvanized steel wire is rolled into a rectangular section by a rolling mill, followed by steam cleaning, straightening, wire diameter detection and wire winding; Wherein, the method also includes a linkage control process for dynamically adjusting the power supply output current of electrolytic pickling and electrogalvanizing according to the state of the whole machine.

[0047] A sulfuric acid solution with a concentration of 160-200 g / L is used in the electrolytic pickling step, and a zinc sulfate solution with a concentration of 200-350 g / L is used in the zinc plating step.

[0048] The whole machine state includes a preparation stage, a pre-starting stage, a just-starting stage, an acceleration stage, a constant speed stage, a deceleration stage and a stop stage.

[0049] In the linkage control process: Stop phase: The equipment in production is in the stop phase, the output current in the electrolytic pickling tank and the electrogalvanizing tank is 0, the purge, lifting pump and circulation pump in the hot water cleaning and rinsing tank, the electrolytic pickling tank, the electrogalvanizing tank and the series water washing tank are turned off, the solution drops, the wiping device is turned on, and the steam in the steam cleaning tank is turned off; Preparation stage: After the start button is pressed, the equipment enters the preparation stage, the hot water cleaning and rinsing tank, electrolytic pickling tank, electrogalvanizing tank and tandem water washing tank are closed, the lifting pump and circulation pump are turned on, and the solution rises; Pre-startup stage: After the liquid level in the electro-galvanizing tank rises to the preset time, the pre-startup stage begins. The power in the electrolytic pickling tank and the electro-galvanizing tank is turned on, and the preset starting current is output. The purge devices in the hot water cleaning and rinsing tank, the electrolytic pickling tank, the electro-galvanizing tank and the series water washing tank are turned on, and the steam in the steam cleaning tank is turned on. Just-starting stage: After the pre-starting stage is maintained for a preset time, it enters the just-starting stage, the whole machine is running, each process is continuously operated, the electrolytic pickling tank outputs the preset starting current, the electro-galvanizing tank outputs the starting compensation current, and the starting compensation time is continued; Acceleration stage: The whole machine is running, the wire speed is V, and it is first in the uniform acceleration stage. After the start-up compensation time, the output current of the electrolytic pickling tank is the pickling current coefficient multiplied by V, and the output current of the electrogalvanizing tank is the galvanizing current coefficient multiplied by V plus the acceleration compensation current; Uniform speed stage: The steel wire runs continuously at the set speed, and the output current of the electrogalvanizing tank is the galvanizing current coefficient multiplied by V; Speed ​​reduction stage: When the equipment presses the stop button or reaches a fixed length, it enters the speed reduction stage. The output current of the electro-galvanizing tank is the galvanizing current coefficient multiplied by V plus the deceleration compensation current, and the output current of the electro-galvanizing tank is not less than the preset minimum effective output current; Stop phase: After completely stopping, the wire speed is 0, the output current of the electrolytic pickling tank and the electro-galvanizing tank is 0, and it re-enters the stop phase.

[0050] The pickling current coefficient is 0.22, the galvanizing current coefficient is 0.82, the starting compensation current is 18 A and the duration is 2 seconds, the acceleration compensation current is 10 A, and the deceleration compensation current is -12 A.

[0051] The steel wire production speed is 0-350 m / min, the acceleration is 6 m / s², the deceleration is 10 m / s², and the zinc coating mass is 0.51-0.61 g / Kg.

[0052] The present embodiment provides a rectangular galvanized steel wire continuous production line and a production method thereof, which reduces the production process, eliminates the need for transfer and storage of galvanized steel wire, shortens the equipment footprint, reduces production and operation costs, and improves production efficiency and quality. In the present invention, the galvanized layer of the steel wire is qualified in the start and stop sections of the equipment, and a single retractable wire does not affect other operating lines, thereby reducing a lot of waste.

[0053] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A rectangular galvanized steel wire continuous production line, characterized in that: It includes a pay-off unit, a pretreatment unit, an electro-galvanizing unit and a rolling mill unit which are arranged in sequence, wherein: The wire-paying unit comprises a wire-paying machine, a tension adjusting device and a straightener arranged in sequence, and is used to stabilize and straighten the transmission of the steel wire; The pretreatment unit includes a mechanical plastering device, a hot water cleaning and rinsing tank and an electrolytic pickling tank arranged in sequence, which are used to remove impurities on the surface of the steel wire and activate the surface of the steel wire; The electrogalvanizing unit comprises an electrogalvanizing tank and a series-connected water washing tank arranged in sequence, which are used to uniformly galvanize the surface of the steel wire and clean the residual plating solution; The rolling mill unit comprises a rolling mill, a steam cleaning tank, a straightener, a wire diameter detection device and a wire take-up machine which are arranged in sequence and are used for rolling the galvanized steel wire into a rectangle and collecting it.

2. The rectangular galvanized steel wire continuous production line according to claim 1 is characterized in that: The tension adjustment device comprises a tension detection sensor and a tension controller. The actual tension value fed back by the tension detection sensor is compared with the preset tension value, and after the tension difference is calculated, the speed of the pay-off motor is adjusted by the tension controller.

3. The rectangular galvanized steel wire continuous production line according to claim 1 is characterized in that: The mechanical plastering device in the pretreatment unit is used to remove most of the lubricating powder and oxide layer on the surface of the steel wire, and is equipped with a collection device; the hot water cleaning and flushing tank is divided into two sections, wherein: The first section is equipped with a first lifting pump, a first liquid wiping device and an automatic temperature control and water replenishment system. The first lifting pump is placed on the upper surface of the tank body of the hot water cleaning and rinsing tank, and is used to lift the solution at the bottom of the tank body. The first liquid wiping device is a linear air knife, suspended above the steel wire, and is used to blow the steel wire and remove the residual liquid on the surface of the steel wire. The automatic temperature control and water replenishment system includes a temperature detection feedback device, an electric heater, a liquid level detection sensor and a pneumatic water replenishment valve, which are placed on the surface or inside of the tank body. The PLC controls the electric heater and the pneumatic water replenishment valve according to the preset temperature, the actual temperature fed back by the temperature detection feedback device and the feedback value of the liquid level detection sensor to ensure that the hot water temperature and water volume meet the standards; The second section is equipped with a first circulation pump, a water replenishment device and a first purging device; the first circulation pump is placed outside the tank body, and the inlet and outlet are connected to the tank body by a pipeline, which is used to form high-pressure water to flush the steel wire. The water replenishment device is arranged inside the tank body, and the water replenishment is determined by a mechanical float. The first purging device is placed at the steel wire outlet end of the tank body, which is used to remove residual liquid on the surface of the steel wire; The electrolytic pickling tank is used for cleaning steel wire with sulfuric acid, and is equipped with at least 3 first overflow plates. An insoluble electrode body is arranged in the first overflow plate, and the positive and negative electrodes of the electrolytic pickling power supply are alternately connected. The second lifting pump, the second wiping device, the second purging device, the first liquid level control equipment and the first acid mist purification treatment equipment are also arranged. The installation method of the second lifting pump, the second wiping device and the second purging device is the same as the installation method of the first lifting pump, the first wiping device and the first purging device in the hot water cleaning and rinsing tank. The first liquid level control equipment includes a liquid level detector and a pneumatic acid replenishing valve. The liquid level fed back by the liquid level detector is used to determine whether the amount of acid liquid meets the standard, and the pneumatic acid replenishing valve is controlled by PLC to replenish acid. The first acid mist purification treatment equipment is connected to the pipeline above the tank body, and is used to treat the gas generated by the steel wire reaction and the volatilization of the solution.

4. The rectangular galvanized steel wire continuous production line according to claim 3 is characterized in that: The electro-galvanizing tank in the electro-galvanizing unit is provided with left and right cathode rollers, which are connected to the negative electrode of the electro-galvanizing power supply. An upper and lower second overflow disk is provided between the two cathode rollers. An insoluble electrode body is provided in the second overflow disk, which is connected to the positive electrode of the electro-galvanizing power supply. The steel wire is wound back through the left and right cathode rollers to form two sections of steel wire in the lower second overflow disk and one section of steel wire in the upper second overflow disk. The unit is also provided with a second circulation pump, a filter, a plating solution reaction circulation tank, a third liquid wiping device, a third purge device, a second liquid level control device and a second acid mist purification treatment device. The plating solution reaction circulation tank is a separate tank body, which is used to store the galvanizing solution and is connected to the electro-galvanizing tank pipeline through the second circulation pump and the filter device. The second circulation pump, the third liquid wiping device and the third purge device are installed in the same manner as the first circulation pump, the first liquid wiping device and the first purge device in the hot water cleaning and rinsing tank. The second liquid level control device and the second acid mist purification treatment device are installed in the same manner as the first liquid level control device and the first acid mist purification treatment device in the electrolytic pickling tank. The series water washing tank is used to clean the residual plating solution of the steel wire, and is equipped with at least 3 sections of water washing tanks, and is equipped with a third lifting pump, a fourth liquid wiping device, a fourth purge device and a PH detection automatic water replenishment control device. The PH detection automatic water replenishment control facility includes a pneumatic water replenishment valve and a PH detection feedback device, which are placed in the last section of water washing. The pneumatic water replenishment valve is controlled to replenish water according to the feedback value and the preset value of the PH detection feedback device to adjust the solution in the water washing tank to be neutral; the installation method of the third lifting pump, the fourth liquid wiping device and the fourth purge device is the same as the installation method of the first lifting pump, the first liquid wiping device and the first purge device in the hot water washing and rinsing tank.

5. A method for continuously producing rectangular galvanized steel wire, applicable to the continuous production line of rectangular galvanized steel wire according to any one of claims 1 to 4, characterized in that: include: The steel wire is paid out through the pay-out unit and goes through tension adjustment and straightening treatment; Pre-treatment of the tension-adjusted and straightened steel wire includes mechanical dust removal, hot water cleaning, cold water rinsing and electrolytic pickling in sequence; The pretreated steel wire is galvanized in an electrogalvanizing tank, and the residual plating solution is cleaned through a series of water washing tanks; The galvanized steel wire is rolled into a rectangular section by a rolling mill, followed by steam cleaning, straightening, wire diameter detection and wire winding; Wherein, the method also includes a linkage control process for dynamically adjusting the power supply output current of electrolytic pickling and electrogalvanizing according to the state of the whole machine.

6. The method for continuous production of rectangular galvanized steel wire according to claim 5, characterized in that: A sulfuric acid solution with a concentration of 160-200 g / L is used in the electrolytic pickling step, and a zinc sulfate solution with a concentration of 200-350 g / L is used in the zinc plating step.

7. The method for continuously producing rectangular galvanized steel wire according to claim 5, characterized in that: The whole machine state includes a preparation stage, a pre-starting stage, a just-starting stage, an acceleration stage, a constant speed stage, a deceleration stage and a stop stage.

8. The method for continuously producing rectangular galvanized steel wire according to claim 7, characterized in that: In the linkage control process: Stop phase: The equipment in production is in the stop phase, the output current in the electrolytic pickling tank and the electrogalvanizing tank is 0, the purge, lifting pump and circulation pump in the hot water cleaning and rinsing tank, the electrolytic pickling tank, the electrogalvanizing tank and the series water washing tank are turned off, the solution drops, the wiping device is turned on, and the steam in the steam cleaning tank is turned off; Preparation stage: After the start button is pressed, the equipment enters the preparation stage, the hot water cleaning and rinsing tank, electrolytic pickling tank, electrogalvanizing tank and tandem water washing tank are closed, the lifting pump and circulation pump are turned on, and the solution rises; Pre-startup stage: After the liquid level in the electro-galvanizing tank rises to the preset time, the pre-startup stage begins. The power in the electrolytic pickling tank and the electro-galvanizing tank is turned on, and the preset starting current is output. The purge devices in the hot water cleaning and rinsing tank, the electrolytic pickling tank, the electro-galvanizing tank and the series water washing tank are turned on, and the steam in the steam cleaning tank is turned on. Just-starting stage: After the pre-starting stage is maintained for a preset time, it enters the just-starting stage, the whole machine is running, each process is continuously operated, the electrolytic pickling tank outputs the preset starting current, the electro-galvanizing tank outputs the starting compensation current, and the starting compensation time is continued; Acceleration stage: The whole machine is running, the wire speed is V, and it is first in the uniform acceleration stage. After the start-up compensation time, the output current of the electrolytic pickling tank is the pickling current coefficient multiplied by V, and the output current of the electrogalvanizing tank is the galvanizing current coefficient multiplied by V plus the acceleration compensation current; Uniform speed stage: The steel wire runs continuously at the set speed, and the output current of the electrogalvanizing tank is the galvanizing current coefficient multiplied by V; Speed ​​reduction stage: When the equipment presses the stop button or reaches a fixed length, it enters the speed reduction stage. The output current of the electro-galvanizing tank is the galvanizing current coefficient multiplied by V plus the deceleration compensation current, and the output current of the electro-galvanizing tank is not less than the preset minimum effective output current; Stop phase: After completely stopping, the wire speed is 0, the output current of the electrolytic pickling tank and the electro-galvanizing tank is 0, and it re-enters the stop phase.

9. The method for continuously producing rectangular galvanized steel wire according to claim 8, characterized in that: The pickling current coefficient is 0.22, the galvanizing current coefficient is 0.82, the starting compensation current is 18 A and the duration is 2 seconds, the acceleration compensation current is 10 A, and the deceleration compensation current is -12 A.

10. The method for continuously producing rectangular galvanized steel wire according to claim 9, characterized in that: The steel wire production speed is 0-350 m / min, the acceleration is 6 m / s², the deceleration is 10 m / s², and the zinc coating mass is 0.51-0.61 g / Kg.

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