A pickling and phosphating treatment system for steel used in socket tools

Abstract

The present invention relates to the technical field of pickling and phosphating treatment, and in particular to a pickling and phosphating treatment system for steel for socket tools. The system sequentially performs spheroidizing treatment, a first pickling treatment, a placement treatment, a second pickling treatment, a rinsing treatment, a phosphating treatment, a water washing treatment, and a saponification treatment on a wire rod to obtain a pickling and phosphating-treated wire rod, and detects the wire rod to obtain the phosphating porosity and the phosphating film weight. The system determines whether the treatment process of the wire rod is qualified based on the phosphating porosity, and generates corresponding instructions based on the judgment result in combination with the phosphating film weight to adjust the operating parameters in the corresponding treatment, or generates corresponding instructions based on the reason for failure determined based on the phosphating porosity to adjust the operating parameters of the corresponding module during the treatment process of the next wire rod, thereby improving the refractory performance of the wire rod by improving the phosphating film quality of the wire rod, thereby accelerating the cold heading rate when manufacturing socket wrenches to improve production efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of pickling and phosphating treatment, in particular to a pickling and phosphating treatment system for sleeve tool steel. Background Art

[0002] The primary material used in the manufacture of hand tools such as socket wrenches, extension rods, screwdrivers, and pliers is 50BV30 alloy steel with a 0.3% carbon content and containing Cr, B, and V. Socket wrenches are primarily formed through cold heading, using the following process: 1. Forming die; 2. Forming die; 3. Hexagonal punching die; 4. Deep hole punching die; 5. Square punching die; 6. Through-hole punching die. Due to the significant deformation and thin walls of the hexagonal socket after stretching, the cold heading process generates significant heat. Furthermore, the cold heading punch is primarily made of high-speed tool steel, which also contains Cr and V. Therefore, a certain degree of metal affinity occurs during stretching, making it difficult to separate the punch from the material, resulting in greater deformation heat than when forming other materials. Therefore, excessive deformation heat will cause the phosphate film on the surface of the material to produce a coking reaction, forming a charred layer on the surface, which loses the lubrication effect. After the fourth station, the lubrication of the phosphate film will fail, causing the product to turn black and the machine to make noises during cold heading, and the cold heading rate to be slow, thus affecting the quality and production efficiency of the socket wrench.

[0003] Chinese patent application publication number CN103353776B discloses a method for controlling the temperature of pickling acid solution in a pickling mill. This technical solution uses a three-stage pickling step control method to control the pickling temperature. The acid solution is heated indirectly by a block-hole graphite heat exchanger. The steam feed opening is continuously adjusted by a regulating valve. The regulating valve opening control curve is modified to avoid damage caused by direct impact of saturated steam on the block-hole graphite heat exchanger, thereby ensuring stable pickling operation. However, this technical solution lacks the ability to test the material or steel after pickling and phosphating and adjust the pickling and phosphating process based on the test results, which in turn affects the performance of the material and the production efficiency of products based on the material. Summary of the Invention

[0004] To this end, the present invention provides a pickling and phosphating treatment system for steel for sleeve tools, which is used to overcome the problem in the prior art that there is a lack of detection and adjustment of the steel pickling and phosphating treatment process according to the phosphating porosity and phosphating film weight, which in turn affects the performance of the steel and thus affects the production efficiency of products manufactured based on the steel.

[0005] To achieve the above-mentioned object, the present invention provides a pickling and phosphating treatment system for sleeve tool steel, comprising:

[0006] A spheroidizing module comprising a pit furnace for spheroidizing the wire rod;

[0007] a first pickling module connected to the spheroidizing module, configured to perform a first pickling treatment on the spheroidized wire rod, and to place the wire rod after the first pickling treatment;

[0008] a second pickling module connected to the first pickling module, for performing a second pickling treatment on the placed wire rod, and for rinsing the wire rod that has completed the second pickling treatment;

[0009] a phosphating module connected to the second pickling module, for performing a phosphating treatment on the rinsed wire rod and a water washing treatment on the phosphated wire rod;

[0010] a saponification module connected to the phosphating module for saponifying the wire rod after washing;

[0011] a detection module connected to the saponification module, for detecting the saponified wire rod to obtain the phosphating porosity and the phosphating film weight;

[0012] an analysis module connected to the detection module, configured to determine whether the treatment process of the wire rod is qualified based on the phosphate porosity, and to generate corresponding instructions for adjusting the spheroidizing temperature or holding time during the spheroidizing process according to the determination result in combination with the phosphate film regeneration, or to generate corresponding instructions for adjusting the rinsing time during the rinsing process or the phosphating temperature during the phosphating process according to the reason for the failure determined based on the phosphate porosity;

[0013] An adjustment module is connected to the analysis module, the spheroidization module, the second pickling module and the phosphating module respectively, and is used to adjust the operating parameters of the corresponding modules during the processing of the next wire rod based on the instructions.

[0014] Furthermore, the analysis module is further configured to determine whether the treatment process of the wire rod is qualified based on a comparison result of the phosphate porosity and a preset phosphate porosity, and based on the determination result combined with a comparison result of the phosphate film weight and a critical film weight;

[0015] Wherein, when the phosphating porosity is greater than the first preset phosphating porosity and less than or equal to the second preset phosphating porosity, the phosphating film weight is introduced for further determination;

[0016] The analysis module is further configured to determine the cause of the failure according to the difference between the phosphating porosity and the preset phosphating porosity when the treatment process of the wire rod is determined to be unqualified;

[0017] Wherein, when the phosphating porosity is greater than the second preset phosphating porosity, it is determined that the treatment process of the wire rod is unqualified.

[0018] Furthermore, the analysis module is also used to determine whether to lower the spheroidization temperature or extend the holding time based on the comparison result of the phosphate film weight and the critical film weight.

[0019] Furthermore, the analysis module is further configured to determine whether to lower the spheroidization temperature when determining that the phosphate film weight is less than the critical film weight, and to generate a corresponding instruction to lower the spheroidization temperature based on a comparison result of the average pore spacing with a preset average pore spacing, wherein the magnitude of the reduction in the spheroidization temperature is positively correlated with the average pore spacing;

[0020] The detection module is also connected to the spheroidization module, and is used to detect the wire rod that has completed the spheroidization process to obtain a plurality of spheroidization pore spacings, wherein each spheroidization pore spacing is the spacing between any two adjacent spheroidization pores;

[0021] The average pore spacing is the average of the spacings between a plurality of spheroidized pores.

[0022] Furthermore, the analysis module is further configured to determine whether to extend the holding time when it is determined that the phosphate film weight is less than the critical film weight, and to generate a corresponding instruction to extend the holding time based on a comparison result of the average pore spacing with a preset average pore spacing, wherein the extension of the holding time is positively correlated with the average pore spacing;

[0023] The detection module is also connected to the spheroidization module, and is used to detect the wire rod that has completed the spheroidization process to obtain a plurality of spheroidization pore spacings, wherein each spheroidization pore spacing is the spacing between any two adjacent spheroidization pores;

[0024] The average pore spacing is the average of the spacings between a plurality of spheroidized pores.

[0025] Furthermore, the analysis module is further configured to determine the reason why the wire rod processing process is unqualified and generate corresponding instructions based on the comparison result of the phosphating porosity deviation value with the preset phosphating porosity deviation value, including:

[0026] When it is determined that the reason is that the rinsing process performed 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 of the pH value with the preset pH value;

[0027] Alternatively, when it is determined that the reason is that the wire rod fails the phosphating treatment, the analysis module further generates a corresponding instruction to increase the phosphating temperature based on a comparison result of the phosphating acid ratio with a preset phosphating acid ratio;

[0028] Or issue instructions to maintain the corresponding equipment if it is determined that the cause is equipment failure in the pickling and phosphating treatment system;

[0029] The detection module is also connected to the second pickling module and the phosphating module respectively, for detecting the wire rod that has completed the rinsing treatment to obtain the pH value, and for detecting the phosphating liquid during the phosphating treatment to obtain the phosphating acid ratio.

[0030] Furthermore, the analysis module is also used to generate a corresponding instruction to extend the flushing time based on the comparison result of the pH value and the preset pH value when it is determined that the cause is unqualified flushing treatment, and the extension of the flushing time is negatively correlated with the pH value.

[0031] Furthermore, the analysis module is further configured to generate a corresponding instruction to increase the frequency of backflow water replenishment during the flushing process based on a comparison result of the water conductivity with a preset water conductivity when the flushing time extension adjustment is completed, wherein the increase in the frequency of backflow water replenishment is positively correlated with the water conductivity;

[0032] The detection module is also used to detect the sewage that has completed the flushing treatment to obtain the water conductivity.

[0033] Furthermore, the analysis module is also used to generate corresponding instructions to increase the phosphating temperature based on the comparison result of the phosphating acid ratio and the preset phosphating acid ratio when it is determined that the reason is that the wire rod is unqualified for phosphating treatment, and the increase in the phosphating temperature is positively correlated with the phosphating acid ratio.

[0034] Furthermore, the analysis module is further configured to generate a corresponding instruction to shorten the phosphating time during the phosphating process based on a comparison result of the temperature change with a preset temperature change when the phosphating temperature is increased, wherein the shortening of the phosphating time is positively correlated with the temperature change.

[0035] The detection module is also used to detect the change of the phosphating temperature during the phosphating treatment process to obtain the temperature change amount.

[0036] Compared with the prior art, the beneficial effect of the pickling and phosphating treatment system for socket tool steel of the present invention is that the wire rod is subjected to spheroidizing treatment, first pickling treatment, placement treatment, second pickling treatment, rinsing treatment, phosphating treatment, water washing treatment, and saponification treatment in sequence to obtain the pickled and phosphating treated wire rod, and the wire rod is inspected to obtain the phosphating porosity and phosphating film weight, and whether the treatment process of the wire rod is qualified is determined based on the phosphating porosity, and corresponding instructions are generated according to the judgment result in combination with the phosphating film weight to adjust the operating parameters in the corresponding treatment, or, corresponding instructions are generated according to the reason for unqualifiedness determined based on the phosphating porosity to adjust the operating parameters of the corresponding module in the treatment process of the next wire rod, thereby improving the refractory performance of the wire rod by improving the phosphating film quality of the wire rod, thereby accelerating the cold heading rate when manufacturing socket wrenches to improve production efficiency.

[0037] Furthermore, the present invention further combines the comparison results of the phosphating porosity and the preset phosphating porosity with the comparison results of the phosphating film weight and the critical film weight to judge the processing process of the wire rod, thereby improving the detection accuracy of the phosphating mold of the wire rod.

[0038] Furthermore, when the present invention determines that the spheroidization temperature needs to be lowered or the insulation time needs to be extended based on the comparison between the phosphate film weight and the critical film weight, it can determine the reduction range of the spheroidization temperature based on the comparison result between the average pore spacing and the preset average pore spacing, or determine the extension range of the insulation time, so as to achieve precise adjustment, thereby increasing the phosphate film weight, thereby improving the phosphate film performance of the wire rod, and thus improving the production efficiency of the socket wrench.

[0039] Furthermore, the present invention can also determine the reason why the wire rod processing process is unqualified based on the comparison result of 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 time, or increasing the phosphating temperature, or issuing instructions to maintain the corresponding equipment.

[0040] Furthermore, when determining that the rinsing time needs to be extended, the present invention can accurately adjust the rinsing time based on the comparison result of the pH value and the preset pH value, thereby reducing the amount of acid remaining in the pickling process, thereby reducing the phosphating porosity, and thus improving the heat resistance of the phosphating film of the wire rod.

[0041] Furthermore, when determining that the phosphating temperature needs to be increased, the present invention can accurately adjust the phosphating temperature based on the comparison result of the phosphating acid ratio and the preset phosphating acid ratio, thereby compensating for the insufficient concentration of film-forming ions during the phosphating process, thereby reducing the phosphating porosity and improving the heat resistance of the phosphating film of the wire rod.

[0042] Furthermore, after completing the adjustment of the flushing time, the present invention can accurately adjust the frequency of countercurrent water replenishment based on the comparison results of the water conductivity and the preset water conductivity, thereby reducing the amount of acid remaining in the pickling process, thereby reducing the phosphating porosity, and thus improving the heat resistance of the phosphating film of the wire rod.

[0043] Furthermore, after completing the phosphating temperature adjustment, the present invention can accurately adjust the phosphating time based on the comparison result of the temperature change and the preset temperature change, thereby reducing the volatilization loss of the phosphating solution and the amount of sediment generated, extending the life of the tank liquid, and reducing the waste liquid treatment cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 This is a schematic diagram of a module of a pickling and phosphating treatment system for sleeve tool steel according to the present invention;

[0045] Figure 2 This is a schematic flow chart of a method for pickling and phosphating sleeve tool steel according to the present invention;

[0046] Figure 3 This is a logic determination diagram for determining whether a wire rod treatment process is qualified based on phosphating porosity and phosphating film weight, and corresponding treatment;

[0047] Figure 4 This is a logic decision diagram for determining the reasons for unqualified wire rod processing based on the phosphating porosity deviation value and the corresponding processing. DETAILED DESCRIPTION

[0048] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention.

[0049] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0050] It should be noted that, in the description of the present invention, unless otherwise expressly specified or limited, the term "connection" should be understood in a broad sense. For example, it can mean a fixed connection, a detachable connection, or an integral connection; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0051] See also Figure 1As shown, it is a module schematic diagram of a pickling and phosphating treatment system for steel for sleeve tools 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 to perform a first pickling treatment on the wire rod that has completed spheroidization, and to place the wire rod that has completed the first pickling; the second pickling module is connected to the first pickling module to perform a second pickling treatment on the wire rod that has completed placement, and to rinse the wire rod that has completed the second pickling; the phosphating module is connected to the second pickling module to perform a phosphating treatment on the wire rod that has completed rinsing, and to wash the phosphated wire rod with water; the saponifying module is connected to the phosphating module to perform a saponifying treatment on the wire rod that has completed water washing; the detection module is connected to the saponifying module The first embodiment is a method for testing the saponified wire rod to obtain the phosphate porosity and phosphate film weight. The analysis module is connected to the detection module to determine whether the wire rod treatment process is qualified based on the phosphate porosity and, based on the determination result and the phosphate film weight, to generate corresponding instructions to adjust the spheroidization temperature or holding time during the spheroidization process. Alternatively, the adjustment module is connected to the analysis module, the spheroidization module, the second pickling module, and the phosphating module to adjust the operating parameters of the corresponding modules during the treatment of the next wire rod based on the instructions. By testing the wire rod that has completed the entire pickling and phosphating process and monitoring the treatment process, the various operating parameters that affect the wire rod phosphate film during the treatment process are determined and adjusted accordingly to improve the subsequent wire rod treatment process. The pickling and phosphating process of the wire rod is optimized by adjusting the treatment process of the wire rod according to the phosphating porosity and the weight of the phosphating film. The fire resistance of the wire rod is improved by improving the quality of the phosphating film of the wire rod, thereby accelerating the cold heading rate in the manufacture of socket wrenches to improve production efficiency.

[0052] See also Figure 2 As shown, it is a schematic diagram of the process of pickling and phosphating treatment of steel for sleeve tools in this embodiment. The process includes at least the following steps:

[0053] S1: Spheroidizing the wire rod;

[0054] S2: performing a first pickling treatment on the wire rod after the spheroidizing treatment, and placing the wire rod after the first pickling treatment;

[0055] S3: performing a second pickling treatment on the wire rod after the placement treatment, and performing a rinsing treatment on the wire rod after the second pickling treatment;

[0056] S4: performing phosphating treatment on the wire rod after the rinsing treatment, and performing water washing treatment on the wire rod after the phosphating treatment;

[0057] S5: saponifying the wire rod after washing;

[0058] S6: Testing the wire rod after saponification treatment to obtain the phosphate porosity and phosphate film weight;

[0059] S7: determining whether the wire rod treatment process is qualified based on the phosphate porosity, and generating corresponding instructions based on the determination result and the phosphate film regeneration to adjust the spheroidizing temperature or the holding time during the spheroidizing treatment, or generating corresponding instructions based on the reason for failure determined based on the phosphate porosity to adjust the rinsing time during the rinsing treatment or the phosphating temperature during the phosphating treatment;

[0060] S8: Based on the instruction, the operating parameters of the corresponding module during the processing of the next wire rod are adjusted.

[0061] In this embodiment, the composition of 50BV30 wire rod is as follows: C: 0.27% to 0.33%, Si: ≤0.1%, Mn: 0.7% to 1.0%, Cr: 0.9%-1.2%, V: 0.1%-0.5%, B: ≥0.0005%. During the spheroidization process, the spheroidization temperature is set at 750°C to 760°C, the holding time is set at 8 to 10 hours, and the decarburization layer is controlled to be less than or equal to 0.15mm. During the first pickling process, the spheroidized wire rod is first immersed in 15% to 20% hydrochloric acid for 15 to 20 minutes at a temperature of 20°C to 40°C to remove large areas of oxide scale. After the immersion, high-pressure water washing is performed to remove residual acid on the surface. During the storage process, the wire rod, after the large areas of oxide scale are removed but some areas of oxide scale still remain, is placed outdoors for 12 to 24 hours to allow a small amount of chloride ions to continue to react with the local oxide scale. During the second pickling process, the wire rod is re-immersed in 20% to 30% concentration of hydrochloric acid, heated at 30℃ to 40℃, and immersed for 5 to 10 minutes to basically remove the residual oxide scale on the surface of the wire rod; then the wire rod is suspended in hydrochloric acid with a concentration of less than 10% and immersed for 10 to 15 minutes. The lower concentration of hydrochloric acid forms a uniform and dense oxide passivation film that resists external corrosion, which is beneficial to improving the rust prevention performance. During the rinsing process, the wire rod that has been immersed in weak acid is immersed in high-pressure water and clean water tanks to remove the residual acid on the wire rod surface. During the phosphating process, the wire rod is immersed in a phosphating solution with a total acid concentration of 50% to 60% at a temperature of 75°C to 80°C. The main components of the phosphating solution include phosphoric acid (with a phosphoric acid content greater than 88%), zinc oxide, copper nitrate, a film-forming aid, and a chelating agent. 0.35% potassium chlorate is also added to activate the metal surface, 0.8% nickel nitrate is added to refine the phosphate film, and 0.5% calcium carbonate is added to enhance the film's heat resistance. During the washing process, the phosphated wire rod is rinsed in a clean water tank. During the saponification process, the cleaned wire rod is immersed in a saponification tank at a temperature of 80°C to 85°C for 1 to 2 minutes. After the pickling and phosphating process, the phosphate film of the wire rod exhibits a granular crystalline structure and has improved heat resistance. As a result, when using the wire rod to manufacture short sleeves, the cold heading rate can be increased from 60 pieces / minute to 75 pieces / minute, and when manufacturing long sleeves, the cold heading rate can be increased from 35 pieces / minute to 45-50 pieces / minute. It is understandable that in the specific processing process, some process production parameters may fall within a range of values ​​or include a specific value on the range boundary, while some parameters may have a fluctuating range of values.

[0062] See also Figure 3, which is a logical determination diagram for determining whether a wire rod treatment process is qualified based on the phosphate porosity and phosphate film weight, and the corresponding processing according to this embodiment. The analysis module is further configured to make a determination based on the comparison result of the phosphate porosity with a preset phosphate porosity, and to determine whether the wire rod treatment process is qualified based on the determination result combined with the comparison result of the phosphate film weight with a critical film weight. If the wire rod treatment process is determined to be unqualified, the analysis module is further configured to determine the cause based on the difference between the phosphate porosity and the preset phosphate porosity.

[0063] Specifically, in this embodiment, by analyzing historical data collected in the past and combining statistical methods and application scenarios to determine the values ​​of corresponding preset or critical parameters. 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 a first preset phosphating porosity W1 and a second preset phosphating porosity W2. The root cause of the abnormality is located by grading the preset parameters. The phosphating porosity W is compared with W1 and W2 to more accurately determine the processing process of the wire rod. To determine that the processed wire rod is used to manufacture socket wrenches, W1 can be set to 1.8% and W2 to 2.5%. The specific process based on the comparison of W with W1 and W2 is as follows:

[0064] If W is less than or equal to W1, it indicates that the density of the phosphate film layer is excellent at this time, and no additional parameter detection is required. The current treatment process can be directly judged as qualified. If W is greater than W1 and less than or equal to W2, the phosphate porosity is within the intermediate threshold, and it is impossible to accurately determine whether the current treatment process is qualified based on W. Additional detection is initiated to avoid misjudgment due to reliance on a single indicator and improve the accuracy of the judgment process. The film weight index of the wire rod can be tested, and further judgment can be made by introducing the phosphate film weight A and adjusting the corresponding parameters in the corresponding module to reduce W in the subsequent treatment process. If W is greater than W2, it indicates that the phosphate film performance of the wire rod is seriously insufficient and cannot meet the basic use requirements. At this time, the current treatment process can be directly judged as unqualified. The reason for the unqualified can be determined based on the difference between W and W0, more specifically the difference between W and W2.

[0065] Furthermore, the analysis module is also used to determine whether to lower the spheroidization temperature or extend the holding time based on the comparison result of the phosphate film weight and the critical film weight.

[0066] Specifically, in this embodiment, the critical film weight A0 can be set to 3.5 g / m 2 , by comparing the weight of the phosphate film A with A0, it is determined whether it is necessary to reduce the annealing spheroidizing temperature or extend the holding time. The comparison process based on A and A0 is as follows:

[0067] If A is less than A0, it indicates that the phosphate film coverage is incomplete. Even if the phosphate porosity does not exceed the standard, it still cannot meet the basic protection requirements, and it is determined that there are defects in the wire rod processing process; the factors affecting the phosphate film weight during the wire rod processing are the spheroidizing temperature and holding time during the spheroidizing process. Inappropriate spheroidizing temperature will cause grain recrystallization and coarsening, increase surface roughness, reduce grain boundary density, and increase the number of abnormal grains, thereby reducing the phosphate film weight. Inappropriate holding time cannot complete the full transformation of carbides from flake to spherical. The residual flake carbides will hinder the effective contact between the phosphating solution and the substrate, thereby reducing the phosphate film weight; at this time, it is necessary to perform a uniformity test on 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 in spheroidizing temperature or the extension of the holding time.

[0068] If A is greater than or equal to A0, it indicates that the phosphate film has complete coverage and uniform thickness. Even if the phosphate porosity is close to the upper limit, basic protection can still be provided through sufficient film quality. Then, A can be met to compensate 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). At this time, the wire rod processing process is judged to be qualified.

[0069] Furthermore, the analysis module is also used to determine whether to lower the spheroidization temperature when it is determined that the phosphate film weight is less than the critical film weight, and generate a corresponding instruction to lower the spheroidization temperature based on the comparison result of the average pore spacing and the preset average pore spacing, and the reduction amplitude of the spheroidization temperature is positively correlated with the average pore spacing; the detection module is also connected to the spheroidization module to detect the wire rod that has completed the spheroidization treatment to obtain a number of spheroidization pore spacings, wherein each spheroidization pore spacing is the spacing between any two adjacent spheroidization pores; the average pore spacing is the average value of a number of the spheroidization pore spacings.

[0070] Specifically, in this embodiment, the larger the average pore spacing (e.g., the more initial forging defects), the lower the spheroidizing temperature needs to be to suppress pore expansion. Therefore, the reduction in the spheroidizing temperature is positively correlated with the average pore spacing. The preset average pore spacing F0 can be divided into a first preset average pore spacing F1 and a second preset average pore spacing F2. The reduction in the spheroidizing temperature can be accurately determined by comparing the average pore spacing F with F1 and F2. F1 can be set to 2.1 μm and F2 to 2.4 μm. The specific process of comparing F with F1 and F2 is as follows.

[0071] If F is less than or equal to F1, the analysis module generates a first spheroidization temperature adjustment instruction, based on which the adjustment module controls the spheroidization module to reduce the original spheroidization temperature by 5°C. If F is greater than F1 and less than or equal to F2, the analysis module generates a second spheroidization temperature adjustment instruction, based on which the adjustment module controls the spheroidization module to reduce the original spheroidization temperature by 8°C. If F is greater than F2, the analysis module generates a second spheroidization temperature adjustment instruction, based on which the adjustment module controls the spheroidization module to reduce the original spheroidization temperature by 10°C. Alternatively, if F is greater than twice F2, a command to interrupt the processing flow and perform manual intervention inspection is directly issued. It should be noted that the reduction in spheroidization temperature can also be set to other standard values. For example, when F is greater than F2, the temperature can be reduced by 15°C. It is clear that the reduction in spheroidization temperature is limited to not negatively impact the wire rod processing process.

[0072] Furthermore, the analysis module is also used to determine whether to extend the insulation time when it is determined that the phosphate film weight is less than the critical film weight, and generate a corresponding instruction to extend the insulation time based on the comparison result of the average pore spacing and the preset average pore spacing, and the extension of the insulation time is positively correlated with the average pore spacing; the detection module is also connected to the spheroidization module to detect the wire rod that has completed the spheroidization treatment to obtain a number of spheroidization pore spacings, wherein each spheroidization pore spacing is the spacing between any two adjacent spheroidization pores; the average pore spacing is the average value of a number of the spheroidization pore spacings.

[0073] 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, requiring an increase in time compensation. Therefore, the extension of the holding time is positively correlated with the average pore spacing. A new first preset average pore spacing F11 and a second preset average pore spacing F21 can be set, with F11=2.2μm and F21=2.6μm. The comparison process based on F with F11 and F21 is as follows:

[0074] If F is less than or equal to F11, the analysis module generates a first holding time adjustment instruction, based on which the adjustment module controls the spheroidization module to extend the holding time by 1.5% based on the original holding time. If F is greater than F11 and less than or equal to F21, the analysis module generates a second holding time adjustment instruction, based on which the adjustment module controls the spheroidization module to extend the holding time by 2% based on the original holding time. If F is greater than F21, the analysis module generates a third holding time adjustment instruction, based on which the adjustment module controls the spheroidization module to extend the holding time by 3% based on the original holding time. Alternatively, 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 of the holding time can also be set to a value that meets the standard. For example, when F is greater than F21, the holding time can be extended by 3.5% based on the original holding time. It is clear that the extension of the holding time is limited to not negatively impact the wire rod processing process.

[0075] See also Figure 4 The figure shows a logic decision diagram for determining the reason for wire rod treatment failure based on the phosphating porosity deviation value and the corresponding treatment according to this embodiment. The analysis module is further configured to determine the reason for wire rod treatment failure and generate corresponding instructions based on the comparison result of the phosphating porosity deviation value with the preset phosphating porosity deviation value. The following examples include: if the reason is determined to be failure of the rinse treatment after the second pickling of the wire rod, the analysis module generates a corresponding instruction to extend the rinse time based on the comparison result of the pH value with the preset pH value; if the reason is determined to be failure of the phosphating treatment of the wire rod, the analysis module generates a corresponding instruction to increase the phosphating temperature based on the comparison result of the phosphating acid ratio with the preset phosphating acid ratio; or if the reason is determined to be equipment failure in the pickling and phosphating treatment system, the analysis module issues a maintenance instruction for the corresponding equipment. The detection module is also connected to the second pickling module and the phosphating module respectively, and is configured to detect the wire rod after the rinse treatment to obtain the pH value, and to detect the phosphating solution during the phosphating treatment to obtain the phosphating acid ratio.

[0076] Specifically, in this embodiment, the reasons for the unqualified processing of the wire rod are analyzed only by comparing the phosphating porosity deviation value D with the preset phosphating porosity deviation value D0. It is assumed that other situations will not affect the analysis process. D0 can be divided into a first preset phosphating porosity deviation value D1 and a second preset phosphating porosity deviation value D2. By grading the preset parameters to achieve the specific reasons for the unqualified processing, D1=0.3% and D2=0.7% can be set. The comparison process based on D with D1 and D2 is as follows:

[0077] If D is less than or equal to D1, it indicates that W at this time slightly exceeds W2, and the phosphating film is close to the ideal dense state. At this time, the film defect is mainly caused by incomplete water washing. It can be determined that the reason for the unqualified wire rod processing process is that the rinsing treatment after the second pickling of the wire rod is unqualified, resulting in excessive acid remaining on the surface of the wire rod after pickling. The residual acid will cause the acidity of the phosphating solution to be unbalanced in the subsequent phosphating process, thereby causing the phosphating film to crystallize too quickly during the phosphating process, so that W increases. At this time, the pH value of the wire rod that has been rinsed is tested to determine the pH value B, and a command to extend the rinsing time is determined based on the pH value B. If D is greater than D1 and less than or equal to D2, it indicates that W at this time moderately exceeds W2, and the phosphate film has obvious defects (such as coarse crystals or local uncovered), but has not yet reached the level of serious failure. At this time, it can be determined that the reason for the unqualified wire rod processing process is unqualified phosphating treatment. The imbalance of the acid ratio in the phosphating solution during the phosphating process causes W to increase. At this time, the command to increase the phosphating temperature during the phosphating process can be determined based on the phosphating acid ratio N. The phosphating acid ratio is calculated based on the ratio of total acidity (TA) and free acidity (FA). Among them, out-of-control phosphating parameters will cause global porosity defects (such as abnormal crystallization of the entire batch of film layers), while problems with flushing usually only lead to local point-like porosity. If D is greater than D2, it indicates that W at this time seriously exceeds W2, indicating that there are systemic defects in the phosphate film (such as continuous large-area film failure 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 have caused W to seriously exceed the standard. It is necessary to suspend the treatment process and equipment operation, issue a command for a comprehensive check of the equipment status, determine the equipment that needs maintenance, and perform maintenance.

[0078] Furthermore, the analysis module is also used to generate a corresponding instruction to extend the flushing time based on the comparison result of the pH value and the preset pH value when it is determined that the cause is unqualified flushing treatment, and the extension of the flushing time is negatively correlated with the pH value.

[0079] 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 of the flushing time can be accurately determined. B1=3.5 and B2=4.5 can be set. The specific process of comparing B with B1 and B2 is as follows:

[0080] If B is less than or equal to B1, the analysis module generates an instruction for adjusting the first flushing time, and the adjustment module controls the second pickling module to extend the original flushing time by 5 minutes based on the instruction; if B is greater than B1 and less than or equal to B2, the analysis module generates an instruction for adjusting the second sprint time, and the adjustment module controls the second pickling module to extend the original flushing time by 4 minutes based on the instruction; if B is greater than B2, the analysis module generates an instruction for adjusting the third flushing time, and the adjustment module controls the second pickling module to extend the original flushing time by 2 minutes based on the instruction; or when the detected B meets the requirements, the original flushing time remains unchanged. It should be noted that the extension range of the flushing time can also be set to other values ​​that meet the requirements. For example, when B is greater than B2, the flushing time is extended by 2.5 minutes based on the original flushing time.

[0081] Furthermore, the analysis module is also used to generate corresponding instructions based on the comparison results of the water conductivity and the preset water conductivity to increase the frequency of backflow water replenishment during the flushing process when the extension adjustment of the flushing time is completed, and the increase in the frequency of backflow water replenishment is positively correlated with the water conductivity; the detection module is also used to detect the sewage that has completed the flushing treatment to obtain the water conductivity.

[0082] 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. The frequency of countercurrent water replenishment is accurately determined by comparing the water conductivity V with V1 and V2. The frequency of countercurrent water replenishment refers to the frequency of periodically replenishing the flushing tank by reverse water flow during the flushing process. The water replenishment rate is dynamically adjusted to improve the removal efficiency of residual acid. V1=40μS / cm and V2=80μS / cm can be set. The specific process of comparing V with V1 and V2 is as follows:

[0083] If V is less than or equal to V1, the analysis module generates an instruction for adjusting the first countercurrent water replenishment frequency, and the adjustment module controls the second pickling module to increase the original countercurrent water replenishment frequency to 3 times / hour during the flushing process based on the instruction; 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, and the adjustment module controls the second pickling module to increase the original countercurrent water replenishment frequency to 6 times / hour during the flushing process based on the instruction; if V is greater than V2, the analysis module generates an instruction for adjusting the third countercurrent water replenishment frequency, and the adjustment module controls the second pickling module to increase the original countercurrent water replenishment frequency to 8 times / hour during the flushing process based on the instruction.

[0084] Furthermore, the analysis module is also used to generate corresponding instructions to increase the phosphating temperature based on the comparison result of the phosphating acid ratio and the preset phosphating acid ratio when it is determined that the reason is that the wire rod is unqualified for phosphating treatment, and the increase in the phosphating temperature is positively correlated with the phosphating acid ratio.

[0085] 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 phosphating temperature can be graded and regulated by comparing the phosphating acid ratio N with N1 and N2. N1=4.5 and N2=5.5 can be set. The specific process of comparing N with N1 and N2 is as follows:

[0086] If N is less than or equal to N1, the analysis module generates a command for adjusting the first phosphating temperature. Based on this command, the control module controls the phosphating module to increase the original phosphating temperature by 2°C. If N is greater than N1 and less than or equal to N2, the analysis module generates a command for adjusting the second phosphating temperature. Based on this command, the control module controls the phosphating module to increase the original phosphating temperature by 4°C. If N is greater than N2, the analysis module generates a command for adjusting the third phosphating temperature. Based on this command, the control module controls the phosphating module to increase the original phosphating temperature by 5°C. It should be noted that the increase in the phosphating temperature can also be set to other values ​​that meet standards. For example, when N is greater than N2, the phosphating temperature can be increased by 6°C. It is clear that the increase in the phosphating temperature is limited to a value that does not negatively impact the wire rod processing process.

[0087] The analysis module is further configured to generate corresponding instructions based on a comparison result of the temperature change with a preset temperature change to shorten the phosphating time during the phosphating treatment process after the increase adjustment of the phosphating temperature is completed, and the shortening of the phosphating time is positively correlated with the temperature change; the detection module is further configured to detect the change of the phosphating temperature during the phosphating treatment process to obtain the temperature change.

[0088] Furthermore, in this embodiment, the preset temperature change K0 can be divided into a first preset temperature change K1 and a second preset temperature change K2. By comparing the temperature change K with K1 and K2, hierarchical control of the phosphating time can be achieved. K1=3°C and K2=5°C can be set. The specific comparison process based on K with K1 and K2 is as follows:

[0089] If K is less than or equal to K1, the analysis module generates an instruction for adjusting the first phosphating time. Based on this instruction, the control module controls the phosphating module to shorten the original phosphating time by 10%. If K is greater than K1 and less than or equal to K2, the analysis module generates an instruction for adjusting the second phosphating time. Based on this instruction, the control module controls the phosphating module to shorten the original phosphating time by 13%. If K is greater than K2, the analysis module generates an instruction for adjusting the third phosphating time. Based on this instruction, the control module controls the phosphating module to shorten the original phosphating time by 15%. It should be noted that the reduction in the phosphating time can also be set to other values ​​that meet the standards. For example, when K is greater than K2, the reduction in the phosphating time can be set to 17%. It is understood that the reduction in the phosphating time is limited to a value that does not negatively impact the wire rod processing process.

[0090] It is understandable that in the embodiments of the present invention, no specific limitation is imposed on any preset parameter or critical parameter, and the above values ​​are not limited thereto. Those skilled in the art may adjust the preset parameters or critical parameters accordingly based on actual needs, analysis of historical data, or equipment usage.

[0091] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

[0092] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A pickling and phosphating treatment system for sleeve tool steel, characterized in that: include: A spheroidizing module comprising a pit furnace for spheroidizing the wire rod; a first pickling module connected to the spheroidizing module, configured to perform a first pickling treatment on the spheroidized wire rod, and to place the wire rod after the first pickling treatment; a second pickling module connected to the first pickling module, for performing a second pickling treatment on the placed wire rod, and for rinsing the wire rod that has completed the second pickling treatment; a phosphating module connected to the second pickling module, for performing a phosphating treatment on the rinsed wire rod and a water washing treatment on the phosphated wire rod; a saponification module connected to the phosphating module for saponifying the wire rod after washing; a detection module connected to the saponification module, for detecting the saponified wire rod to obtain the phosphating porosity and the phosphating film weight; an analysis module connected to the detection module, configured to determine whether the treatment process of the wire rod is qualified based on the phosphate porosity, and to generate corresponding instructions for adjusting the spheroidizing temperature or holding time during the spheroidizing process according to the determination result in combination with the phosphate film regeneration, or to generate corresponding instructions for adjusting the rinsing time during the rinsing process or the phosphating temperature during the phosphating process according to the reason for the failure determined based on the phosphate porosity; an adjustment module, connected to the analysis module, the spheroidization module, the second pickling module, and the phosphating module, respectively, for adjusting operating parameters of the corresponding modules during processing of the next wire rod based on the instruction; The analysis module is further configured to determine whether the treatment process of the wire rod is qualified based on a comparison result of the phosphating porosity with a preset phosphating porosity, and based on the determination result combined with a comparison result of the phosphating film weight with a critical film weight; Wherein, when the phosphating porosity is greater than the first preset phosphating porosity and less than or equal to the second preset phosphating porosity, the phosphating film weight is introduced for further determination; The analysis module is further configured to determine the cause of the failure according to the difference between the phosphating porosity and the preset phosphating porosity when the treatment process of the wire rod is determined to be unqualified; Wherein, when the phosphating porosity is greater than the second preset phosphating porosity, it is determined that the treatment process of the wire rod is unqualified; The analysis module is further configured to determine whether to lower the spheroidization temperature or extend the holding time based on a comparison result of the phosphate film weight and the critical film weight; The analysis module is further configured to determine whether to lower the spheroidization temperature if it is determined that the phosphate film weight is less than the critical film weight, and to generate a corresponding instruction to lower the spheroidization temperature based on a comparison result of the average pore spacing with a preset average pore spacing, wherein the magnitude of the reduction in the spheroidization temperature is positively correlated with the average pore spacing; Adjusting the weight of the phosphate film based on a comparison result of the average pore spacing and the preset average pore spacing; The detection module is also connected to the spheroidization module, and is used to detect the wire rod that has completed the spheroidization process to obtain a plurality of spheroidization pore spacings, wherein each spheroidization pore spacing is the spacing between any two adjacent spheroidization pores; The average pore spacing is the average of the spacings between a plurality of spheroidized pores.

2. The pickling and phosphating treatment system for sleeve tool steel according to claim 1, characterized in that: The analysis module is further configured to determine whether to extend the holding time if it is determined that the phosphate film weight is less than the critical film weight, and to generate a corresponding instruction to extend the holding time based on a comparison result of the average pore spacing with a preset average pore spacing, wherein the extension of the holding time is positively correlated with the average pore spacing; The detection module is also connected to the spheroidization module, and is used to detect the wire rod that has completed the spheroidization process to obtain a plurality of spheroidization pore spacings, wherein each spheroidization pore spacing is the spacing between any two adjacent spheroidization pores; The average pore spacing is the average of the spacings between a plurality of spheroidized pores.

3. The pickling and phosphating treatment system for sleeve tool steel according to claim 1, characterized in that: The analysis module is further configured to determine the reason why the wire rod processing process is unqualified and generate corresponding instructions based on a comparison result of the phosphating porosity deviation value and a preset phosphating porosity deviation value, including: When it is determined that the reason is that the rinsing process performed 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 of the pH value with the preset pH value; Alternatively, when it is determined that the reason is that the wire rod fails the phosphating treatment, the analysis module further generates a corresponding instruction to increase the phosphating temperature based on a comparison result of the phosphating acid ratio with a preset phosphating acid ratio; Or issue instructions to maintain the corresponding equipment if it is determined that the cause is equipment failure in the pickling and phosphating treatment system; The detection module is also connected to the second pickling module and the phosphating module respectively, for detecting the wire rod that has completed the rinsing treatment to obtain the pH value, and for detecting the phosphating liquid during the phosphating treatment to obtain the phosphating acid ratio.

4. The pickling and phosphating treatment system for sleeve tool steel according to claim 3, characterized in that: The analysis module is also used to generate a corresponding instruction to extend the flushing time based on the comparison result of the pH value and the preset pH value when it is determined that the cause is unqualified flushing treatment, and the extension of the flushing time is negatively correlated with the pH value.

5. The pickling and phosphating treatment system for sleeve tool steel according to claim 4, characterized in that: The analysis module is further configured to generate a corresponding instruction to increase the frequency of backflow water replenishment during the flushing process based on a comparison result of the water conductivity with a preset water conductivity after the flushing time extension adjustment is completed, wherein the increase in the frequency of backflow water replenishment is positively correlated with the water conductivity; The detection module is also used to detect the sewage that has completed the flushing treatment to obtain the water conductivity.

6. The pickling and phosphating treatment system for sleeve tool steel according to claim 3, characterized in that: The analysis module is also used to generate a corresponding instruction to increase the phosphating temperature based on the comparison result of the phosphating acid ratio and the preset phosphating acid ratio when it is determined that the reason is that the wire rod is unqualified for phosphating treatment, and the increase in the phosphating temperature is positively correlated with the phosphating acid ratio.

7. The pickling and phosphating treatment system for sleeve tool steel according to claim 6, characterized in that: The analysis module is further configured to generate a corresponding instruction to shorten the phosphating time during the phosphating process based on a comparison result of the temperature change with a preset temperature change after the phosphating temperature increase adjustment is completed, wherein the shortening of the phosphating time is positively correlated with the temperature change; The detection module is also used to detect the change of the phosphating temperature during the phosphating treatment process to obtain the temperature change amount.

Images