A kind of heavy brushing device for improving galvanizing platability

Abstract

The application discloses a heavy brushing device for improving galvanizing platability, and belongs to the technical field of strip steel pretreatment in a galvanizing production line. The device comprises a closed frame, two-stage grading pressure brush roller groups, an eccentric variable-frequency vibration unit in the roller, an eccentric counterweight compensation unit, an intermediate ultrasonic cleaning unit, a waste residue vibration flow guide unit and an intelligent electric control unit; an ultrasonic array is arranged between the two-stage brush rollers to remove stripped iron oxide powder in real time; a variable-frequency vibrator is arranged in the shaft core of the brush roller, and cooperates with an arc-shaped eccentric block to strip the embedded iron oxide scale in a high-frequency stripping groove; when the device is stopped, double counterweight compensators offset the eccentric centrifugal force; and a vibration slag guide plate at the bottom of the frame automatically collects waste residues. A matching process sequentially completes pickling / alkali cleaning, grading vibration heavy brushing, ultrasonic online purification, rinsing and drying, and galvanizing forming. The application can significantly improve the surface quality and production efficiency of the galvanized plate and reduce the production cost.

Description

Technical Field

[0001] This invention pertains to the production process of surface treatment of strip steel in galvanizing production lines, specifically relating to a re-brushing device for improving the galvanization applicability. Background Technology

[0002] After the raw materials in the galvanizing production line are pickled or alkali-washed, there are inclusions and iron oxide scale on the surface of the strip steel. In particular, the roller rings of the hot rolling heating furnace scratch the surface of the strip steel, causing new iron oxide scale to form in the scratched areas. Even after high-pressure descaling during hot rolling, the scale remains. The iron oxide scale generated in the scratched grooves is difficult to remove. After pickling, it is used as the base material for cold rolling or galvanized products. After galvanizing, the iron oxide scale in severely affected areas becomes more obvious due to the obstruction of the formation of the zinc-iron alloy layer, resulting in linear defects in the product. Even with current re-brushing equipment, it cannot be effectively eliminated.

[0003] The cleaning effect of brush rollers directly affects the surface quality of products and the efficiency of subsequent processes. Traditional brush roller cleaning methods suffer from problems such as uneven cleaning and incomplete removal of dirt. These defects lead to numerous complaints from downstream customers, with serious quality objections resulting in compensation claims. This, in turn, causes technical problems such as low production efficiency and unstable product quality.

[0004] The main reason why conventional heavy brush roller cleaning is currently ineffective is: 1. Insufficient scrubbing force: Ordinary brush rollers rely only on static pressure friction, making it difficult to peel off the iron oxide scale deep in the grooves. This hinders the uniform growth of the zinc-iron alloy layer during galvanizing, resulting in continuous linear defects in the finished product and triggering customer quality claims. 2. Secondary adhesion of dirt: When a single set of brush rollers continuously brushes, the brush bristles carry iron oxide powder and repeatedly rub against the board surface, resulting in uneven cleaning. Furthermore, there is no intermediate purification process, causing the bristles to wear out quickly and the cleaning efficiency to continuously decrease. 3. Imbalanced vibration conditions and poor controllability: A few brush rollers with vibration function use external vibration motors, resulting in large vibration transmission losses; after the machine stops, the eccentric block continues to generate centrifugal force, causing the brush roller to rotate and jump, and scratching the plate surface; there is no real-time detection and automatic compensation structure, making it unable to adapt to strip steel of different materials and different levels of dirt. Summary of the Invention

[0005] This invention provides a re-brushing device to improve the galvanization plating properties, with the aim of improving the existing brush roller cleaning structure and process to enhance the cleaning effect of the re-brushing brush roller.

[0006] Therefore, the present invention adopts the following technical solution: A re-brushing device for improving galvanization plating properties includes a closed re-brushing frame, a two-stage re-brushing roller group arranged sequentially along the strip travel direction, an ultrasonic online cleaning unit, an eccentric vibration unit inside the roller, an eccentric counterweight compensation unit, a waste slag vibration guiding unit, and an electrical control and monitoring unit. The two-stage heavy brush roller group includes a front brush roller group and a rear brush roller group. The working pressure of the front brush roller group is greater than that of the rear brush roller group. Each heavy brush roller has a hollow steel core structure, and corrosion-resistant combined brush blades are assembled on the outside of the steel core. The working side shaft and the drive side shaft of the brush roller have built-in working side vibrators and transmission side vibrators, respectively. The roller-mounted eccentric vibration unit is a closed integrated structure, including a variable frequency vibration motor, a drive shaft, a vibration brake, an arc-shaped eccentric block, and an eccentric block position detector. The variable frequency motor drives the drive shaft to drive the arc-shaped eccentric block to generate high-frequency vibration, and the eccentric block position detector collects the eccentric block rotation angle signal in real time. The vibrator's cable is led out to an external control box through a drive-side slip ring. The eccentric counterweight compensation unit includes counterweight compensator A and counterweight compensator B symmetrically arranged inside the working side shaft of the brush roller; when the vibration operation stops, the eccentric block position detector positions the arc-shaped eccentric block to a fixed zero position, the vibration brake locks the transmission shaft, and the two sets of counterweight compensators counteract the centrifugal force generated by the arc-shaped eccentric block. The ultrasonic online cleaning unit is located between the front brush roller group and the rear brush roller group, and includes four sets of ultrasonic generators arranged in upper and lower layers, respectively corresponding to the cleaning of the upper and lower surfaces of the strip. The waste slag vibration guide unit includes left and right inclined guide plate vibrators located on both sides of the triangular inclined slag guide plate at the bottom of the closed re-brushing frame, which are used to shake the iron sheet washed off by the cooling water into the guide groove at the bottom of the frame. The electrical control and monitoring unit includes an external control box and a host computer. The control box is used to adjust the vibration frequency, brush roller pressure, and ultrasonic power in real time, and has the functions of fault self-diagnosis and automatic shutdown in case of abnormality.

[0007] Furthermore, the brush blades of the heavy brush roller are made of a polymer material resistant to acid and alkali corrosion.

[0008] Furthermore, the mounting base positions of the working-side vibrator and the transmission-side vibrator are adjustable to accommodate heavy brush rollers of different diameters and widths.

[0009] Furthermore, the closed re-brushing frame, the two-stage brush roller assembly, the ultrasonic online cleaning unit, and the in-roller eccentric vibration unit are all modular and can be disassembled and maintained individually.

[0010] Furthermore, the electrical control and monitoring unit is equipped with a communication interface, which enables process linkage control with the pickling tank, rinsing tank, and drying equipment of the galvanizing production line.

[0011] The design principle of this invention is as follows: 1. Two-stage graded heavy brush roller assembly The closed re-brushing machine frame is equipped with two sets of opposing brush rollers: the front brush roller set includes the front upper brush roller and the front lower brush roller, and the rear brush roller set includes the rear upper brush roller and the rear lower brush roller. The front brush roller is set to a higher working pressure than the rear brush roller. It first uses high pressure to peel off large pieces of iron oxide scale, and then uses low pressure to finely polish the plate surface.

[0012] 2. In-roller eccentric frequency conversion vibration unit The working-side vibrator is a closed integrated structure, including a variable frequency vibration motor, a drive shaft, a brake, an arc-shaped eccentric block, and an eccentric block position detector. The variable frequency motor drives the drive shaft to rotate, causing the arc-shaped eccentric block to generate radial high-frequency vibration, with a vibration frequency range of 20kHz~40kHz. The eccentric block position detector collects the eccentric block's rotation angle position signal in real time. The power cables and detection signal lines of the drive-side and working-side vibrators are led out through the drive-side slip ring to prevent the rotating brush roller cables from tangling.

[0013] 3. Eccentric counterweight compensation unit The brush roller has two symmetrically arranged counterweight compensators, A and B, inside the working side shaft. When the process does not require vibration, the position detector positions the arc-shaped eccentric block to a fixed zero position, the brake locks the drive shaft, and the two sets of counterweight compensators synchronously counteract the remaining centrifugal force of the eccentric block, eliminating the high-speed rotation and jumping of the brush roller.

[0014] 4. Intermediate ultrasonic online cleaning unit A double-layer ultrasonic generator array is arranged between the two-stage brush roller group: the upper ultrasonic generators A and C correspond to the upper surface of the strip, and the lower ultrasonic generators B and D correspond to the lower surface of the strip; the ultrasonic generators output 20~40kHz ultrasonic waves to simultaneously cavitate and clean the upper and lower surfaces of the strip after the previous stage of brushing, instantly removing suspended iron oxide powder, avoiding secondary scratches on the plate surface by brush bristles carrying dirt, and reducing wear on the subsequent brush rollers.

[0015] 5. Waste residue vibration guide unit The bottom of the closed frame is equipped with a triangular inclined slag guide plate, and left and right inclined guide plate vibrators are installed on the left and right sides of the slag guide plate respectively. The iron oxide powder washed off by the high-pressure cooling water falls onto the slag guide plate. The vibrator continuously excites the slag, and the waste slag automatically slides down to the guide trough at the bottom of the frame for centralized collection, preventing the waste slag from accumulating and causing secondary pollution to the strip steel.

[0016] 6. Electrical control and monitoring unit The external control box communicates with the host computer and features: automatic adjustment of frequency conversion vibration parameters, matching the vibration frequency according to the strip material and surface dirt level; real-time monitoring of eccentric block position, fault self-diagnosis, and automatic shutdown in case of abnormality; modular communication interface, which can be seamlessly linked with the pickling and rinsing processes of existing galvanizing production lines; the equipment adopts a modular disassembly structure, and the brush roller, ultrasonic module, and vibrator can all be disassembled and maintained individually.

[0017] Existing conventional brushing equipment uses only a single static brush roller without graded pressure design; a small number of vibrating brush rollers have external motors and lack a built-in vibrator in the brush roller shaft and an automatic counterweight compensation structure for the eccentric block; at the same time, there is no technical solution for setting up an ultrasonic online cleaning between the two brush rollers.

[0018] The beneficial effects of this invention are as follows: 1. Multi-stage composite cleaning thoroughly eliminates iron oxide scale defects in trenches. Existing technologies only involve static brushing. This invention employs a three-stage composite purification mechanism: high-pressure vibrating brush roller peeling, ultrasonic intermediate cavitation cleaning, and low-pressure fine polishing. High-frequency vibration inside the roller penetrates deep into the scratches and grooves of the strip steel to peel off embedded iron oxide scale. Ultrasonic waves are added between the two brush rollers to remove dirt in real time, preventing secondary adhesion of iron powder and eliminating galvanized linear defects from the source. The surface qualification rate of the finished product is increased by more than 90%.

[0019] 2. Integrated vibration and dynamic counterweight compensation within the roller solves the problem of imbalance under vibration conditions. Compared to external vibration motor solutions, this invention integrates the vibrator into the brush roller shaft, significantly improving vibration transmission efficiency. When the machine stops, centrifugal force is offset by eccentric position detection, brake locking, and dual counterweight compensation, completely solving the problems of high-speed jumping of traditional vibrating brush rollers, surface scratches, and severe bearing wear, thus extending the effective service life of the equipment.

[0020] 3. Automatic waste diversion and cleaning reduces the frequency of downtime maintenance. The bottom of the frame is equipped with a vibrating slag guide plate, which automatically slides down and collects the flushed waste residue. This eliminates the need for regular manual cleaning of the slag inside the frame, increases the continuous operation time of the production line, and reduces manual maintenance costs.

[0021] 4. Intelligent adaptive control throughout the entire process, adaptable to multi-specification production. The electrical control system can automatically adjust the vibration frequency, brush roller pressure, and ultrasonic power according to the degree of contamination of the incoming material; it has fault self-diagnosis and automatic shutdown protection; the modular structure can be directly connected to the existing galvanizing pretreatment production line, with low transformation investment and strong versatility.

[0022] 5. Improve the overall performance of galvanized products The strip steel surface is free of oxide inclusions, the zinc-iron alloy layer is continuous and uniform, and the corrosion resistance of the galvanized sheet is significantly improved. This reduces customer compensation due to quality defects, lowers scrap steel and consumable waste, and reduces overall production costs. It solves a long-standing technical problem, producing unexpected technical effects. The industry has long suffered from the inability to completely remove iron oxide scale from strip steel grooves and the frequent occurrence of linear defects in galvanization. This invention uses high-frequency vibration within the rollers to deeply peel away embedded contaminants, while ultrasonic waves remove iron powder instantly to prevent secondary scratches. Eccentric counterweights solve the problem of imbalance during vibration shutdowns. The synergy of these multiple technologies significantly reduces defects, achieving a product quality improvement effect that exceeds expectations. Attached Figure Description

[0023] Figure 1 This is an overall schematic diagram of the production line for the re-brushing device of the present invention; Figure 2 This is a schematic diagram of the re-brushing device; Figure 3 This is a schematic diagram of the structure of the heavy brush roller; Figure 4 This is a cross-sectional view of the brush roller; Figure 5 This is a schematic diagram of the vibrator's structure; In the picture: 1-Strip steel, 2-Pickling or alkaline washing tank, 3-Brushing tank, 4-Re-brushing device, 5-Rinsing tank, 6-Hot air drying device.

[0024] 4001-Drive side shaft, 4002 - Drive-side slip ring, 4003 - Heavy-duty brush roller, 4004 - Working side shaft, 40041-Counterweight Compensator A, 40042-Counterweight Compensator B, 4005 - Working Side Vibrator 400501 - Variable frequency vibration motor 400502 - Drive shaft 400503 - Vibration Brake 400504 - Arc-shaped eccentric block, 400505 - Eccentric block position detector 4006 - Transmission-side vibrator 401-Front Upper Brush Roller 402-Front Lower Brush Roller 403 - Rear upper brush roller, 404-rear lower brush roller, 405-Ultrasonic Generator 1, 406-Ultrasonic Generator 2, 407-Ultrasonic Generator 3 408-Ultrasonic Generator 4, 409-Left-inclined guide plate vibrator, 4010-Right-inclined guide plate vibrator; 4011 - Re-brush Closed Rack. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings and specific embodiments: refer to Figure 1 As shown, a re-brushing device and production process for improving galvanization plating properties are disclosed. The raw material for galvanization is cold-rolled or hot-rolled base material. The strip steel 1 is produced and then enters the brushing tank 3 after being pickled or alkaline washed in the pickling tank 2. The re-brushing device 4 connected to the brushing tank 3 is equipped with squeezing roller devices in front and behind. After being rinsed clean in the rinsing tank 5, the strip steel is further dried by the hot air drying device 6 and then sent to the subsequent equipment for further processing.

[0026] The re-brushing device 4 of this invention comprises two-stage re-brushing roller groups, including a front-stage roller group and a rear-stage roller group. The front-stage roller group is designed to apply a higher re-brushing pressure than the rear-stage roller group. An ultrasonic online cleaning unit is provided between the re-brushing roller groups for immediate ultrasonic cleaning after re-brushing, improving the re-brushing efficiency of subsequent rollers and reducing bristle wear. The internal rollers of the re-brushing device 4 are designed with a vibration device featuring an adjustable counterweight compensator, further enhancing re-brushing efficiency and resulting in a more uniform and delicate surface quality.

[0027] refer to Figure 2 The diagram shows a schematic of the re-brushing device of the present invention. The re-brushing device 4 has a closed frame 4011 containing a set of re-brushing rollers, which are divided into upper and lower rollers and arranged on the upper and lower surfaces of the strip 1. As shown in the figure, the front upper roller 401 and the front lower roller 402 are the first set of re-brushing rollers, and the rear upper roller 403 and the rear lower roller 404 are the second set of re-brushing rollers, which are defined here as the front re-brushing and the rear re-brushing. Two sets of ultrasonic cleaning devices are installed between the front and rear heavy brushes. The first set consists of ultrasonic generators A 405 and B 406, and the second set consists of ultrasonic generators C 407 and D 409. The four ultrasonic generators directly perform ultrasonic cleaning on the upper and lower surfaces of the strip 1, further eliminating iron oxide powder and other solid particles on the surface of the strip 1. Two pairs of vibration devices are designed below the heavy brush closed frame 4011, arranged on both sides of the triangular inclined guide plate, namely the left inclined guide plate vibrator 409 and the right inclined guide plate vibrator 4010. The iron oxide and other debris after being cooled and cleaned by the high-pressure cooling water nozzles of the heavy brush rollers (cooling nozzle and pipeline diagram omitted) are shaken into the iron oxide powder guide groove at the bottom of the heavy brush closed frame 4011.

[0028] refer to Figure 3 The diagram shows the structure of the heavy brush roller of the present invention. Two or more vibration devices are symmetrically arranged inside the heavy brush roller 4003. The diagram shows that the transmission-side vibrator 4006 is located on the side of the drive-side roller of the heavy brush roller 4003 and is installed inside the drive-side shaft 4001 of the heavy brush roller. The working-side vibrator 4005 is located on the side of the working-side roller of the heavy brush roller 4003 and is installed inside the working-side shaft 4004 of the heavy brush roller. The power cables and position detection signal transmission cables of the working-side vibrator 4005, the transmission-side vibrator 4006, and the counterweight compensators A 40041 and B 40042 are connected to an external control box through the electric slip ring 4002 on the drive side of the heavy brush roller. The control box is connected to a computer for control.

[0029] refer to Figure 3 and 4 The diagram shows a cross-sectional view of the heavy brush roller of the present invention. The heavy brush roller 4003 has a steel core with assembled brush blades mounted on its exterior. The steel core has a hollow design in the middle. A working-side vibrator 4005 is installed inside a working-side shaft 4004 and is connected to the heavy brush roller 4003, rotating with it. The cross-sectional view shows that an arc-shaped eccentric block 400504 is fixedly connected to the drive shaft of the working-side vibrator 4005. An eccentric block position detector 400505 is installed inside to detect the real-time position of the arc-shaped eccentric block 400504. The working-side shaft 4004 is internally designed with two counterweight compensators: counterweight compensator A 40041 and counterweight compensator B 40042. When the surface quality of the strip is good and the vibration of the heavy brush roller 4003 is not required, the vibration stops. After being positioned by the eccentric block position detector 400505, it stops at a fixed position, working with the counterweight compensators to eliminate the centrifugal force generated by the eccentric block.

[0030] refer to Figure 5 The diagram shows the structure of the vibration motor of this invention. The vibrator 4005 on the working side is a closed device. The variable frequency vibration motor 400501 is installed inside the support ring 400506. The vibration brake 400503 and the arc-shaped eccentric block 400504 are installed on the transmission shaft 400502. After the motor rotates, it generates vibration force through the arc-shaped eccentric block 400504. The variable frequency vibration motor 400501 controls the motor speed through frequency to reach the set target vibration value. The eccentric block position detector 4005005 is a detection sensor that detects the actual position of the arc-shaped eccentric block 400504. When the vibration mode is stopped, the stopping position of the arc-shaped eccentric block 400504 is determined by the relative measurement of the counterweight compensator A and the counterweight compensator B. The vibration brake 400503 holds the transmission shaft 400502 in a fixed state.

[0031] This invention is based on a built-in brush roller shaft vibrator and an eccentric block automatic counterweight compensation structure. At the same time, it does not use the technical solution of setting ultrasonic online cleaning between the two brush rollers. This invention uses high-frequency vibration inside the roller to deeply remove embedded dirt, and ultrasonic waves in the middle to remove iron powder in time to avoid secondary scratches. The eccentric counterweight solves the problem of imbalance when the vibration stops. The synergy of multiple technologies achieves a significant reduction in defects and achieves a product quality improvement effect that exceeds expectations.

Claims

1. A re-brushing device for improving galvanizing plating applicability, characterized in that: It includes a closed re-brush frame, two-stage re-brush roller groups arranged sequentially along the travel direction of the strip (1), an ultrasonic online cleaning unit, an eccentric vibration unit inside the roller, an eccentric counterweight compensation unit, a waste slag vibration guiding unit, and an electrical control monitoring unit. The two-stage heavy brush roller assembly includes a front brush roller assembly and a rear brush roller assembly, with the working pressure of the front brush roller assembly being greater than that of the rear brush roller assembly; each heavy brush roller (4003) has a hollow steel core structure, with corrosion-resistant composite brush blades mounted on the outside of the steel core; the working side shaft (4004) and the drive side shaft (4001) of the brush roller have built-in working side vibrators (4005) and transmission side vibrators (4006), respectively. The roller-mounted eccentric vibration unit is a closed integrated structure, comprising a variable frequency vibration motor (400501), a drive shaft (400502), a vibration brake (400503), an arc-shaped eccentric block (400504), and an eccentric block position detector (400505). The variable frequency motor drives the drive shaft (400502) to drive the arc-shaped eccentric block (400504) to generate high-frequency vibration, and the eccentric block position detector (400505) collects the eccentric block rotation angle signal in real time. The vibrator's cable is led out to an external control box through the drive-side slip ring (4002). The eccentric counterweight compensation unit includes counterweight compensator A and counterweight compensator B symmetrically arranged inside the working side shaft (4004) of the brush roller; when the vibration operation stops, the eccentric block position detector (400505) positions the arc-shaped eccentric block (400504) to a fixed zero position, the vibration brake (400503) locks the drive shaft (400502), and the two sets of counterweight compensators counteract the centrifugal force generated by the arc-shaped eccentric block (400504); The ultrasonic online cleaning unit is located between the front brush roller group and the rear brush roller group, and includes four sets of ultrasonic generators arranged in upper and lower layers, respectively corresponding to the cleaning of the upper and lower surfaces of the strip steel (1). The waste slag vibration guide unit includes left and right inclined guide plate vibrators (4010) located on both sides of the triangular inclined slag guide plate at the bottom of the closed re-brushing frame, which are used to shake the iron sheet washed off by the cooling water to the guide groove at the bottom of the frame. The electrical control and monitoring unit includes an external control box and a host computer. The control box is used to adjust the vibration frequency, brush roller pressure, and ultrasonic power in real time, and has the functions of fault self-diagnosis and automatic shutdown in case of abnormality.

2. The re-brushing device for improving galvanizing plating suitability according to claim 1, characterized in that, The brush blades of the heavy brush roller (4003) are made of a polymer material that is resistant to acid and alkali corrosion.

3. The re-brushing device for improving galvanizing plating suitability according to claim 1, characterized in that, The mounting base positions of the working side vibrator (4005) and the transmission side vibrator (4006) are adjustable to accommodate brush rollers (4003) of different diameters and widths.

4. The re-brushing device for improving galvanizing plating suitability according to claim 1, characterized in that, The closed re-brushing frame, two-stage brush roller assembly, ultrasonic online cleaning unit, and roller eccentric vibration unit are all modular and can be disassembled and maintained individually.

5. The re-brushing device for improving galvanizing plating suitability according to claim 1, characterized in that, The electrical control and monitoring unit is equipped with a communication interface, which can realize process linkage control with the pickling tank, rinsing tank (5) and drying equipment of the galvanizing production line.

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