Method for automatically adjusting plating layer of copper-plated steel wire

Abstract

According to the method for automatically adjusting the plating layer of the copper-plated steel wire, the copper-plated steel wire is a necessary semi-finished product in a steel cord product, current is applied according to the Coulomb law, copper and zinc metal ions are electrically deposited on the surface of the steel wire, preparation is made for subsequent drawing, and the plating layer is provided for firmer combination of the steel cord and rubber. Technological parameters are collected to enter a laboratory for calculation, detection results of the laboratory and the technological parameters are fed back to a control system of a production line, and the control system compares detection results of copper content and plating gram weight, copper plating current density, zinc plating current density, copper plating current efficiency and calculation results of zinc plating current efficiency with preset values. And the new copper plating current is calculated according to the comparison result, and the new zinc plating current is automatically adjusted, so that the problem of errors caused by human factors such as personal calculation and calculation modes is avoided, and orderly production is ensured.

Description

TECHNICAL FIELD

[0001] The present application relates to steel wire plating control technology, in particular to a method for automatically adjusting copper plating layer of steel wire. BACKGROUND

[0002] Copper-plated steel wire is a necessary semi-finished product in steel cord products. According to Coulomb's law, current is applied to make copper and zinc metal ions electrodeposit on the surface of the steel wire, preparing for subsequent drawing and providing a plating layer for the steel cord to be combined more firmly with rubber.

[0003] The main parameters of the plating layer of the steel wire are two: copper content (unit: %) and plating weight per kilogram (unit: g / kg). The copper content is the proportion of copper in the plating layer on the surface of the steel wire, and the plating weight per kilogram is the weight of the plating layer plated on the surface of each kilogram of steel wire. The plating layer is composed of copper and zinc metal.

[0004] In order to plate different weights and different metals of the plating layer, different plating tanks and different currents are applied. First, the current is applied to plate copper on the steel wire, and then the current is applied to plate zinc after cleaning. Copper plating and zinc plating are carried out in copper plating tanks and zinc plating tanks, respectively.

[0005] In actual production process, the plating layer of the steel wire will change due to various factors. When the plating layer deviates greatly, the currents for copper plating and zinc plating need to be adjusted so that the copper content and the plating weight per kilogram of the plating layer of the steel wire meet the requirements. After the laboratory reports, the foreman manually calculates and modifies the current according to experience, and then takes a steel wire sample for testing and confirmation. This will cause the following problems: 1. The foreman may make a mistake; 2. Different foremen will have different algorithms; 3. The foreman may sometimes overlook some factors when adjusting, resulting in incorrect adjustment. SUMMARY

[0006] The present application provides a method for automatically adjusting the plating layer of copper-plated steel wire. The method collects process parameters and enters the laboratory for calculation, and feeds back the detection results and process parameters of the laboratory to the control system of the production line. The control system compares the detection results of the copper content and the plating weight per kilogram, the calculation results of the copper plating current density, the zinc plating current density, the copper plating current efficiency, and the zinc plating current efficiency with the preset values, calculates the new copper plating current and zinc plating current according to the comparison results, and automatically adjusts them, thereby avoiding errors caused by personal calculation and calculation methods and other human factors, and ensuring the orderly progress of production.

[0007] The technical scheme adopted by the present application is as follows: a method for automatically adjusting the plating layer of copper-plated steel wire, comprising, Data collection: collecting process parameters of each specification of steel wire in the electroplating process; Data processing: after the electroplating is completed, the steel wire enters the laboratory for detection of copper content and coating weight of the steel wire, and the production conditions are judged according to the detection results of the laboratory and the collected process parameters, and the current size is automatically adjusted according to the judgment results.

[0008] On the basis of the above scheme, as a preferred, When the copper content exceeds the preset range, the system adjusts the current size according to the following formula: New copper plating current = copper content standard / actual copper content * original copper plating current, New zinc plating current = original copper plating current - new copper plating current + original zinc plating current.

[0009] On the basis of the above scheme, as a preferred, When the coating weight exceeds the preset range, the system adjusts the current size according to the following formula: New copper plating current = coating weight standard / actual coating weight * original copper plating current, New zinc plating current = coating weight standard / actual coating weight * original zinc plating current.

[0010] On the basis of the above scheme, as a preferred, When the copper content and the coating weight both exceed the preset range, the system adjusts the current size according to the following formula: New copper plating current one = copper content standard / actual copper content * original copper plating current, New zinc plating current one = original copper plating current - new copper plating current + original zinc plating current, New copper plating current two = coating weight standard / actual coating weight * new copper plating current one, New zinc plating current two = coating weight standard / actual coating weight * new zinc plating current one.

[0011] On the basis of the above scheme, as a preferred, The collected process parameters include original copper plating current, original zinc plating current, steel wire diameter, steel wire number, steel wire speed, length of copper plating tank, length of zinc plating tank.

[0012] On the basis of the above scheme, as a preferred, The control system of the production line calculates the current density of the steel wire according to the collected process parameters and compares it with the system preset value, and if it exceeds the range, an alarm signal is sent.

[0013] On the basis of the above scheme, as a preferred, The current density of the steel wire is calculated as follows: Copper plating current density = original copper plating current (A) / (Π * steel wire diameter (mm) * length of copper plating tank (mm) * number of steel wires) * 10000, Galvanizing current density = galvanizing primary current / (Π * steel wire diameter (mm) * length of galvanizing tank (mm) * number of steel wires) * 10000.

[0014] On the basis of the above scheme, as a preferred, The control system of the production line calculates the current efficiency of the steel wire according to the collected process parameters and the detection results in the laboratory, and compares it with the preset value of the system, and if it is out of range, an alarm signal is sent.

[0015] On the basis of the above scheme, as a preferred, Copper plating current efficiency = 0.37 * actual copper content (%) * actual gram weight (g / kg) * steel wire speed (m / min) * steel wire diameter (mm) * diameter (mm) * number of steel wires / 1.185 / copper plating primary current (A), 0.37 is a constant, 1.185 is the electrodeposition constant of copper, with a unit of g / (A*h), g is the weight unit gram, A is the current unit ampere, and h is the time unit hour; Galvanizing current efficiency = 0.37 * (1-actual copper content (%)) * actual gram weight (g / kg) * steel wire speed (m / min) * steel wire diameter (mm) * steel wire diameter (mm) * number of steel wires / 1.215 / galvanizing primary current (A), 0.37 is a constant, 1.215 is the electrodeposition constant of zinc, with a unit of g / (A*h), g is the weight unit gram, A is the current unit ampere, and h is the time unit hour.

[0016] The present application has the following technical effects: Through collecting process parameters into the laboratory for calculation, and feeding back the detection results in the laboratory and the process parameters to the control system of the production line, the control system compares the detection results of copper content and coating gram weight, copper plating current density, zinc plating current density, copper plating current efficiency, zinc plating current efficiency with the preset value, calculates the size of the new copper plating current and the new zinc plating current according to the comparison result, and automatically adjusts, so as to improve the stability of the coating of the steel wire, and avoid human error adjustment and input error.

[0017] Stable coating can ensure smooth drawing in the later process, and the coating of the finished steel wire is stable, so that the combination of steel wire and rubber is more stable when the tire factory produces tires.

[0018] In the present application: (1) In the case of preset adjustment logic, the current of the plating tank is automatically adjusted, so that the produced steel wire is quickly adjusted, the number of steel wires with large coating parameter deviation is reduced, and the influence on the later cord product is reduced.

[0019] (2) After the automatic adjustment, the human error of the foreman in inputting the current parameters on the production line can be reduced, such as inputting the wrong current; after inputting the wrong current, the steel wire on the production line cannot be used and can only be scrapped.

[0020] (3) Another effect of the technical effect is that the two hidden parameters of the electroplating, i.e., the current density and the current efficiency, are actively tracked, and the working efficiency is improved; in addition, when an abnormality is tracked, a pre-warning is immediately issued to remind the technical personnel. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 is the problem of copper content and weight exceeding the standard in the production process of the steel wire with a specification of 1.53NT; Figure 2 is the display data after manual adjustment in the production process (deviated from the manually calculated process setting card, and the deviation is the result of experience adjustment); Figure 3 is the process setting card calculated manually according to experience; Figure 4 is the calculation result of the scheme of the present application. DETAILED DESCRIPTION

[0022] In order to further understand the present application, the present application is further described in detail in combination with the embodiments below, but is not limited to the present application, and it should be understood that the description is only for further illustrating the features and advantages of the present application, and is not a limitation on the claims of the present application. Any equivalent replacement in the art according to the disclosure of the present application belongs to the protection scope of the present application.

[0023] An automatic adjustment method of a copper-plated steel wire coating, comprising, Data acquisition: collecting the process parameters of each specification of steel wire in the electroplating process, which usually includes: original copper plating current, original zinc plating current, steel wire diameter, steel wire quantity, steel wire speed, length of the copper plating tank, length of the zinc plating tank; Data processing: after the electroplating is completed, the steel wire is sampled into the laboratory for detection of the copper content and the coating weight of the steel wire, if the detection result is within the preset range, the collected process parameters and the detected parameters are taken as the original performance data and uploaded to the big data processing system, otherwise, the laboratory uploads the data to the control system of the production line (which can also be other independent computer processing programs and carriers storing the programs), and the control system of the production line calculates and automatically adjusts the current size according to the data uploaded by the laboratory.

[0024] Among them, the following situations may occur when the laboratory detects: (1) When the copper content exceeds the preset range, the system adjusts the current size according to the following formula: New copper plating current (target value to be adjusted) = copper content standard / actual copper content (laboratory test result) * original copper plating current (data collected on the production line), New zinc plating current = original copper plating current - new copper plating current + original zinc plating current (data collected on the production line).

[0025] (2) When the coating weight exceeds the preset range, the system adjusts the current size according to the following formula: New copper plating current = weight standard / actual weight (laboratory test result) * original copper plating current, New zinc plating current = weight standard / actual weight * original zinc plating current.

[0026] (3) When both the copper content and the coating weight exceed the preset range, the system adjusts the current size according to the following formula: New copper plating current one = copper content standard / actual copper content * original copper plating current, New zinc plating current one = original copper plating current - new copper plating current + original zinc plating current, New copper plating current two = weight standard / actual weight * new copper plating current one, New zinc plating current two = weight standard / actual weight * new zinc plating current one.

[0027] The control system of the production line calculates the current density of the steel wire according to the collected process parameters and compares it with the system preset value. If it exceeds the range, an alarm signal is sent to remind the technician to exclude the abnormality.

[0028] The calculation method of the current density of the steel wire is as follows: Copper plating current density = original copper plating current (A) / (Π (3.14) * steel wire diameter (mm) * length of copper plating tank (mm) * number of steel wires) * 10000, Zinc plating current density = original zinc plating current / (Π * steel wire diameter (mm) * length of zinc plating tank (mm) * number of steel wires) * 10000.

[0029] The control system of the production line calculates the current efficiency of the steel wire according to the collected process parameters and the laboratory test results, and compares it with the system preset value. If it exceeds the range, an alarm signal is sent to remind the technician to exclude the abnormality.

[0030] Copper plating current efficiency = 0.37 * actual copper content (%) * actual weight (g / kg) * steel wire speed (m / min) * steel wire diameter (mm) * diameter (mm) * number of steel wires / 1.185 / original copper plating current (A), 0.37 is a constant, 1.185 is the copper deposition constant, unit g / (A*h), g is the weight unit gram, A is the current unit ampere, h is the time unit hour; Galvanizing current efficiency = 0.37 * (1 - actual copper content (%)) * actual weight (g / kg) * wire speed (m / min) * wire diameter (mm) * wire diameter (mm) * number of wires / 1.215 / galvanizing current (A). 0.37 is a constant, and 1.215 is the zinc electrodeposition constant, with units of g / (A*h), where g is the weight unit (gram), A is the current unit (ampere), and h is the time unit (hour).

[0031] Specifically, after a batch of steel wire is produced, samples are taken to the laboratory to test its performance. This technology only affects the copper content and coating weight related to the plating. Taking production line A as an example, if... Figure 1 As shown, the production specification is 1.53NT, where 1.53 is the diameter in mm, and NT represents the steel grade of the raw material wire rod, actually C72DA; the production line settings are: speed ①: 47 m / min, number of steel wires ②: 64; average copper content ⑤: 62.99%, average coating weight ⑥: 4.52%; target copper content ⑦: 63.3%; target weight ⑧: 4.4%; copper content control limit: ±0.3%, weight control limit: ±0.1 g / kg, control limits are specified by the factory. The batch shown below contains 1.53mm steel wire with copper content and coating weight exceeding the control limits, requiring adjustment. The foreman's adjustment process is as follows... Figures 2-4 This adjustment process was based on experience, and there were issues with making corrections after calculation. The results calculated based on experience were: copper plating current ③: 6510A, zinc plating current ④: 3731A. Figure 2 The on-site adjustments were not entirely based on the calculation results), and the following occurred after the adjustments: Figure 4 The results are shown.

[0032] When using the solution of this invention, the system will automatically make the following adjustments based on existing process parameters and laboratory reports: The following formula needs to be used to adjust the amount of copper and the weight of the plating: New copper plating current = (Standard copper content / Actual copper content) * Original copper plating current New current for galvanizing = Original current for copper plating - New current for copper plating + Original current for galvanizing New Copper Plating Current 2 = Standard Weight / Actual Weight * New Copper Plating Current 1 New galvanizing current 2 = Standard weight / Actual weight * New galvanizing current 1

[0033] The calculation process is as follows: The new current for copper plating is calculated as follows: 63.3 / 62.99 * 6584 = 6616A New current for galvanizing = 6584 - 6616 + 3773 = 3741A Plating copper new current two = 4.4 / 4.52*6616 = 6440A Plating zinc new current two = 4.4 / 4.52*3741 = 3641A The plating copper new current two / plating zinc new current two must be inputted as the adjusting current and automatically adjusted. In this process, there will be no calculation errors caused by human and no adjustment deviation caused by subjective adjustment.

[0034] The above detailed description of the preferred embodiments of the present application, however, it should be understood that the above description is for the purpose of illustration only and is not intended to limit the scope of the present application in any way. Those ordinarily skilled in the art can make substitutions or changes to certain features of the present application without departing from the spirit and scope of the present application, and these substitutions or changes should be considered to fall within the scope of protection of the claims of the present application.

Claims

1. A method of automatically adjusting the plating of copper on steel wire, characterized by, Comprising, Data collection: collect the process parameters of each specification of steel wire in the process of electroplating; Data processing: after the electroplating is completed, the steel wire enters the laboratory for detection of copper content and coating weight of the steel wire, and the production conditions are judged according to the detection results of the laboratory and the collected process parameters, and the current size is automatically adjusted according to the judgment results.

2. The method of automatically adjusting the coating of a copper plated steel wire of claim 1 wherein, When the copper content exceeds the preset range, the system adjusts the current size according to the following formula: New copper plating current = copper content standard / actual copper content * original copper plating current, New zinc plating current = original copper plating current - new copper plating current + original zinc plating current.

3. The method of automatically adjusting the coating of a copper plated steel wire of claim 1 wherein, When the coating weight exceeds the preset range, the system adjusts the current size according to the following formula: New copper plating current = coating weight standard / actual coating weight * original copper plating current, New zinc plating current = coating weight standard / actual coating weight * original zinc plating current.

4. The method of automatically adjusting the coating of a copper plated steel wire of claim 1 wherein, When both the copper content and the coating weight exceed the preset range, the system adjusts the current size according to the following formula: New copper plating current one = copper content standard / actual copper content * original copper plating current, New zinc plating current one = original copper plating current - new copper plating current + original zinc plating current, New copper plating current two = coating weight standard / actual coating weight * new copper plating current one, New zinc plating current two = coating weight standard / actual coating weight * new zinc plating current one.

5. The method of automatically adjusting the coating of copper clad steel wire of claim 1 wherein, The collected process parameters include original copper plating current, original zinc plating current, steel wire diameter, steel wire quantity, steel wire speed, length of copper plating tank, and length of zinc plating tank.

6. The method of automatically adjusting the coating of a copper plated steel wire as claimed in claim 5, wherein, The control system of the production line calculates the current density of the steel wire according to the collected process parameters and compares it with the system preset value. If it exceeds the range, an alarm signal is sent out.

7. The method of automatically adjusting the coating of a copper plated steel wire as claimed in claim 6, wherein, The calculation method of the current density of the steel wire is as follows: Copper plating current density = original copper plating current (A) / (Π * steel wire diameter (mm) * length of copper plating tank (mm) * number of steel wire roots) * 10000, Zinc plating current density = original zinc plating current / (Π * steel wire diameter (mm) * length of zinc plating tank (mm) * number of steel wire roots) * 10000.

8. The method of automatically adjusting the coating of a copper plated steel wire of claim 5 wherein, The control system of the production line calculates the current efficiency of the steel wire according to the collected process parameters and the detection results of the laboratory, and compares it with the system preset value. If it exceeds the range, an alarm signal is sent out.

9. The method for automatically adjusting the coating of copper-plated steel wire according to claim 8, characterized in that, Copper plating current efficiency = 0.37 * actual copper content (%) * actual coating weight (g / kg) * steel wire speed (m / min) * steel wire diameter (mm) * steel wire diameter (mm) * number of steel wire roots / 1.185 / original copper plating current (A), 0.37 is a constant, and 1.185 is the electrodeposition constant of copper, with the unit of g / (A * h), g is the weight unit gram, A is the current unit ampere, and h is the time unit hour; Zinc plating current efficiency = 0.37 * (1 - actual copper content (%)) * actual coating weight (g / kg) * steel wire speed (m / min) * steel wire diameter (mm) * steel wire diameter (mm) * number of steel wire roots / 1.215 / original zinc plating current (A), 0.37 is a constant, and 1.215 is the electrodeposition constant of zinc, with the unit of g / (A * h), g is the weight unit gram, A is the current unit ampere, and h is the time unit hour.

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