Pickling and phosphating treatment system for steel for sleeve tool

Abstract

The invention relates to the technical field of acid pickling and phosphating treatment, in particular to an acid pickling and phosphating treatment system for steel for sleeve tools, which is characterized in that a wire rod subjected to acid pickling and phosphating treatment is obtained by sequentially performing spheroidizing treatment, first-time acid pickling treatment, placing treatment, second-time acid pickling treatment, flushing treatment, phosphating treatment, water washing treatment and saponification treatment on the wire rod; the method comprises the following steps: taking a steel wire rod as a raw material, detecting the steel wire rod to obtain phosphating porosity and phosphating film weight, judging whether the treatment process of the steel wire rod is qualified or not based on the phosphating porosity, and generating a corresponding instruction according to a judgment result in combination with the phosphating film weight so as to adjust operating parameters in corresponding treatment; according to the unqualified reason determined based on the phosphating porosity, the corresponding instruction is generated so as to adjust the operation parameters of the corresponding module in the treatment process of the next wire rod, then the fire resistance of the wire rod is improved by improving the phosphating film quality of the wire rod, and therefore the cold heading speed during manufacturing of the socket spanner is increased so as to improve the production efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of pickling and phosphating treatment, and particularly to a pickling and phosphating treatment system for steel used in socket tools. Background Art

[0002] When manufacturing hand tools such as socket wrenches, extension bars, screwdrivers, and pliers, the main material used is 50BV30 alloy steel with a carbon content of 0.3% and containing metals such as Cr, B, and V. Among them, socket wrenches are mainly formed by cold heading, and the forming process is as follows: 1st die sizing; 2nd die sizing; 3rd die punching hexagon; 4th die punching deep hole; 5th die punching square; 6th die punching through hole. Since the deformation amount after the hexagon stretching in the third station of the socket is relatively large and the wall is relatively thin, the heat generated during the cold heading process is extremely large. Moreover, the cold heading punch rod is mainly made of high-speed tool steel and itself contains Cr and V elements. Therefore, during the stretching forming process, there is also a certain degree of metal affinity reaction, making it difficult for the punch rod and the material to separate from each other, and the deformation heat is greater than that during the forming of other materials. Therefore, the excessive deformation heat will cause the phosphating film on the material surface to undergo a coking reaction, forming a coke-black layer on the surface, losing the lubrication effect, and after the fourth station, the lubrication failure of the phosphating film will cause the product to turn black and the machine to make noise during cold heading, and the cold heading rate is relatively slow, thus affecting the quality and production efficiency of socket wrenches.

[0003] Chinese Patent Application Publication No.: CN103353776B discloses a method for controlling the pickling acid liquid temperature of an acid rolling mill. This technical solution uses a three-stage pickling step control method to control the pickling temperature. The acid liquid is heated indirectly by a block-hole graphite heat exchanger, and the feed opening of the steam volume is continuously adjusted by a regulating valve, and the opening control curve of the regulating valve is modified to avoid damage caused by the direct impact of saturated steam on the block-hole graphite heat exchanger, thereby ensuring the stable operation of pickling. However, this technical solution lacks the detection of materials or steel after pickling and phosphating and the adjustment of the pickling and phosphating process based on the detection results, which will affect the performance of the materials and thus the production efficiency of product manufacturing based on these materials. Summary of the Invention

[0004] Therefore, the present invention provides a pickling and phosphating treatment system for steel used in socket tools to overcome the problems in the prior art that the pickling and phosphating treatment process of steel is not detected and adjusted according to the phosphating porosity and phosphating film weight, which affects the performance of the steel and thus the production efficiency of product manufacturing based on this steel.

[0005] To achieve the above object, the present invention provides a pickling and phosphating treatment system for steel used in socket tools, including: A spheroidizing module, which includes a pit furnace for spheroidizing the wire rod; The first pickling module, which is connected to the spheroidizing module, is used to perform the first pickling treatment on the wire rod after spheroidizing, and to place the wire rod after the first pickling treatment; The second pickling module, which is connected to the first pickling module, is used to perform the second pickling treatment on the wire rod after placement, and to rinse the wire rod after the second pickling treatment; The phosphating module, which is connected to the second pickling module, is used to perform phosphating treatment on the wire rod after rinsing, and to perform water washing treatment on the wire rod after phosphating; The saponification module, which is connected to the phosphating module, is used to perform saponification treatment on the wire rod after water washing; The detection module, which is connected to the saponification module, is used to detect the wire rod after saponification to obtain the phosphating porosity and the phosphating film weight; The analysis module, which is connected to the detection module, is used to determine whether the processing process of the wire rod is qualified based on the phosphating porosity, and to generate corresponding instructions in combination with the phosphating film weight according to the determination result to adjust the spheroidizing temperature or the holding time during the spheroidizing process, or to generate corresponding instructions according to the unqualified reasons determined based on the phosphating porosity to adjust the rinsing time during the rinsing process or the phosphating temperature during the phosphating process; The adjustment module, which is respectively connected to the analysis module, the spheroidizing module, the second pickling module and the phosphating module, is used to adjust the operating parameters of the corresponding module during the processing of the next wire rod based on the instruction.

[0006] Further, the analysis module is also used to make a determination based on the comparison result between the phosphating porosity and the preset phosphating porosity, and to determine whether the processing process of the wire rod is qualified based on the comparison result between the phosphating film weight and the critical film weight in combination with the determination result; The analysis module is also used to determine the reason according to the difference between the phosphating porosity and the preset phosphating porosity when it is determined that the processing process of the wire rod is unqualified.

[0007] Further, the analysis module is also used to determine to lower the spheroidizing temperature or extend the holding time based on the comparison result between the phosphating film weight and the critical film weight.

[0008] Further, the analysis module is also used to determine to lower the spheroidizing temperature when it is determined that the phosphating film weight is less than the critical film weight, to generate a corresponding instruction to lower the spheroidizing temperature based on the comparison result between the average pore spacing and the preset average pore spacing, and the decreasing amplitude of the spheroidizing temperature is positively correlated with the average pore spacing; The detection module is also connected to the spheroidizing module for detecting the wire rod after spheroidizing treatment to obtain a number of spheroidizing pore spacings, where each spheroidizing pore spacing is the spacing between any two adjacent spheroidizing pores; The average pore spacing is the average value of a number of the spheroidizing pore spacings.

[0009] Furthermore, the analysis module is also used to determine to extend the heat preservation duration when it is determined that the weight of the phosphating film is less than the critical film weight, generate a corresponding instruction based on the comparison result between the average pore spacing and the preset average pore spacing to extend the heat preservation duration, and the extension amplitude of the heat preservation duration is positively correlated with the average pore spacing; The detection module is also connected to the spheroidizing module for detecting the wire rod after spheroidizing treatment to obtain a number of spheroidizing pore spacings, where each spheroidizing pore spacing is the spacing between any two adjacent spheroidizing pores; The average pore spacing is the average value of a number of the spheroidizing pore spacings.

[0010] Furthermore, the analysis module is also used to determine the reason for the unqualified treatment process of the wire rod and generate a corresponding instruction according to the comparison result between the phosphating pore deviation value and the preset phosphating pore deviation value, including: When it is determined that the reason is that the rinsing treatment after the second pickling of the wire rod is unqualified, the analysis module generates a corresponding instruction based on the comparison result between the pH value and the preset pH value to extend the rinsing duration; Or when it is determined that the reason is that the phosphating treatment of the wire rod is unqualified, the analysis module also generates a corresponding instruction based on the comparison result between the phosphating acid ratio and the preset phosphating acid ratio to increase the phosphating temperature; Or issue an instruction to maintain the corresponding equipment when it is determined that the reason is a equipment failure in the pickling and phosphating treatment system; The detection module is respectively connected to the second pickling module and the phosphating module for detecting the wire rod after rinsing treatment to obtain the pH value, and for detecting the phosphating solution during the phosphating treatment to obtain the phosphating acid ratio.

[0011] Furthermore, the analysis module is also used to generate a corresponding instruction based on the comparison result between the pH value and the preset pH value to extend the rinsing duration when it is determined that the reason is that the rinsing treatment is unqualified, and the extension amplitude of the rinsing duration is negatively correlated with the pH value.

[0012] Further, the analysis module is also configured to, when the extension adjustment of the flushing duration is completed, generate a corresponding instruction based on the comparison result between the water conductivity and the preset water conductivity to increase the frequency of countercurrent water replenishment during the flushing process, and the increase amplitude of the countercurrent water replenishment frequency is positively correlated with the water conductivity; The detection module is also configured to detect the sewage after the flushing process is completed to obtain the water conductivity.

[0013] Further, the analysis module is also configured to, when it is determined that the reason is that the phosphating treatment of the wire rod is unqualified, generate a corresponding instruction based on the comparison result between the phosphating acid ratio and the preset phosphating acid ratio to increase the phosphating temperature, and the increase amplitude of the phosphating temperature is positively correlated with the phosphating acid ratio.

[0014] Further, the analysis module is also configured to, when the increase adjustment of the phosphating temperature is completed, generate a corresponding instruction based on the comparison result between the temperature change amount and the preset temperature change amount to shorten the phosphating duration during the phosphating process, and the shortening amplitude of the phosphating duration is positively correlated with the temperature change amount; The detection module is also configured to detect the change situation of the phosphating temperature during the phosphating process to obtain the temperature change amount.

[0015] Compared with the prior art, the beneficial effect of the pickling and phosphating treatment system for the steel used in the sleeve tool of the present invention is that the wire rod is successively subjected to spheroidizing treatment, first pickling treatment, placement treatment, second pickling treatment, flushing treatment, phosphating treatment, water washing treatment, and saponification treatment to obtain the pickled and phosphated wire rod, and the wire rod is detected to obtain the phosphating porosity and the phosphating film weight, and based on the phosphating porosity, it is determined whether the treatment process of the wire rod is qualified, and corresponding instructions are generated in combination with the phosphating film weight according to the determination result to adjust the operating parameters in the corresponding treatment, or corresponding instructions are generated according to the unqualified reason determined based on the phosphating porosity to adjust the operating parameters of the corresponding module during the treatment process for the next wire rod, thereby improving the fire resistance of the wire rod by improving the quality of the phosphating film of the wire rod, and thus accelerating the cold heading rate during the manufacturing of the socket wrench to improve the production efficiency.

[0016] Further, the present invention further determines the treatment process of the wire rod by further combining the comparison result between the phosphating film weight and the critical film weight with the comparison result between the phosphating porosity and the preset phosphating porosity, thereby improving the detection accuracy of the phosphating die of the wire rod.

[0017] Further, when the present invention determines that it is necessary to reduce the spheroidizing temperature or extend the heat preservation duration according to the comparison between the phosphating film weight and the critical film weight, it can determine the reduction amplitude of the spheroidizing temperature or the extension amplitude of the heat preservation duration based on the comparison result between the average pore spacing and the preset average pore spacing, so as to achieve precise adjustment, thereby increasing the phosphating film weight, improving the phosphating film performance of the wire rod, and improving the production efficiency of the socket wrench.

[0018] Further, the present invention can also determine the reason for the unqualified treatment process of the wire rod according to the comparison result between the phosphating pore deviation value and the preset phosphating pore deviation value, and then determine the corresponding treatment based on the reason, including: extending the flushing duration, or increasing the phosphating temperature, or issuing an instruction to maintain the corresponding equipment.

[0019] Further, when the present invention determines that it is necessary to extend the flushing duration, it can achieve precise adjustment of the flushing duration based on the comparison result between the pH value and the preset pH value, thereby reducing the amount of residual acid solution during the pickling process, reducing the phosphating porosity, and improving the heat resistance of the phosphating film of the wire rod.

[0020] Further, when the present invention determines that it is necessary to increase the phosphating temperature, it can achieve precise adjustment of the phosphating temperature based on the comparison result between the phosphating acid ratio and the preset phosphating acid ratio, thereby compensating for the insufficient concentration of film-forming ions during the phosphating process, reducing the phosphating porosity, and improving the heat resistance of the phosphating film of the wire rod.

[0021] Further, after the adjustment of the flushing duration is completed, the present invention can achieve precise adjustment of the countercurrent water replenishment frequency based on the comparison result between the water conductivity and the preset water conductivity, thereby reducing the amount of residual acid solution during the pickling process, reducing the phosphating porosity, and improving the heat resistance of the phosphating film of the wire rod.

[0022] Further, after the adjustment of the phosphating temperature is completed, the present invention can achieve precise adjustment of the phosphating duration based on the comparison result between the temperature change amount and the preset temperature change amount, thereby reducing the volatilization loss of the phosphating solution and the amount of sediment generated, extending the life of the bath solution, and reducing the waste liquid treatment cost. Description of the Drawings

[0023] Figure 1 It is a module schematic diagram of an acid pickling and phosphating treatment system for steel used in a socket tool according to the present invention; Figure 2 It is a process schematic diagram of an acid pickling and phosphating treatment method for steel used in a socket tool according to the present invention; Figure 3 It is a logic determination diagram for determining whether the treatment process of the wire rod is qualified and the corresponding treatment based on the phosphating porosity and the phosphating film weight according to the present invention; Figure 4This is a logic decision diagram for determining the reasons for the unqualified processing of wire rods based on the phosphating pore deviation value and corresponding processing. Detailed implementation mode

[0024] In order to make the objectives and advantages of the present invention more clearly understood, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0025] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principles of the present invention and do not limit the protection scope of the present invention.

[0026] It should be noted that in the description of the present invention, unless otherwise clearly specified and limited, the term "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the internal communication of two components. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0027] Please refer to Figure 1As shown, it is a module schematic diagram of a pickling and phosphating treatment system for the steel used in a socket tool in this embodiment. The system includes a spheroidizing module, a first pickling module, a second pickling module, a phosphating module, a saponifying module, a detection module, an analysis module, and an adjustment module. The spheroidizing module includes a pit furnace for spheroidizing the wire rod; the first pickling module is connected to the spheroidizing module for performing the first pickling treatment on the wire rod after spheroidizing and placing the wire rod after the first pickling treatment; the second pickling module is connected to the first pickling module for performing the second pickling treatment on the wire rod after placement and rinsing the wire rod after the second pickling treatment; the phosphating module is connected to the second pickling module for performing a phosphating treatment on the wire rod after rinsing and performing a water washing treatment on the wire rod after phosphating; the saponifying module is connected to the phosphating module for performing a saponifying treatment on the wire rod after water washing; the detection module is connected to the saponifying module for detecting the wire rod after saponifying to obtain the phosphating porosity and the phosphating film weight; the analysis module is connected to the detection module for determining whether the processing process of the wire rod is qualified based on the phosphating porosity, and generating a corresponding instruction to adjust the spheroidizing temperature or the holding time during the spheroidizing process in combination with the determination result and the phosphating film weight, or generating a corresponding instruction to adjust the rinsing time during the rinsing process or the phosphating temperature during the phosphating process according to the unqualified reason determined based on the phosphating porosity; the adjustment module is respectively connected to the analysis module, the spheroidizing module, the second pickling module, and the phosphating module for adjusting the operating parameters of the corresponding module during the processing of the next wire rod based on the instruction. By detecting the wire rod after completing the entire pickling and phosphating treatment and monitoring the processing process to determine each operating parameter that affects the phosphating film of the wire rod during the processing and making corresponding adjustments to improve the subsequent wire rod processing process. By adjusting the processing process of the wire rod according to the phosphating porosity and the phosphating film weight to optimize the pickling and phosphating process of the wire rod, and then improving the fire resistance of the wire rod by improving the quality of the phosphating film of the wire rod, thereby accelerating the cold heading rate when manufacturing socket wrenches to improve production efficiency.

[0028] Please refer to Figure 2 As shown, it is a flow schematic diagram of a pickling and phosphating treatment method for the steel used in a socket tool in this embodiment. This process at least includes the following steps: S1; Perform spheroidizing treatment on the wire rod; S2: Perform the first pickling treatment on the wire rod after spheroidizing treatment and perform a placement treatment on the wire rod after the first pickling treatment; S3: Perform the second pickling treatment on the wire rod after placement treatment and perform a rinsing treatment on the wire rod after the second pickling treatment; S4: Perform phosphating treatment on the wire rod after rinsing treatment, and perform water washing treatment on the wire rod after phosphating treatment; S5: Perform saponification treatment on the wire rod after water washing treatment; S6: Detect the wire rod after saponification treatment to obtain the phosphating porosity and phosphating film weight; S7: Determine whether the processing process of the wire rod is qualified based on the phosphating porosity, and generate corresponding instructions in combination with the phosphating film weight according to the determination result to adjust the spheroidizing temperature or holding time during the spheroidizing treatment, or generate corresponding instructions according to the unqualified reasons determined based on the phosphating porosity to adjust the rinsing time during the rinsing treatment or the phosphating temperature during the phosphating treatment; S8: Adjust the operating parameters of the corresponding module during the processing of the next wire rod based on the instructions.

[0029] In this embodiment, the chemical composition of the 50BV30 wire rod is as follows: C: 0.27% - 0.33%, Si: ≤0.1%, Mn: 0.7% - 1.0%, Cr: 0.9% - 1.2%, V: 0.1% - 0.5%, B: ≥0.0005%. During the spheroidizing treatment, the spheroidizing temperature is set at 750°C - 760°C, the holding time is set at 8 - 10 hours, and the decarburized layer is controlled to be less than or equal to 0.15 mm. During the first pickling treatment, the spheroidized wire rod is first immersed in hydrochloric acid with a concentration of 15% - 20% for 15 - 20 minutes, and the heating temperature of the hydrochloric acid is 20°C - 40°C to remove a large area of scale. After immersion, it is rinsed with high-pressure water to remove the residual acid on the surface. During the placement treatment, the wire rod with a large area of scale removed but still having local scale is placed outdoors for 12 - 24 hours, allowing a small amount of chloride ions to continue to react with the local scale. During the second pickling process, the wire rod after placement is immersed again in hydrochloric acid with a concentration of 20% - 30%, the heating temperature of the hydrochloric acid is 30°C - 40°C, and the immersion time is 5 - 10 minutes to basically remove the residual scale on the wire rod surface; then the wire rod is lifted into hydrochloric acid with a concentration of less than 10% and immersed for 10 - 15 minutes to form a uniform and dense oxidation passivation film that resists external corrosion through the lower hydrochloric acid concentration, which is beneficial to improving the rust prevention performance. During the rinsing process, the wire rod immersed in weak acid is soaked in high-pressure water and a water tank to remove the residual acid on the wire rod surface. During the phosphating treatment, the wire rod is immersed in a phosphating solution with a total acid concentration of 50% - 60%, and the phosphating process temperature is 75°C - 80°C. Among them, the main components of the phosphating solution include: phosphoric acid (phosphoric acid content greater than 88%), zinc oxide, copper nitrate, as well as film-forming aids and chelating agents. At the same time, 0.35% potassium chlorate is added to facilitate the surface activation of the metal, 0.8% nickel nitrate is added to make the phosphating film finer, and 0.5% calcium carbonate is added to increase the heat resistance of the phosphating film. During the water washing process, the phosphated wire rod is rinsed through a water tank. During the saponification process, the washed wire rod is immersed in a saponification tank, and the saponification temperature is set at 80°C - 85°C for 1 - 2 minutes. After the above pickling and phosphating process, the phosphating film of the wire rod presents a granular crystal structure, and the heat resistance is improved. Thus, when using this wire rod to manufacture the short sleeve of the sleeve, the cold heading rate can be increased from 60 pieces per minute to 75 pieces per minute, and when manufacturing the long sleeve of the sleeve, the cold heading rate can be increased from 35 pieces per minute to 45 - 50 pieces per minute. It can be understood that during the specific treatment process, some of the process production parameters are specific values that fall within the range values and include the values on the range boundaries, and some parameters are a fluctuating range value.

[0030] Please refer to Figure 3As shown, it is a logical decision diagram for determining whether the processing process of the wire rod is qualified based on the phosphating porosity and phosphating film weight and the corresponding processing. The analysis module is also used to make a determination based on the comparison result between the phosphating porosity and the preset phosphating porosity, and determine whether the processing process of the wire rod is qualified based on the determination result combined with the comparison result between the phosphating film weight and the critical film weight; the analysis module is also used to determine the cause according to the difference between the phosphating porosity and the preset phosphating porosity when determining that the processing process of the wire rod is unqualified.

[0031] Specifically, in this embodiment, by analyzing the historical data collected in the past, and combining statistical methods and application scenarios, the values of the corresponding preset or critical parameters are determined. In order to more accurately determine the processing process of the wire rod and refine the corresponding parameters in the processing process, the preset phosphating porosity W0 can be divided into the first preset phosphating porosity W1 and the second preset phosphating porosity W2. The abnormal root cause is located by grading the preset parameters, and the phosphating porosity W is compared with W1 and W2 to more accurately determine the processing process of the wire rod. It is determined that the processed wire rod is used to manufacture socket wrenches. W1 = 1.8% and W2 = 2.5% can be set. The comparison process based on W and W1 and W2 is as follows: If W is less than or equal to W1, it indicates that the phosphating film layer has excellent compactness at this time, and no additional parameter detection is required. It can be directly determined that the current processing process is qualified. If W is greater than W1 and less than or equal to W2, the phosphating porosity is in the middle threshold at this time, and it is impossible to accurately determine whether the current processing process is qualified based on W. Additional detection is started to avoid misjudgment relying on a single index and improve the accuracy of the determination process; the film weight index of the wire rod can be detected, and the phosphating film weight A is introduced for further determination and the corresponding parameters in the corresponding module are adjusted to reduce W in the subsequent processing process. If W is greater than W2, it indicates that the phosphating film performance of the wire rod is seriously insufficient and cannot meet the basic use requirements. At this time, it can be directly determined that the current processing process is unqualified. At this time, the cause of unqualified can be determined according to the difference between W and W0, and more specifically, the difference between W and W2.

[0032] Furthermore, the analysis module is also used to determine to lower the spheroidizing temperature or extend the holding time based on the comparison result between the phosphating film weight and the critical film weight.

[0033] Specifically, in this embodiment, the critical film weight A0 = 3.5 g / m can be set 2 , and it is determined whether to lower the annealing spheroidizing temperature or extend the holding time based on the comparison result between the phosphating film weight A and A0. The comparison process based on A and A0 is as follows: When A is less than A0, it indicates that the phosphating film coverage is incomplete. Even if the phosphating porosity does not exceed the standard, the basic protection requirements cannot be met, and it is determined that there are defects in the processing of the wire rod. Considering that the factors affecting the phosphating film weight during the processing of the wire rod are the spheroidizing temperature and the holding time during the spheroidizing process. An inappropriate spheroidizing temperature will cause grain recrystallization and coarsening, increase the surface roughness, reduce the grain boundary density, resulting in an increase in the number of abnormal grains, thereby reducing the phosphating film weight. An inappropriate holding time cannot complete the full transformation of carbides from flaky to spherical, and the remaining flaky carbides will hinder the effective contact between the phosphating solution and the substrate, thereby reducing the phosphating film weight. At this time, it is necessary to detect the uniformity of the pore distribution during the spheroidizing process to determine the spacing between any two adjacent spheroidizing pores, calculate the average pore spacing and compare it with the preset average spheroidizing pore spacing to determine the reduction range of the spheroidizing temperature or the extension range of the holding time.

[0034] When A is greater than or equal to A0, it indicates that the phosphating film coverage is complete and the thickness is uniform. Even if the phosphating porosity is close to the upper limit, it can still provide basic protection through sufficient film quality, and then make up for the impact caused by W exceeding the strict standard (the standard corresponding to W1) but not exceeding the loose standard (the standard corresponding to W2) through A reaching the standard. At this time, it is determined that the processing of the wire rod is qualified.

[0035] Furthermore, the analysis module is also used to determine to reduce the spheroidizing temperature when it is determined that the phosphating film weight is less than the critical film weight, generate corresponding instructions based on the comparison result of the average pore spacing and the preset pore spacing to reduce the spheroidizing temperature, and the reduction range of the spheroidizing temperature is positively correlated with the average pore spacing; the detection module is also connected to the spheroidizing module to detect the wire rod after spheroidizing treatment to obtain several spheroidizing pore spacings, where each spheroidizing pore spacing is the spacing between any two adjacent spheroidizing pores; the average pore spacing is the average value of several spheroidizing pore spacings.

[0036] Specifically, in this embodiment, the larger the average pore spacing (such as more initial forging defects), the more necessary it is to reduce the spheroidizing temperature to inhibit pore expansion. Therefore, the reduction range of the spheroidizing temperature is positively correlated with the average pore spacing. The preset average pore spacing F0 can be divided into the first preset average pore spacing F1 and the second preset average pore spacing F2. By comparing the average pore spacing F with F1 and F2, the reduction range of the spheroidizing temperature can be accurately determined. It can be set that F1 = 2.1μm and F2 = 2.4μm. The specific comparison process based on F with F1 and F2 is as follows; If F is less than or equal to F1, the analysis module generates an instruction for adjusting the first spheroidizing temperature, and the adjustment module controls the spheroidizing module to decrease the temperature by 5°C based on this instruction on the basis of the original spheroidizing temperature; if F is greater than F1 and less than or equal to F2, the analysis module generates an instruction for adjusting the second spheroidizing temperature, and the adjustment module controls the spheroidizing module to decrease the temperature by 8°C based on this instruction on the basis of the original spheroidizing temperature; if F is greater than F2, the analysis module generates an instruction for adjusting the second spheroidizing temperature, and the adjustment module controls the spheroidizing module to decrease the temperature by 10°C based on this instruction on the basis of the original spheroidizing temperature; or if F is greater than 2 times F2, a command for interrupting the processing flow and performing manual intervention inspection is directly issued. It should be noted that the decreasing amplitude of the spheroidizing temperature can also be set to other values that meet the standards. For example, when F is greater than F2, the temperature can be decreased by 15°C on the basis of the original spheroidizing temperature; it is clear that the decreasing amplitude of the spheroidizing temperature is limited so as not to have a negative impact on the processing of the wire rod.

[0037] Furthermore, the analysis module is also used to determine to extend the holding time when it is determined that the phosphating film weight is less than the critical film weight, generate a corresponding instruction based on the comparison result between the average pore spacing and the preset average pore spacing to extend the holding time, and the extending amplitude of the holding time is positively correlated with the average pore spacing; the detection module is also connected to the spheroidizing module and is used to detect the wire rod after the spheroidizing treatment to obtain a plurality of spheroidizing pore spacings, wherein each spheroidizing pore spacing is the spacing between any two adjacent spheroidizing pores; the average pore spacing is the average value of a plurality of the spheroidizing pore spacings.

[0038] Specifically, in this embodiment, an increase in the average pore spacing will lead to an increase in the atomic diffusion path and a decrease in the surface diffusion efficiency, and time compensation is required. Therefore, the extending amplitude of the holding time is positively correlated with the average pore spacing; new first preset average pore spacing F11 and second preset average pore spacing F21 can be set, with F11 = 2.2 μm and F21 = 2.6 μm. The comparison process based on F, F11, and F21 is as follows: If F is less than or equal to F11, the analysis module generates a first holding time adjustment instruction, and the adjustment module controls the spheroidizing module to extend the original holding time by 1.5% based on this instruction; if F is greater than F11 and less than or equal to F21, the analysis module generates a second holding time adjustment instruction, and the adjustment module controls the spheroidizing module to extend the original holding time by 2% based on this instruction; if F is greater than F21, the analysis module generates a third holding time adjustment instruction, and the adjustment module controls the spheroidizing module to extend the original holding time by 3%; or when F is greater than twice F21, a command to interrupt the processing flow and perform a manual intervention check is directly issued. It should be understood that the extension amplitude of the holding time can also be set to a value that meets the standard. For example, when F is greater than F21, it can be extended by 3.5% based on the original holding time; it is clear that the extension amplitude of the holding time is limited so as not to have a negative impact on the processing process of the wire rod.

[0039] Please refer to Figure 4 As shown, it is a logical decision diagram for determining the reasons for the unqualified processing process of the wire rod based on the phosphating pore deviation value and the corresponding processing in this embodiment. The analysis module is also used to determine the reasons for the unqualified processing process of the wire rod and generate corresponding instructions according to the comparison result between the phosphating pore deviation value and the preset phosphating pore deviation value, including: when it is determined that the reason is that the rinsing process after the second pickling of the wire rod is unqualified, the analysis module generates a corresponding instruction to extend the rinsing time according to the comparison result between the pH value and the preset pH value; or when it is determined that the reason is that the phosphating process of the wire rod is unqualified, the analysis module also generates a corresponding instruction to increase the phosphating temperature according to the comparison result between the phosphating acid ratio and the preset phosphating acid ratio; or when it is determined that the reason is a device failure in the pickling and phosphating processing system, an instruction to maintain the corresponding device is issued; the detection module is also respectively connected to the second pickling module and the phosphating module, and is used to detect the wire rod after the rinsing process is completed to obtain the pH value, and is used to detect the phosphating solution during the phosphating process to obtain the phosphating acid ratio.

[0040] Specifically, in this embodiment, only starting from the direction of comparing the phosphating pore deviation value D with the preset phosphating pore deviation value D0 to analyze the reasons for the unqualified processing process of the wire rod, and defaulting that other situations will not affect this analysis process, D0 can be divided into the first preset phosphating pore deviation value D1 and the second preset phosphating pore deviation value D2. By grading the preset parameters, the specific reasons for nonconformity can be subdivided. It can be set that D1 = 0.3% and D2 = 0.7%. The specific process of comparing D with D1 and D2 is as follows: If D is less than or equal to D1, it indicates that W slightly exceeds W2 at this time, and the phosphating film is close to the ideal dense state. At this time, the film layer defects mainly originate from incomplete water washing. It can be determined that the reason for the unqualified treatment process of the wire rod is that the rinsing treatment after the second pickling of the wire rod is unqualified, resulting in too much acid solution remaining on the surface of the wire rod after pickling. The remaining acid solution will cause the acidity of the phosphating solution to become unbalanced during the subsequent phosphating process, resulting in too fast crystallization rate of the phosphating film during the phosphating process, causing W to increase. At this time, the pH value of the rinsed wire rod is detected to determine the pH value B, and an order to extend the rinsing duration is issued according to the pH value B. If D is greater than D1 and less than or equal to D2, it indicates that W moderately exceeds W2 at this time, and there are obvious defects in the phosphating film (such as coarse crystallization or partial non-coverage), but it has not reached the severe failure degree. At this time, it can be determined that the reason for the unqualified treatment process of the wire rod is unqualified phosphating treatment. The increase in W is caused by the acid ratio imbalance in the phosphating solution during the phosphating process. At this time, an order to increase the phosphating temperature during the phosphating process can be determined according to the phosphating acid ratio N. The phosphating acid ratio is calculated based on the ratio of the total acidity (TA) and the free acidity (FA). Among them, the out-of-control phosphating parameters will cause global pore defects (such as abnormal crystallization of the entire batch of film layers), while problems with rinsing usually only result in local punctate pores. If D is greater than D2, it indicates that W seriously exceeds W2 at this time, indicating that there are systematic defects in the phosphating film (such as continuous large-area non-film formation or abnormal crystallization), which has exceeded the repair range of conventional process parameter adjustment. It can be determined that there are major problems in the current pickling and phosphating treatment process, that is, problems with the corresponding equipment and processes cause W to seriously exceed the standard. It is necessary to stop the treatment process and equipment operation, issue an order to comprehensively check the equipment status, determine the equipment that needs to be maintained, and perform maintenance treatment.

[0041] Furthermore, when determining that the reason is unqualified rinsing treatment, the analysis module is further configured to generate a corresponding instruction to extend the rinsing duration based on the comparison result between the pH value and the preset pH value. The extension amplitude of the rinsing duration is negatively correlated with the pH value.

[0042] Specifically, in this embodiment, the preset pH value B0 can be divided into a first preset pH value B1 and a second preset pH value B2. By comparing the pH value B with B1 and B2, the extension amplitude of the rinsing duration can be accurately determined. It can be set that B1 = 3.5 and B2 = 4.5. The specific comparison process based on B with B1 and B2 is as follows: If B is less than or equal to B1, the analysis module generates an instruction for adjusting the first flushing duration. Based on this instruction, the adjustment module controls the second pickling module to extend the original flushing duration by 5 minutes. If B is greater than B1 and less than or equal to B2, the analysis module generates an instruction for adjusting the second flushing duration. Based on this instruction, the adjustment module controls the second pickling module to extend the original flushing duration by 4 minutes. If B is greater than B2, the analysis module generates an instruction for adjusting the third flushing duration. Based on this instruction, the adjustment module controls the second pickling module to extend the original flushing duration by 2 minutes. Or when the detected B meets the requirements, the original flushing duration remains unchanged. It should be noted that the extension amplitude of the flushing duration can also be set to other values that meet the requirements. For example, when B is greater than B2, the original flushing duration is extended by 2.5 minutes.

[0043] Furthermore, when the extension adjustment of the flushing duration is completed, the analysis module is also used to generate a corresponding instruction based on the comparison result between the water conductivity and the preset water conductivity to increase the countercurrent water replenishment frequency during the flushing process. The increase amplitude of the countercurrent water replenishment frequency is positively correlated with the water conductivity. The detection module is also used to detect the sewage after the flushing process to obtain the water conductivity.

[0044] Specifically, in this embodiment, the preset water conductivity V0 can be divided into a first preset water conductivity V1 and a second preset water conductivity V2. By comparing the water conductivity V with V1 and V2, the countercurrent water replenishment frequency can be accurately determined. The countercurrent water replenishment frequency refers to the frequency of periodically replenishing the flushing tank through reverse water flow during the flushing process. By dynamically adjusting the water replenishment rate, the cleaning efficiency of the residual acid solution can be improved. It can be set that V1 = 40 μS / cm and V2 = 80 μS / cm. The specific comparison process of V with V1 and V2 is as follows: If V is less than or equal to V1, the analysis module generates an instruction for adjusting the first countercurrent water replenishment frequency. Based on this instruction, the adjustment module controls the second pickling module to increase the original countercurrent water replenishment frequency to 3 times per hour during the flushing process. If V is greater than V1 and less than or equal to V2, the analysis module generates an instruction for adjusting the second countercurrent water replenishment frequency. Based on this instruction, the adjustment module controls the second pickling module to increase the original countercurrent water replenishment frequency to 6 times per hour during the flushing process. If V is greater than V2, the analysis module generates an instruction for adjusting the third countercurrent water replenishment frequency. Based on this instruction, the adjustment module controls the second pickling module to increase the original countercurrent water replenishment frequency to 8 times per hour during the flushing process.

[0045] Further, when it is determined that the reason is unqualified phosphating treatment of the wire rod, the analysis module is further configured to generate a corresponding instruction based on the comparison result between the phosphating acid ratio and the preset phosphating acid ratio to increase the phosphating temperature, and the increase range of the phosphating temperature is positively correlated with the phosphating acid ratio.

[0046] Specifically, in this embodiment, the preset phosphating acid ratio N0 can be divided into a first preset phosphating acid ratio N1 and a second preset phosphating acid ratio N2. The hierarchical regulation of the phosphating temperature is realized by comparing the phosphating acid ratio N with N1 and N2. It can be set that N1 = 4.5 and N2 = 5.5. The specific comparison process based on N with N1 and N2 is as follows: If N is less than or equal to N1, the analysis module generates an instruction for the first phosphating temperature adjustment. The adjustment module controls the phosphating module to increase by 2°C based on the original phosphating temperature according to this instruction; if N is greater than N1 and less than or equal to N2, the analysis module generates an instruction for the second phosphating temperature adjustment. The adjustment module controls the phosphating module to increase by 4°C based on the original phosphating temperature according to this instruction; if N is greater than N2, the analysis module generates an instruction for the third phosphating temperature adjustment. The adjustment module controls the phosphating module to increase by 5°C based on the original phosphating temperature according to this instruction. It should be noted that the increase range of the phosphating temperature can also be set to other standard-compliant values. For example, when N is greater than N2, it can be increased by 6°C based on the original phosphating temperature; it is clear that the increase range of the phosphating temperature is limited so as not to have a negative impact on the processing of the wire rod.

[0047] When the increase adjustment of the phosphating temperature is completed, the analysis module is further configured to generate a corresponding instruction based on the comparison result between the temperature change amount and the preset temperature change amount to shorten the phosphating duration during the phosphating treatment, and the shortening range of the phosphating duration is positively correlated with the temperature change amount; the detection module is further configured to detect the change of the phosphating temperature during the phosphating treatment to obtain the temperature change amount.

[0048] Further, in this embodiment, the preset temperature change amount K0 can be divided into a first preset temperature change amount K1 and a second preset temperature change amount K2. The hierarchical regulation of the phosphating duration is realized by comparing the temperature change amount K with K1 and K2. It can be set that K1 = 3°C and K2 = 5°C. The specific comparison process based on K with K1 and K2 is as follows: If K is less than or equal to K1, the analysis module generates an instruction for adjusting the first phosphating duration, and the adjustment module controls the phosphating module to shorten the original phosphating duration by 10% based on this instruction; if K is greater than K1 and less than or equal to K2, the analysis module generates an instruction for adjusting the second phosphating duration, and the adjustment module controls the phosphating module to shorten the original phosphating duration by 13% based on this instruction; if K is greater than K2, the analysis module generates an instruction for adjusting the third phosphating duration, and the adjustment module controls the phosphating module to shorten the original phosphating duration by 15%. It should be noted that the reduction amplitude of the phosphating duration can also be set to other standard-compliant values. For example, when K is greater than K2, it can also be set to shorten the original phosphating duration by 17%. It can be understood that the reduction amplitude of the phosphating duration is limited so as not to have a negative impact on the processing of the wire rod.

[0049] It can be understood that in the embodiments of the present invention, no specific limitations are imposed on any preset parameter or critical parameter. The above-mentioned values are not limited to this, and those skilled in the art can adjust the preset parameter or critical parameter according to actual needs, analysis of historical data, or equipment usage conditions.

[0050] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

[0051] The above are only the preferred embodiments of the present invention and are not used to limit the present invention; for those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A pickling and phosphating treatment system for a sleeve tool steel, characterized in that, including: a spheroidizing module including a pit furnace for spheroidizing wire rods; a first pickling module connected to the spheroidizing module for performing a first pickling treatment on the wire rods after spheroidizing and for placing the wire rods after the first pickling; a second pickling module connected to the first pickling module for performing a second pickling treatment on the wire rods after placement and for rinsing the wire rods after the second pickling; a phosphating module connected to the second pickling module for performing a phosphating treatment on the wire rods after rinsing and for performing a water washing treatment on the wire rods after phosphating; a saponifying module connected to the phosphating module for performing a saponifying treatment on the wire rods after water washing; a detection module connected to the saponifying module for detecting the wire rods after saponifying to obtain the phosphating porosity and the phosphating film weight; an analysis module connected to the detection module for determining whether the processing process of the wire rods is qualified based on the phosphating porosity, and for generating corresponding instructions based on the determination result in combination with the phosphating film weight to adjust the spheroidizing temperature or the holding time during the spheroidizing process, or for generating corresponding instructions based on the unqualified reasons determined based on the phosphating porosity to adjust the rinsing time during the rinsing process or the phosphating temperature during the phosphating process; an adjustment module connected to the analysis module, the spheroidizing module, the second pickling module, and the phosphating module respectively for adjusting the operating parameters of the corresponding modules during the processing of the next wire rod based on the instructions; 2. The pickling and phosphating treatment system for the steel of the sleeve tool according to claim 1, characterized in that, the analysis module is further configured to make a determination based on the comparison result between the phosphating porosity and a preset phosphating porosity, and to determine whether the processing process of the wire rods is qualified based on the determination result in combination with the comparison result between the phosphating film weight and a critical film weight; the analysis module is further configured to determine the reason according to the difference between the phosphating porosity and the preset phosphating porosity when it is determined that the processing process of the wire rods is unqualified; 3. The pickling and phosphating treatment system for the steel of the sleeve tool according to claim 2, characterized in that, the analysis module is further configured to determine to lower the spheroidizing temperature or extend the holding time based on the comparison result between the phosphating film weight and the critical film weight; 4. The pickling and phosphating treatment system for the steel used in the sleeve tool according to claim 3, characterized in that, the analysis module is further configured to determine to lower the spheroidizing temperature when it is determined that the phosphating film weight is less than the critical film weight, and to generate a corresponding instruction to lower the spheroidizing temperature based on the comparison result between the average pore spacing and a preset average pore spacing, and the decreasing amplitude of the spheroidizing temperature is positively correlated with the average pore spacing; the detection module is further connected to the spheroidizing module for detecting the wire rods after spheroidizing to obtain a plurality of spheroidizing pore spacings, where each spheroidizing pore spacing is the spacing between any two adjacent spheroidizing pores; the average pore spacing is the average value of a plurality of the spheroidizing pore spacings; 5. The pickling and phosphating treatment system for the steel of the sleeve tool according to claim 3, characterized in that, the analysis module is further configured to determine to extend the holding time when it is determined that the phosphating film weight is less than the critical film weight, and to generate a corresponding instruction to extend the holding time based on the comparison result between the average pore spacing and a preset average pore spacing, and the extending amplitude of the holding time is positively correlated with the average pore spacing; The detection module is also connected to the spheroidizing module, and is used to detect the wire rod after spheroidizing treatment to obtain a plurality of spheroidizing pore spacings, where each spheroidizing pore spacing is the spacing between any two adjacent spheroidizing pores; The average pore spacing is the average value of a plurality of the spheroidizing pore spacings.

6. The pickling and phosphating treatment system for the steel of the sleeve tool according to claim 2, characterized in that, The analysis module is further used to determine the reason for the unqualified processing of the wire rod and generate corresponding instructions according to the comparison result between the phosphating pore deviation value and the preset phosphating pore deviation value, including: When it is determined that the reason is that the rinsing treatment after the second pickling of the wire rod is unqualified, the analysis module generates corresponding instructions according to the comparison result between the pH value and the preset pH value to extend the rinsing duration; Or when it is determined that the reason is that the phosphating treatment of the wire rod is unqualified, the analysis module also generates corresponding instructions according to the comparison result between the phosphating acid ratio and the preset phosphating acid ratio to increase the phosphating temperature; Or when it is determined that the reason is a device failure in the pickling and phosphating treatment system, an instruction to maintain the corresponding device is issued; The detection module is also connected to the second pickling module and the phosphating module respectively, and is used to detect the wire rod after rinsing treatment to obtain the pH value, and is used to detect the phosphating solution during the phosphating treatment to obtain the phosphating acid ratio.

7. The pickling and phosphating treatment system for the steel of the sleeve tool according to claim 6, characterized in that, The analysis module is further used to, when it is determined that the reason is that the rinsing treatment is unqualified, generate corresponding instructions according to the comparison result between the pH value and the preset pH value to extend the rinsing duration, and the extension amplitude of the rinsing duration is negatively correlated with the pH value.

8. The pickling and phosphating treatment system for the steel of the sleeve tool according to claim 7, characterized in that, The analysis module is further used to, when the extension adjustment of the rinsing duration is completed, generate corresponding instructions according to the comparison result between the water conductivity and the preset water conductivity to increase the countercurrent water replenishment frequency during the rinsing treatment, and the increase amplitude of the countercurrent water replenishment frequency is positively correlated with the water conductivity; The detection module is also used to detect the sewage after rinsing treatment to obtain the water conductivity.

9. The pickling and phosphating treatment system for the steel of the sleeve tool according to claim 6, characterized in that, The analysis module is further used to, when it is determined that the reason is that the phosphating treatment of the wire rod is unqualified, generate corresponding instructions according to the comparison result between the phosphating acid ratio and the preset phosphating acid ratio to increase the phosphating temperature, and the increase amplitude of the phosphating temperature is positively correlated with the phosphating acid ratio.

10. The pickling and phosphating treatment system for the sleeve tool steel according to claim 9, characterized in that, The analysis module is further used to, when the increase adjustment of the phosphating temperature is completed, generate corresponding instructions according to the comparison result between the temperature change amount and the preset temperature change amount to shorten the phosphating duration during the phosphating treatment, and the shortening amplitude of the phosphating duration is positively correlated with the temperature change amount; The detection module is also used to detect the change of the phosphating temperature during the phosphating treatment to obtain the temperature change amount.

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