Large-specification high-speed wire rod coil shape normalizing control method

Abstract

The invention relates to a large-specification high-speed wire rod coil shape normalizing control method. The method comprises a high-speed wire rod coil shape control technology and a surface quality extrusion and scratch prevention control technology. Firstly, the cloth ring stability of an intelligent pinch roll and a silking machine is accurately controlled in the previous procedure, and a solid foundation is laid for the subsequent procedure; secondly, in the process, the ring shape is regulated and controlled through a Stelmor line conveying roller way and a coil collecting station; and finally, a finishing procedure and an on-line bundling technology are utilized, regular forming of the ring shape is achieved, and surface protection control is strengthened. The phenomenon of poor ring shape in the production process of the large-specification high-speed wire rod is effectively improved, the problems of surface extrusion, scratching and the like of the large-specification high-speed wire rod are solved, and the surface quality of a product is remarkably improved.

Description

Technical Field

[0001] This invention relates to a method for controlling the coil shape regularity of large-diameter high-speed wire, belonging to the technical field of high-speed wire coil shape control. Background Technology

[0002] In recent years, with the continuous improvement of high-speed wire rod mill equipment technology and the expansion of application fields, the production and application of large-diameter (>Φ15mm spring steel, cold heading steel, tool steel, bearing steel, etc.) high-speed wire rods have seen broader development. However, after a series of processes including wire spinning on a spinning machine, transport on the Steyrmo line roller conveyor, collection at the coiling station, and finishing and bundling, large-diameter high-speed wire rods often exhibit numerous problems such as poor coil regularity, excessive wire height, uneven inner and outer diameters, uneven bale shape, and frequent mis-layering. These problems not only severely reduce the surface quality of large-diameter high-speed wire rods but also greatly affect the processing efficiency and satisfaction of downstream customers.

[0003] Patent application CN109759459A discloses a method for controlling the coil shape of slowly cooled steel wire. By utilizing increased pressure on the pinch rollers, adjustment of the wire feeder's support plate, and a speed-increasing ratio of the air-cooled roller conveyor for coil transport, the method ensures that both sides of the slowly cooled steel coil land on the support plate simultaneously during feeding, guaranteeing the stability of the coil shape as it falls. Simultaneously, the method appropriately increases the speed of each section of the air-cooled roller conveyor, ensuring uniform overall coil change and maintaining a neat coil shape during coiling. Taking welding wire as an example, the patent application increases the pressure on the pinch rollers of the slowly cooled steel wire to 2.5 MPa, adjusts the wire feeder's support plate to 45°, and increases the speed-increasing ratio of the air-cooled roller conveyor to 105%, ensuring the coil is evenly distributed on the air-cooled roller conveyor, thus achieving a neat coil shape. This invention focuses on the control of coiled fabric by the spinning machine, but for large-size high-speed wires that require controlled cooling, it lacks coil adjustment in the Steyrmo line transport rollers, winding stations and bundling processes, and cannot yet achieve real-time control of large-size coils, coil height and surface quality.

[0004] Patent application CN112275811A discloses a control method for improving coil shape and reducing coil height in high-speed wire rod production. By utilizing the oscillation function of the wire spinneret, the oscillation cycle is calculated to achieve periodic changes in coil shape during the spinning process. During winding, the wire rod is arranged in staggered patterns of different coil sizes, thus controlling both coil shape and coil height. Taking high-carbon chromium bearing steel as an example, under a fixed target coil height (1.2–1.7 m), the oscillation cycle is calculated using a oscillation cycle calculation formula. This controls the different specifications of large coils (≤1.3 m) and small coils (≥0.85 m) during the spinning process, resulting in a staggered arrangement of the wire rod during winding. While this invention focuses on the use of the oscillation function of the wire spinneret, it creates periodic peaks and troughs within the oscillation cycle. Furthermore, it lacks coil shape adjustment in processes such as the Steyrmo line transport rollers, winding station, and bundling, thus failing to achieve true real-time control of coil shape. In addition, due to the presence of peaks and troughs within the swing cycle, the wires develop periodic loops and layers, making them extremely prone to compression and abrasion during bundling.

[0005] Patent application CN114558895A discloses a method for controlling the shape regularity of high-strength wire coils. By adjusting process points such as the distance between the tail of the wire and the finishing mill when the pinch rollers are clamped high, the control of the coiled fabric by the coiler, and the size of the fan blades of the coil distributor, the method reduces air-blowing interference at the coil head, stabilizes the clamping force at the tail, and causes periodic fluctuations in the coiler speed, reducing the control of the coil by the coiler and thus reducing unevenness in the coil shape. Taking tool steel and carbon steel as examples, the method reduces unevenness in the coil shape by adjusting the distance between the tail of the wire and the finishing mill when the pinch rollers are clamped high (15–30 m), the limiting distance of the pinch roller rings (1.5–3.5 mm), the front and back blowing of the coiler, the response time of the coiler motor (25–100 s), the triangular wave fluctuation of the speed with a fluctuation period ≥15 s, and the size of the fan blades of the coil distributor (0–30 mm). This invention application focuses on the control of looped fabric by the spinning machine, but lacks the loop adjustment in the Stellmore line transport rollers, winding station and bundling processes, and cannot achieve the control of coil height.

[0006] In summary, current control of the coil shape regularity of large-diameter high-speed wire rods focuses on the control of the coil shape fabric by the spinning machine, supplemented by the pinch roller adjustment strategy, aiming to control the stability of the coil shape in the upstream process. However, there is a lack of control over the coil shape changes and surface quality protection in downstream processes such as Stellmore wire, winding station, finishing and bundling.

[0007] In view of this, this invention proposes an innovative control method for the regular coil shape of large-diameter high-speed wire from the perspective of whole-process design. Summary of the Invention

[0008] To address the aforementioned problems, this invention discloses a method for controlling the coil shape regularity of large-diameter high-speed wires, the specific technical solution of which is as follows: A method for controlling the coil shape regularity of large-specification high-speed wire rods, the control process is as follows: intelligent pinch roller process → wire feeding process → Steyrmo wire conveying process → coiling station collection process → finishing and bundling process → inspection process, specifically: Intelligent pinch roll process: The heated continuous casting billet is rolled sequentially through roughing mill, intermediate mill and sizing mill to form high temperature wire rod, and finally clamped and conveyed by intelligent pinch roll system; Wire spinning process: The high-temperature wire is conveyed to the wire spinning machine by the intelligent pinch roller. The wire spinning tube is wound and fixed on the wire spinning disc in a spiral shape. The wire spinning disc drives the wire spinning tube to rotate at a constant speed of 7-26 r / min. After the high-temperature wire passes through the wire spinning tube, it is thrown into the inlet section of the receiving conveyor roller below in a spiral shape. The Stellmore line conveyor process: The spiral-shaped high-temperature wire is laid out at equal intervals on the receiving conveyor rollers and moves forward continuously and stably, eventually forming a neatly coiled wire after cooling. Collection process at the coiling station: The telescopic roller conveyor at the exit section of the Stellmore line transports the spiral wire to the coiling station, where it is finally collected on the coiling drum to form a coil, which is then transported to the finishing and bundling process. Finishing and bundling process: When the surface temperature of the coil cools to the range of 60-100℃, spray lubricant evenly on the surface; trim 3-6 turns at the head and tail of each piece of wire; in the bundling process, perform two compression operations. In the first pre-compression stage, apply 4-6 tons of pressure to pre-compress and initially gather the wire into shape; in the second normal compression stage, apply 20-25 tons of pressure for final compaction and bundling. After bundling, the coil height is 1.4-1.7m and the outer diameter of the coil is 1.2-1.4m. Inspection process: Surface quality, cold heading performance and eddy current testing are performed on the wire.

[0009] Furthermore, the intelligent pinch roller system includes a clamping system, a transmission system, and a speed control system; The clamping system includes a roller ring clamping device and a pneumatic proportional system. The roller ring clamping device automatically adjusts the clamping force according to the changes in the diameter and material of the wire, and the pneumatic proportional system dynamically adjusts the roller ring clamping force. The transmission system includes a transmission gear and a transmission motor. The transmission motor provides power, which is transmitted to the roller ring through the transmission gear to drive the roller ring to rotate, thereby achieving speed and torque control. The speed control system includes a PLC and a transmission speed control system. The PLC is responsible for logic operations and instruction sending, while the transmission speed control system adjusts the speed of the transmission motor to achieve dynamic adjustment of the roller ring rotation.

[0010] Furthermore, in the intelligent pinch roller process, the signal acquisition cycle is 10-20ms, the speed lead coefficient is 2-4%, the tail speed increase is 25-35m / s, the torque limit is 10-30%, the tail high clamping torque is 40-65%, and the head low clamping torque is 35-50%.

[0011] Furthermore, in the spinning process, the spinning machine is horizontal and forms a 20° inclination angle with the rolling line; The spinning temperature for different wire specifications is as follows: 875-905℃ for Φ16-20mm wire and 885-915℃ for Φ21-26mm wire; the spinning machine has a swing function with a swing cycle of 3-6s; after installing and debugging the spinning machine and replacing the new spinning tube, a dynamic balance test is performed, and the vibration test is less than 0.1mm / s.

[0012] Furthermore, the spinning tube is made of 10Cr9Mo1VNi steel and its surface is coated with tungsten carbide; the spinning tube has an outer diameter of Φ48mm, an inner diameter of Φ34mm, and a coil diameter of Φ1075mm.

[0013] Furthermore, in the Steilmo line conveying process, the Steilmo line includes three sections of roller conveyors: an inlet section, a conveying section, and an outlet section. The conveying section includes several segments, and the roller conveyor speed is 0.15 to 0.50 m / s, with an initial speed increase of 10 to 20% followed by a speed decrease of 10 to 25%. Rolling centering rollers are symmetrically arranged on both sides of the roller conveyor at the beginning and end of the first section of the conveyor section, the beginning and end of other non-adjacent sections, and the end of the exit section. Several sections in the middle and rear of the conveyor roller conveyor are set as drop sections; The last set of rollers in the exit section adopts a movable design. Several rollers in the exit section are broken in the middle and set on both sides of the exit section. The length of the break from the exit section to the front becomes smaller and smaller, forming a semi-circular arc space. The semi-circular arc space connects to the outside of the collecting drum.

[0014] Furthermore, in the Steilmo line conveying process, the wire is cooled to 600-650°C after passing through the Steilmo line, and the conveying section is divided into eleven sections; symmetrically arranged rolling centering rollers are installed on both sides of the roller conveyor at the beginning and end of sections 1, 3, 6, 8, and 10 of the conveying section roller conveyor and at the end of the exit section; drop sections are set in sections 3, 5, 8, 9, and 10 of the conveying section roller conveyor, with a drop height of 250mm; the last set of rollers in the exit section is displaced towards the collecting drum, and its penetration into the collecting drum is 30% to 45%; after being conveyed by the Steilmo line, the wire is finally collected into a coil by the vertical collecting station.

[0015] Furthermore, the collection station process completes the transformation of the wire's spatial state, from a horizontally laid-out state to a coaxial spiral coil with a vertical central axis, and then rotates the central axis of the coil to a horizontal state before transporting it to the subsequent process via a C-shaped hook. The collecting process at the coil station includes a coil drum, a mandrel, a double-arm mandrel, a nose cone, a lifting pallet, and a separating claw. The coil drum is a hollow cylinder that runs vertically through the coil. The mandrel is coaxially located inside the coil drum, the nose cone is located at the top of the mandrel, and the double-arm mandrel is coaxially located inside the mandrel and can move up and down. The lifting pallet surrounds the mandrel, and the lifting stroke extends from the top of the nose cone to the bottom of the mandrel. The separating claw is located below the lifting pallet and includes two symmetrical pallets. When the coil descends and aligns with the separating claw, the two pallets open, allowing the coil to fall onto the separating claw. The separating claw and the double-arm mandrel descend synchronously, and the coil is placed on the double-arm mandrel, rotated, and flattened before being transported to the next process.

[0016] Furthermore, the collecting drum adopts a steel structure component with an inner diameter of 1250mm and a double-arm mandrel diameter of 850mm. The nose cone is used to position the starting position of the wire and guide the coil to fall onto the lifting tray and mandrel. The lifting tray includes two that are used alternately. After one tray receives the wire, it continues to descend to dock with the separating claw, while the other tray goes up to receive the new wire. During the descent of the lifting tray, by controlling a delay of 5 to 20 seconds and a speed of 30 to 45 mm / s, the height difference between the exit section telescopic roller conveyor and the lifting tray is 0.6 to 0.8m. The wire can fall simultaneously at both ends near and away from the telescopic roller conveyor, and the height gradually decreases as the wire accumulates.

[0017] The beneficial effects of this invention are: (1) Multi-stage coil control strategy throughout the entire production process. Relying on the intelligent pinch roller system and precise yarn spinning, combined with the real-time collaborative fine-tuning mechanism of the Stellmore line and the coiling station, and supplemented by step-by-step bundling control measures such as pre-tightening and normal tightening, a multi-stage coil control strategy is constructed that runs through the entire production process. This strategy can significantly reduce or even eliminate the irregularity of coils in large-specification high-speed wire rods, ensuring dense and neat coil arrangement, thereby laying a solid foundation for product quality.

[0018] (2) Surface quality optimization strategy. On the one hand, a series of coil regularization control technologies are adopted to strictly control the geometric shape from the initial stage of wire forming, so as to achieve the regularity and density of the coil shape of the wire during the spinning and conveying process; on the other hand, in the finishing process, the friction risk caused by the relative displacement between coils is fully considered. The residual heat of the wire is cleverly used in the finishing process to spray lubricant in a timely manner to form a uniform and stable lubricating film; at the same time, two compression and bundling modes are introduced. The first pre-compression initially fixes the position of the wire, and the second normal compression achieves tight bundling, ensuring the stable and controllable surface quality of large-specification high-speed wire during the circulation process.

[0019] (3) Processing and production efficiency has been significantly improved. Thanks to the regularity of the coil shape and the surface quality of the large-specification high-speed wire rod under the whole process quality control, the cold heading inspection pass rate is ≥98.7%. At the same time, the number of defects in the eddy current test (0.05mm defect equivalent) of the wire rod products is controlled within 10 per ton of steel, which enables the downstream customers' production lines to operate at high speed and stably, and the processing and production efficiency has been significantly improved. Attached Figure Description

[0020] Figure 1 This is a top view of the junction between the conveyor roller conveyor and the collecting station at the exit section of the Steilmo line.

[0021] Figure 2 This is an example of a regular package shape for high-speed wire.

[0022] Attached reference numerals: 1—Stelmo line exit section conveyor roller, 2—nose cone, 3—mandrel, 4—collecting drum. Detailed Implementation

[0023] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention.

[0024] This invention, firstly, precisely controls the stability of the coil fabric produced by the intelligent pinch rollers and the spinning machine in the preceding process, laying a solid foundation for subsequent processes; secondly, it achieves coil shape control through the Stellmore line transport roller conveyor and coiling station during the process; finally, it utilizes finishing processes and online bundling technology to achieve regular coil shape formation and enhance surface protection control. This innovative method, through end-to-end control, significantly improves the uniformity and regularity of the coil shape, effectively solving common problems in traditional processes such as uneven inner and outer diameters, uneven wrapping, and frequent layering misalignment, thereby ensuring that large-diameter, high-speed wire rods possess excellent coil shape and surface protection effects. For details on these optimization measures, please refer to... Figure 2 This not only achieves the regularity of the coil shape, but also significantly improves the surface protection quality of the wire, providing a favorable guarantee for subsequent processing steps such as laying, flaw detection and drawing of large-diameter high-speed wire, thereby improving the customer's processing and production efficiency and satisfaction.

[0025] The specific process of this invention is as follows: Intelligent pinch roll process: The heated continuous casting billet is rolled sequentially through a roughing mill, an intermediate mill, and a reducing and sizing mill. Finally, it is stably clamped and conveyed by an intelligent pinch roll system. The intelligent pinch roll system includes a clamping system (roller ring clamping device and pneumatic proportional system), a transmission system (transmission gears and transmission motor), and a speed control system (PLC and transmission speed control system). The signal acquisition cycle is 10~20ms, the speed lead coefficient is 2~4%, the tail acceleration is 25~35m / s, the torque limit is 10~30%, the high clamping torque at the tail is 40~65%, and the low clamping torque at the head is 35~50%. The process parameters can be finely adjusted in real time according to the incoming material conditions. The objectives are: first, the intelligent pinch roll system can reduce damage to the rolled material (wire) during the conveying process, thereby improving product quality and yield; second, the intelligent pinch roll has an adaptive adjustment function, which can automatically adjust the clamping force according to changes in the diameter and material of the rolled material (wire), ensuring the stability of the conveying process and thus improving production efficiency; third, the intelligent pinch roll, through the integration of sensors and analysis and control systems, can achieve high-precision control and intelligent monitoring of the wire; and fourth, the intelligent pinch roll, by matching the speed of the spinning machine, can achieve control over the coil shape of the wire.

[0026] Spinning Process: High-temperature wire is conveyed to the spinning machine by intelligent pinch rollers, and wound onto the spinning reel at a constant speed of 7~26 r / min and in a specific shape through the spinning tube. It is then spirally dropped onto the receiving conveyor rollers below. The purpose is threefold: first, to increase the thickness of the oxide scale on the wire surface through high-temperature spinning, thereby improving the protective effect of the oxide scale on the substrate; second, to improve the high-temperature resistance, wear resistance, and service life of the spinning tube by selecting high-performance spinning tube materials and spraying treatment; and third, to improve phenomena such as spinning ring shape, reel height, and bundling misalignment by optimizing the design and settings of the spinning machine, ensuring the stability and consistency of the ring shape during the spinning process.

[0027] Stellmore wire conveying process: The high-temperature wire is received by the receiving roller conveyor (entry section) under the throwing action of the spinning machine, and moves forward continuously and stably on the roller conveyor in the form of being spread out at equal intervals. In this process, the Steilmo line is 113m long and is divided into three sections of roller conveyors: the inlet section, the conveyor section, and the outlet section, based on their functional characteristics. The conveyor section is further subdivided into eleven sections to ensure the transmission of the wire. The roller conveyor speed is 0.15~0.50m / s and is designed to increase speed first (10~20%) and then decrease speed (10~25%) to meet the needs of wire cooling and coiling. At key locations on the Steilmo line, such as the beginning and end of sections 1, 3, 6, 8, and 10 of the conveyor section and the end of the outlet section, rolling centering rollers are installed to ensure wire centering and coiling. Drop sections are set at sections 3, 5, 8, 9, and 10 of the conveyor section, with a drop height of 250mm, to optimize the wire shape. The Steilmo line's outlet section conveyor roller conveyor 1 adopts a movable design, which can flexibly move towards the winding drum, and its depth into the winding drum can reach 30% to 45%, providing convenience for subsequent wire processing. After being transported via the Stellmore line, the wire is eventually collected by the vertical winding station. The purpose of this is fourfold: first, to optimize the microstructure through controlled cooling in the early stages and to standardize the coil shape in the later stages; second, to adjust the coil shape to achieve consistency; third, to avoid wire accumulation and cross-snagging, maintaining the regularity of the coil's movement; and fourth, to promote the uniform and stable descent of the coil, preparing it for the winding process.

[0028] Collection process at the coiling station: At the Stellmore line's exit section, the telescopic roller conveyor transports the wire to the coiling station. During this stage, the wire undergoes a spatial transformation, changing from an initial horizontal to a vertical position, and then back to a horizontal position. Finally, it is collected and organized on the coiling drum, becoming a uniform and neat coil, and then smoothly transferred to the C-hook for subsequent processing. The coiling station is a core unit of this critical process; see [link to relevant documentation]. Figure 1The winding station's collection process includes a winding drum (4), a mandrel (3), a double-arm mandrel, a nose cone (2), a lifting platform, and separation claws. The winding drum is a cylindrical steel structure with an inner diameter of 1250mm, providing space for the wire and ensuring stable positioning during winding, preventing displacement and entanglement. The double-arm mandrel, with a diameter of 850mm, supports the wire, ensuring it maintains a stable shape during winding and preventing deformation or loosening. The nose cone positions the wire at its starting point, guiding the coil onto the lifting platform and mandrel. The lifting platform carries the wire; during its descent, precise control of the delay (5-20s) and speed (30-45mm / s) ensures a smooth and orderly descent. Meanwhile, the height difference between the telescopic roller conveyor and the lifting pallet at the exit section is 0.6~0.8m. This design allows the wire to fall simultaneously at both ends, near and far from the telescopic roller conveyor, gradually decreasing in height as the wire accumulates, effectively preventing tangling and tilting. Finally, after winding is complete, the separating claws intervene promptly to firmly support the wire, preventing it from loosening or shifting due to loss of support. The purpose is threefold: first, to ensure the efficiency and stability of the winding process; second, to achieve a uniform and dense arrangement of coils, maintaining a stable shape; and third, to ensure that both ends of the coil fall simultaneously, preventing tilting.

[0029] Finishing and Bundling Process: For the neatly arranged wire collected at the coiling station, when the surface temperature of the wire cools to the range of 60~100℃, lubricant is evenly sprayed onto the surface to reduce mutual compression and friction damage between coils. Simultaneously, based on the defects at the head and tail of the wire, 3~6 turns are trimmed at the head and tail of each piece of wire to remove potential surface defects and ensure the stability and consistency of the overall quality of the wire. In the bundling process, two compression operations are implemented. In the first pre-compression stage, 4~6 tons of pressure are used for pre-compression to initially gather and shape the wire. In the second normal compression stage, 20~25 tons of pressure are applied for final compaction and bundling. After bundling, the wire coil height is 1.4~1.7m, and the outer diameter is 1.2~1.4m. The purpose is: firstly, to remove surface defects at the head and tail of the wire; secondly, to optimize the sliding friction between the coils, reducing the probability of bundling compression defects; and thirdly, to ensure that the wire is densely gathered, forming a neat and consistent bundle shape, laying the foundation for subsequent processes.

[0030] Inspection Process: Inspection is conducted on wire rods and their products to ensure that surface quality, cold heading performance, and eddy current testing results all meet the usage standards. The cold heading pass rate for large-diameter high-speed wire rods is consistently above 98.7%. Wire rod products are tested using a 0.05mm defect equivalent, with fewer than 10 defects per ton of steel detected by eddy current testing. The purpose is to verify whether the coil regularity and surface quality of the high-speed wire rod meet the standards, providing data support for subsequent processing and applications.

[0031] By integrating and optimizing processes such as intelligent pinch rollers, wire feeding, and bundling, the system successfully controlled the coil shape regularity of large-diameter high-speed wire rods. Testing and application verification have shown that this not only significantly improved the coil quality of large-diameter high-speed wire rods but also effectively reduced surface extrusion and abrasion defects caused by coil shape issues.

[0032] The following are six specific implementation examples: The production process for Examples 1-6 is as follows: intelligent pinch roller process → wire feeding process → Steyrmo wire conveying process → coiling station collection process → finishing and bundling process → inspection process. Taking Example 2, Φ18mm 55SiCr spring steel high-speed wire rod, as an example: (1) Intelligent pinch roll process: The heated continuous casting billet is rolled sequentially through the roughing mill, intermediate mill and sizing mill, and finally stably clamped and conveyed by the intelligent pinch roll system. The intelligent pinch roll signal acquisition cycle is 10ms, the speed lead coefficient is 3%, the speed after the tail speed-up is 28m / s, the torque limit is 15%, the high clamping torque at the tail is 55%, the low clamping torque at the head is 40%, and the process parameters can be finely adjusted in real time according to the incoming material conditions.

[0033] (2) Wire spinning process: The high-temperature wire is wound onto the spinning reel at a constant speed of 19 r / min and in a specific shape through the spinning tube, and then thrown into the receiving conveyor rollers below in a spiral shape. In this process, the horizontal spinning machine forms a 20° inclination angle with the rolling line; the spinning tube is made of 10Cr9Mo1VNi steel and is coated with tungsten carbide wear-resistant coating; the specifications of the spinning tube are: outer diameter Φ48mm, inner diameter Φ34mm, and the diameter of the spun coil is Φ1075mm; the spinning temperature of the high-speed wire is 890℃; the oscillation cycle of the spinning machine is 3s; the vibration of the spinning tube during production is detected at 0.07mm / s.

[0034] (3) Stellmore wire conveying process: The high-temperature wire is received by the receiving roller (entry section) under the throwing action of the spinning machine, and moves forward continuously and stably on the roller in the form of spreading at equal intervals. The roller conveyor speed is 0.35m / s→0.50m / s→0.20m / s, and it advances by first increasing the speed (10~15%) and then decreasing the speed (10~20%), as detailed in Table 4. The speed increase is every two roller conveyor sections, 18.5m; the speed decrease is every one roller conveyor section, 9.25m, to accommodate the cooling and coiling requirements of the wire. Rolling centering rollers are installed at the beginning and end of sections 1, 3, 6, 8, and 10 of the conveyor section roller conveyor and at the end of the exit section to ensure the centering and coiling of the wire. Drop sections with a drop height of 250mm are set in sections 3, 5, 8, 9, and 10 of the conveyor section roller conveyor to optimize the wire shape. The last set of rollers in the exit section extends 30% into the winding drum to facilitate subsequent processing of the wire.

[0035] (4) Collection process at the coiling station: The telescopic roller conveyor at the exit section of the Stellmore line transports the wire to the coiling station. The height difference between the telescopic roller conveyor at the exit section and the lifting pallet is 0.75m, ensuring that the wire can fall simultaneously at both ends near and away from the telescopic roller conveyor. The coiling drum adopts a cylindrical steel structure component with an inner diameter of 1250mm. The double-arm mandrel is used to support the wire and has a diameter of 850mm. The nose cone is used to position the starting position of the wire and guide the coil to fall onto the lifting pallet and mandrel. The lifting pallet is used to carry the wire and is divided into an upper pallet and a lower pallet. The pallet descends with a delay of 7s. The descending speed of the upper pallet is 32mm / s and the descending speed of the lower pallet is 36mm / s, ensuring that the wire can descend smoothly and orderly.

[0036] (5) Finishing and bundling process: When the surface temperature of the wire cools to 95°C, lubricant is sprayed evenly on its surface. At the same time, defects are cut off for each piece of wire with 4 turns at the head and 5 turns at the tail. In the bundling process, two compression operations are carried out. First, 5 tons of pressure is used for pre-compression to make the wire initially gather and form; then 21 tons of pressure is applied for final compaction and bundling. After bundling, the wire coil height is 1.55m and the outer diameter of the wire is 1.3m.

[0037] (6) Inspection process: The surface inspection of Φ18mm 55SiCr spring steel high-speed wire rod is qualified, no extrusion scratches are found, the cold heading qualification rate is 99.1%, and the number of defect points in the eddy current test (0.05mm defect equivalent) of the wire rod product is 7.

[0038] The process of Examples 1 and 3-6 is the same as that of Example 2, and the differences are listed in Tables 1-6.

[0039] Table 1 shows the steel grades for high-speed wire rods in Examples 1-6.

[0040] Table 2 shows the intelligent pinch roller process for high-speed wire rods in Examples 1-6.

[0041] Table 3 shows the high-speed wire spinning process in Examples 1-6.

[0042] Table 4 shows the roller speeds of the high-speed wire rod Stellmore line in Examples 1-6.

[0043] Table 5 shows the changes in the Stellmore line roller conveyor for high-speed wire rods in Examples 1-6.

[0044] Table 6 shows the high-speed wire coiling process in Examples 1-6.

[0045] Table 7 shows the finishing and bundling processes for high-speed wires in Examples 1-6.

[0046] Table 8 shows the inspection results of high-speed wires in Examples 1-6.

[0047] Table 1. Details of high-speed wire rod steel grades in Examples 1-6

[0048] Table 2. Intelligent pinch roller process for high-speed wire rods in Examples 1-6

[0049] Table 3 High-speed wire spinning process in Examples 1-6

[0050] Table 4. Roller speeds of high-speed wire rods in Examples 1-6 (Stelmo Line)

[0051] Table 5. Variations in the high-speed wire rod roller conveyor of Examples 1-6, Steyrmo Wire

[0052] Table 6 High-speed wire coiling process in Examples 1-6

[0053] Note ①: The height difference between the telescopic roller conveyor and the lifting pallet at the exit section of the Steilmo line.

[0054] Table 7 High-speed wire finishing and bundling processes in Examples 1-6

[0055] Table 8. Inspection results of high-speed wires in Examples 1-6

[0056] Those skilled in the art will understand that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have the same meaning as in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless defined as herein.

[0057] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A method for controlling the coil shape regularity of large-diameter high-speed wire, characterized in that, The control process is as follows: intelligent pinch roller process → yarn feeding process → Steyrmo line conveying process → coil collection station → finishing and bundling process → inspection process, specifically: Intelligent pinch roll process: The heated continuous casting billet is rolled sequentially through roughing mill, intermediate mill and sizing mill to form high temperature wire rod, and finally clamped and conveyed by intelligent pinch roll system; Wire spinning process: The high-temperature wire is conveyed to the wire spinning machine by the intelligent pinch roller. The wire spinning tube is wound and fixed on the wire spinning disc in a spiral shape. The wire spinning disc drives the wire spinning tube to rotate at a constant speed of 7-26 r / min. After the high-temperature wire passes through the wire spinning tube, it is thrown into the inlet section of the receiving conveyor roller below in a spiral shape. The Stellmore line conveyor process: The spiral-shaped high-temperature wire is laid out at equal intervals on the receiving conveyor rollers and moves forward continuously and stably, eventually forming a neatly coiled wire after cooling. Collection process at the coiling station: The telescopic roller conveyor at the exit section of the Stellmore line transports the spiral wire to the coiling station, where it is finally collected on the coiling drum to form a coil, which is then transported to the finishing and bundling process. Finishing and bundling process: When the surface temperature of the coil cools to the range of 60-100℃, spray lubricant evenly on the surface; trim 3-6 turns at the head and tail of each piece of wire; in the bundling process, perform two compression operations. In the first pre-compression stage, apply 4-6 tons of pressure to pre-compress and initially gather the wire into shape; in the second normal compression stage, apply 20-25 tons of pressure for final compaction and bundling. After bundling, the coil height is 1.4-1.7m and the outer diameter of the coil is 1.2-1.4m. Inspection process: Surface quality, cold heading performance and eddy current testing are performed on the wire.

2. The method for controlling the coil shape regularity of large-diameter high-speed wires according to claim 1, characterized in that, The intelligent pinch roller system includes a clamping system, a transmission system, and a speed control system; The clamping system includes a roller ring clamping device and a pneumatic proportional system. The roller ring clamping device automatically adjusts the clamping force according to the changes in the diameter and material of the wire, and the pneumatic proportional system dynamically adjusts the roller ring clamping force. The transmission system includes a transmission gear and a transmission motor. The transmission motor provides power, which is transmitted to the roller ring through the transmission gear to drive the roller ring to rotate, thereby achieving speed and torque control. The speed control system includes a PLC and a transmission speed control system. The PLC is responsible for logic operations and instruction sending, while the transmission speed control system adjusts the speed of the transmission motor to achieve dynamic adjustment of the roller ring rotation.

3. The method for controlling the coil shape regularity of large-diameter high-speed wires according to claim 1, characterized in that, The intelligent pinch roller process has a signal acquisition cycle of 10-20ms, a speed lead coefficient of 2-4%, a tail speed increase of 25-35m / s, a torque limit of 10-30%, a tail high clamping torque of 40-65%, and a head low clamping torque of 35-50%.

4. The method for controlling the coil shape regularity of large-diameter high-speed wire according to claim 1, characterized in that, In the spinning process, the spinning machine is horizontal and forms a 20° inclination angle with the rolling line; The spinning temperature for different wire specifications is as follows: 875-905℃ for Φ16-20mm wire and 885-915℃ for Φ21-26mm wire; the spinning machine has a swing function with a swing cycle of 3-6s; after installing and debugging the spinning machine and replacing the new spinning tube, a dynamic balance test is performed, and the vibration test is less than 0.1mm / s.

5. The method for controlling the coil shape regularity of large-diameter high-speed wire according to claim 1, characterized in that, The spinning tube is made of 10Cr9Mo1VNi steel and is coated with tungsten carbide. The spinning tube has an outer diameter of Φ48mm, an inner diameter of Φ34mm, and a coil diameter of Φ1075mm.

6. The method for controlling the coil shape regularity of large-diameter high-speed wire according to claim 1, characterized in that, In the Steilmo line conveying process, the Steilmo line includes three sections of roller conveyors: an inlet section, a conveying section, and an outlet section. The conveying section includes several segments, and the roller conveyor speed is 0.15 to 0.50 m / s, with an initial speed increase of 10 to 20% followed by a speed decrease of 10 to 25%. Rolling centering rollers are symmetrically arranged on both sides of the roller conveyor at the beginning and end of the first section of the conveyor section, the beginning and end of other non-adjacent sections, and the end of the exit section. Several sections in the middle and rear of the conveyor roller conveyor are set as drop sections; The last set of rollers in the exit section adopts a movable design. Several rollers in the exit section are broken in the middle and set on both sides of the exit section. The length of the break from the exit section to the front becomes smaller and smaller, forming a semi-circular arc space. The semi-circular arc space connects to the outside of the collecting drum.

7. The method for controlling the coil shape regularity of large-diameter high-speed wires according to claim 6, characterized in that, In the Steilmo line conveying process, the wire is cooled to 600-650°C after passing through the Steilmo line, and the conveying section is divided into eleven sections. Rolling centering rollers are symmetrically arranged on both sides of the roller conveyors at the beginning and end of sections 1, 3, 6, 8, and 10 of the conveying section roller conveyor and at the end of the exit section. Drop sections are set in sections 3, 5, 8, 9, and 10 of the conveying section roller conveyor, with a drop height of 250mm. The last set of rollers in the exit section is displaced towards the collecting drum, penetrating 30% to 45% of the drum. After being conveyed by the Steilmo line, the wire is finally collected into a coil by the vertical collecting station.

8. The method for controlling the coil shape regularity of large-diameter high-speed wire according to claim 1, characterized in that, The collecting station process completes the transformation of the wire's spatial state, from a horizontally laid-out state to a coaxial spiral coil with a vertical central axis, and then rotates the central axis of the coil to a horizontal state before transporting it to the subsequent process via a C-shaped hook. The collecting process at the coil station includes a coil drum, a mandrel, a double-arm mandrel, a nose cone, a lifting pallet, and a separating claw. The coil drum is a hollow cylinder that runs vertically through the coil. The mandrel is coaxially located inside the coil drum, the nose cone is located at the top of the mandrel, and the double-arm mandrel is coaxially located inside the mandrel and can move up and down. The lifting pallet surrounds the mandrel, and the lifting stroke extends from the top of the nose cone to the bottom of the mandrel. The separating claw is located below the lifting pallet and includes two symmetrical pallets. When the coil descends and aligns with the separating claw, the two pallets open, allowing the coil to fall onto the separating claw. The separating claw and the double-arm mandrel descend synchronously, and the coil is placed on the double-arm mandrel, rotated, and flattened before being transported to the next process.

9. The method for controlling the coil shape regularity of large-diameter high-speed wire according to claim 8, characterized in that, The collecting drum is made of steel structure with an inner diameter of 1250mm and a double-arm mandrel diameter of 850mm. The nose cone is used to position the starting position of the wire and guide the coil to fall onto the lifting tray and mandrel. There are two lifting trays that are used alternately. After one tray receives the wire, it continues to descend to connect with the separating claw, while the other tray goes up to receive the new wire. During the descent of the lifting tray, by controlling the delay of 5 to 20 seconds and the speed of 30 to 45 mm / s, the height difference between the exit section telescopic roller and the lifting tray is 0.6 to 0.8m. The wire can fall simultaneously at both ends that are close to and away from the telescopic roller, and the height gradually decreases as the wire accumulates.

Images