Lubrication device for lubricating a metal wire with a lubricant

Abstract

The invention relates to a lubrication device for lubricating a metal wire with a liquid lubricant. The lubrication device works by dropping lubricant carrying bodies onto the metal wire as it passes through the lubrication device. Lubrication is increased by arranging a baffle arranged below a wire path, the baffle being arranged to impede at least some of the lubricant carrying bodies. The invention also relates to a method for lubricating a metal why running the wire to such a device and transporting the liquid carrying bodies simultaneously.

Description

[0001] The invention relates to a lubrication device for lubricating a metal wire with a preferably liquid lubricant, for instance for facilitating drawing or rolling the wire, wherein said lubrication device comprises a container with a wire inlet and a wire outlet at two opposite ends of container so that a wire can be pulled through an interior of the container from the inlet to the outlet, the container being configured to hold a multitude of lubricant carrying bodies therein; and a transport mechanism configured to transport lubricant carrying bodies from a bottom of the container towards a top of the container, and to discharge the lubricant carrying bodies in the container at a distance from the bottom thereof.

[0002] Metal wires are used in a variety of products, requiring wires with specific surface finishes or specific diameters. The production process for such wires oftentimes includes pulling the wire through a mould to reduce the diameter, which is called drawing. Surface finishes may be applied by pulling the wire along one or more rotating moulds, thereby providing a texturization of the wire surface. This process is called rolling. In both cases, and optionally in other processes too, the metal wire is pulled through one or more machines. This motion can lead to friction between the wire and the one or more machines, leading of both the metal wire, as well as the equipment used. In order to at least partially remedy this problem, metal wires are lubricated to reduce friction, thereby reducing wear and lowering the chance of failure.

[0003] In practice, metal wires are lubricated by running the wire through a soap box which includes solid soap particles. When the soap particles touch the wire, they break up and some of the soap sticks to the wire.

[0004] While this method of lubrication has worked satisfactory from a lubrication perspective for years, and still does, room for improvement still exists. In particular, the use of solid soap particles generates dust. The dust is not in itself harmful, but nevertheless deteriorates the conditions in the factory.

[0005] An attempt has therefore been made, see e.g. EP 2 233 220 B1, to replace the solid soap particles with a multitude of particles that carry a liquid soap. The soap box presented in EP 2 233 220 B1 is capable of applying liquid soap to the metal wire, proving that the principle of liquid soap carried by particles works in practice. The soap box however could not provide desirably high levels of lubrication.

[0006] On the other hand, it is important that the desired amount of lubricant is applied to the wire, as having too little soap means the problems caused by friction might still occur, albeit at a lower rate. Using too much lubricant soils downstream of the lubrication device.

[0007] It is an object of the invention to at least partially address one or more of these problems. More specifically, it is an object of the invention to provide a lubrication device for lubricating a metal wire with a lubricant, preferably a lubricant in liquid form, that applies sufficient lubricant.

[0008] This object is achieved by a lubrication device according to the preamble, which comprises a baffle arranged between a wire path defined from the wire inlet to the wire outlet on the one hand, and the bottom of the container on the other hand, the baffle being arranged to impede at least some of the lubricant carrying bodies after they are discharged from the transport mechanism.

[0009] The baffle impeding the fall of the lubricant carrying bodies may increase the likelihood of the bodies contacting the wire, thereby increasing the lubrication of the wire. Accordingly, sufficient lubrication may be achieved.

[0010] The principle of using a baffle to increase contact and thus lubrication is not necessarily limited to liquid soap carried by bodies. In fact, dry soap in the form of particles can be readily used in a lubrication device with a baffle. In such a case, the advantage could be that less soap would need to be transported to achieve sufficient lubrication.

[0011] It is noted that when using a liquid soap carried by the liquid carrying bodies, the bodies can interact with the wire, and therefore lubricate the wire. After (repeated) contact, the bodies may expire, i.e. they may not carry sufficient lubricant to keep lubricating the wire. To refresh the bodies, they can be dropped in a layer of liquid soap in the bottom of the container, and then reused using the transport mechanism. The lubrication devices can therefore circulate the bodies within the container.

[0012] Said baffle can be arranged substantially parallel to the wire path. A parallel orientation allows a relatively compact design and / or may prevent directing bodies away from the wire path.

[0013] In particular, the baffle could be arranged substantially horizontally. In the horizontal orientation, the baffle has maximum capability to impede falling lubricant carrying bodies, thereby increasing the likelihood of contact with the wire. Accordingly, lubrication is increased.

[0014] In one embodiment, the lubrication device can comprise an open top box with a box bottom and at least two opposing side walls, the box bottom comprising the baffle and the at least two opposing side walls extending along the wire path. Preferably the walls of the box (or the baffle, for that matter) are solid, but they can also be provided with holes and / or apertures independently of one-another.

[0015] The box can reduce the local mobility of the lubricant carrying bodies, for instance by confining the bodies to a limited volume around the wire path. Accordingly, it may increase the chance of the bodies contacting the wire. In particular, the box may help to provide a bath of lubricant carrying bodies through which the wire can run.

[0016] The open top of the box allows escape of the bodies from the box, which may bring about two advantages. Firstly, allowing escape through the top prevents jamming of the bodies in the box. Escape of the bodies during operation may be brought about by movement of the wire. Typical wire speeds are 6 - 7 m / s, which is sufficiently fast to cause lubricant carrying bodies to be launched out of the box. Secondly, the escape through the top allows refreshing the bodies in the box with new bodies, e.g. also through the open top. Accordingly, the top can also serve as an entry point for lubricant carrying bodies coming from the transport mechanism. Accordingly, when the wire and the transport mechanism are run, the bodies in the box are continuously renewed so that new lubricant carrying bodies are always available for the wire to contact, whilst expired lubricant carrying bodies are automatically dropped out of the box.

[0017] The side walls can extend away from the baffle to beyond the wire path. This is to say they end above the wire path. The side walls being of this height allows creating a bath bodies in the box which has a level above the wire path. The wire being run along the wire path thus runs through the layer of bodies held in the box. The side walls may help to immobilize the bodies and present them for contact with the wire. Of course in use, the bodies may not actually be immobilized, because they interact with the moving wire. However, the side walls may make sure that they do not fall away from the wire path without actually having interacted with the wire.

[0018] It is particularly advantageous if the box is open between the at least two opposing side walls to allow ingress and egress of the wire. The opening may prevent jamming. In particular, it is possible to simply provide a gap between the side walls. As an alternative, a front or rear wall can be provided which extend between the side walls on opposing longitudinal ends of the box. These front and rear walls may have an opening or slot for the wire to pass through. The front wall could be the one closest to the wire inlet, whereas the rear wall could be the one closest to the wire outlet. It is also possible to provide only a rear wall with an aperture or slot, whilst no front wall is present, or vice versa.

[0019] Therefore, in another embodiment, the open top box further comprises front and rear walls opposite each other and extending between the side walls, the front and rear wall each comprising an aperture or slot for the wire to pass through. The front and rear walls can prevent, or at least reduce, the number of lubricant carrying bodies that escape from the lubrication device. The aperture and / or slot ensures that the wire is still able to enter and exit the lubrication device, while simultaneously acting as a guiding system for the cable, reducing slack and large movements of the wire out of the direction of the wire path, which could possibly be damaging to surrounding equipment and / or reduce lubrication efficacy.

[0020] In particular, the front wall may comprise a reinforced wire inlet that has been arranged in the aperture. The reinforced wire inlet can prevent damage to the front wall, thereby prolonging lifetime of the lubrication device and / or reducing servicing needs. The wire inlet may be reinforced by providing an insert (which can be arranged in the wall either fixedly or removably), with a hardness that is higher than the walls of the lubrication device. The insert can be made from a hardened metal, or more specifically a hardened steel. Likelihood of damage to the rear wall is smaller, as the wire has already been lubricated before reaching said rear wall, and therefore will not be as abrasive, but the reinforced wire inlet, in this case used as an outlet, can still be applied to the rear wall as an additional or in the alternative. Of course, the rear wall could be dispensed with entirely as described above, so that no reinforcement of the inlet is needed.

[0021] In yet another embodiment of the lubrication device, the box can have a cross section defined in a plane normal to the wire path which decreases in a direction towards the wire outlet. One way of achieving this decreasing cross section would be if at least one of the side walls tapers inwards on a longitudinal end facing the wire outlet.

[0022] Having a decreasing transversal cross section towards the wire outlet can have advantages, such as increasing the number of times the lubricant carrying bodies bounce of the walls towards the wire, thus increasing contact time with the wire and lubricating it better. It could also promote ejecting bodies after contact with the wire, so that they make place for new, non-expired lubricant carrying bodies.

[0023] The transport mechanism may be configured to discharge into the box. As most lubrication of the wire takes place inside of the box, it can be advantageous to discharge the lubricant carrying bodies e.g. directly into the box. Reducing the number of other parts the bodies will touch before entering the box may lead to a reduction of lubricant getting lost along the way, which in turn may lead to a better lubrication of the wire. Discharge into the box has the further advantage of keeping the box filled with at least some bodies for lubrication as the wire is run.

[0024] One or both of the side walls could be arranged at a first angle with respect to the box bottom as measured on the interior of the box, the angle being obtuse. The resulting position of the side walls could thus resemble a U or V shape as seen in cross section.

[0025] Due to the obtuse angle, the side walls will act as guides for the lubricant carrying bodies, guiding them towards the wire path, through gravity.

[0026] In particular, it may be possible for one or both of the side walls to be arranged at the first angle with respect to the box bottom as measured on the interior of the box, wherein the first angle is adjustable, preferably between obtuse positions.

[0027] In another embodiment of the invention a distance between the side walls is adjustable.

[0028] Both these features, in combination or each separately, may aid in adjusting the lubricating behaviour of the lubrication device. In particular, it allows to influence the amount of lubricant applied to the wire. This could be used for instance to optimize performance, for instance to adjust for wires of different diameters, or when circumstances change. As an example, a different type of (liquid) lubricant could require a different degree of lubrication, different wire diameters could require different degree of lubrication, and a different propagation speed of the wire could require a different degree of lubrication. It will therefore be apparent that adjustability of the lubricating behaviour contributes to the versatility of the lubrication device described herein.

[0029] Adjustment of the walls, be it their mutual distance or orientation with respect to the bottom, can be provided by a suitable mechanism. As an example, the side walls may be hingedly connected to the bottom, and be further provided with a locking mechanism that selectively locks the side walls in an orientation. Mutual distance between the side walls could be changed by attaching the sidewalls with a lockable pin-and-slot connection with respect to the bottom of the box. Accordingly, by unlocking movement, and therefore adjustment, is facilitated, while the locking allows a unchanging continuous operation after adjustment.

[0030] The transport mechanism may be arranged transversal of the wire path. accordingly, lubrication takes place mainly due to and above the baffle, so that lubrication can be controlled more or less independent the transport mechanism by positioning the baffle in a desired position and orientation. Additionally or alternatively, the transversal positioning allows sufficient space for the baffle and / or open top box, even in a compact design.

[0031] The baffle may be extendible and / or retractable, e.g. telescopically, in a length direction substantially parallel to the wire path. Depending on the thickness of the wire, among other factors, different amounts of lubricant may be needed, for instance per unit length of the wire. These varying lubrication needs may be met if the baffle is extendible and / or retractable in a length direction, such that the wire travels along the baffle for a longer distance. In turn this may lead to a longer contact time between the lubrication carrying bodies and the wire, thus resulting in a higher amount of lubricant being disposed on the wire. Of course if an (open top) box is used, the entire box may be extendible and / or retractable.

[0032] The lubrication device may further include a magnetic filter configured for filtering the lubricant, for example for removing the mill scale from the lubricant. Mill scale is usually still present on metal wire as it is delivered, because it has a protecting function during transport and storage. However, mill scale may be a source of debris in the lubrication device. When present in the lubricant, pieces of mill scale may act as abrasives downstream of the lubrication device or in the lubrication device. This problem can be counteracted or even avoided if a magnet is used to remove said mill scale, or other possible magnetic contaminants from the lubricant.

[0033] The lubricant in the lubrication device could be continuously drained from the lubrication box, run through the filter, and then be recycled into the lubrication device, so that a relatively clean lubricant is continuously available.

[0034] The invention further relates to a method for lubricating a metal wire, the method comprising several steps, starting with a) providing the lubrication device as described hereabove, with a liquid lubricant in the container carried by the lubricant carrying bodies; then b) running the transport mechanism to discharge the lubricant carrying bodies over the baffle; and c) pulling the metal wire over the baffle, wherein steps b) and c) are performed simultaneously.

[0035] The method may be used for instance to perform the lubrication of a metal wire through using the lubrication device as it was described above, with any one, more or all of the above described features. Therefore, it may offer any of the earlier described advantages.

[0036] Running the latter steps together allows continuous lubrication.

[0037] The method can possibly comprise a further step, namely monitoring a lubricant level in the container. Monitor the lubricant level during operation of the device may ensure lubricant is added in a timely manner. Of course, this could be automated, or an alarm could be given for an operator to add lubricant. It could further be possible to log the lubricant level for quality control or assurance purposes.

[0038] The invention will be further elucidated with reference to the attached drawings, in which: Figure 1 shows schematically a perspective view of an embodiment of the lubrication device; Figure 2 shows schematically a top view of the lubrication device of figure 1; Figure 3 shows schematically a side cross sectional view of the lubrication device of figures 1 and 2; and Figure 4 shows schematically a variation of the lubrication device of figures 1 - 3 in a side cross sectional view; and Figures 5A and 5B schematically show a variation of the lubrication device of figures 1 - 3 in a side cross sectional view.

[0039] Throughout the figures, like elements will be referred to using like reference numerals.

[0040] Figure 1 shows an embodiment of a lubrication device 99, as it could be used in a setup for drawing and / or rolling a metal wire. A container 1 surrounds the interior of the lubrication device. The container has a wire inlet 2 and a wire outlet 3, located at opposite ends of the container, through which a wire 4 enters and exits said container 1. The wire 4 runs along a wire path. As stated earlier, the aim of the lubrication device 99 is to lubricate said wire 4, which it does by moving lubricant 98 from the bottom of container 1 and getting it to stick to the wire 4. In this embodiment, the lubricant 98 is a liquid soap, in which lubricant carrying bodies 5 are present. These lubricant carrying bodies 5 can for example be made of a ceramic or a plastic material, to which the liquid soap can stick. When the bodies 5 get into contact with the wire 4, they will transfer some or all of the soap to the wire 4, thus lubricating it. The container 1 holding multiple lubricant carrying bodies 5 is shown as including a body of lubricant 98 highlighted with equidistant points for reasons of simplicity, whereas in reality relatively large lubricant carrying bodies 5 could be used in a relatively small amount of liquid applied to the surface of the bodies 5. Furthermore, container 1 has a lid (not shown), which can be opened, so the lubricant level in the container 1 can be monitored. Of course, this monitoring could also be done in a variety of other ways, such as providing a transparent or removable panel or arranging one or more sensors in the container 1. When using sensors, the amount of lubricant could be automatically regulated using means known in the art.

[0041] Contact between the lubricant carrying bodies 5 and the wire 4 is achieved by moving the lubricant carrying bodies 5 through the use of a transport mechanism 6. The transport mechanism 6 in this embodiment comprises a rotatable Archimedean screw 61 arranged to lift said lubricant carrying bodies 5 and discharge them on said wire 4. The Archimedean screw 61 is connected to a motor 62, not shown in figure 1. Of course, another type of transport mechanism could be used. The discharging of the bodies 5 is done using a guide 14, which in this embodiment runs from transversally to the wire path, where the transport mechanism 6 is, to above the wire 4.

[0042] Once discharged, the lubricant carrying bodies 5 fall into an open top box 8. This box comprises a bottom 9, and two side walls 10. The bottom acts as a baffle 7, which together with the side walls causes the bodies 5 to contact the wire 4, in order to deposit the lubricant from the bodies 5 onto the wire 4. As can be seen, the baffle 7 runs parallel to the wire path, and is arranged substantially horizontally. Furthermore, a front wall 11 and a rear wall 12 are present in the box 8. It is also envisioned to use only a front wall 11 but no rear wall 12. A slot 13 has been provided in the front 11 and rear 12 walls, in order for the wire to be able to enter and exit the box 8. An insert is placed in the slot (not shown in the figures), which acts as a reinforced wire inlet. This is especially preferred for the slot 13 in the front wall 11, but it is possible to also place such a reinforced insert in the rear wall 12.

[0043] As can be seen, the side walls 10 are connected to the bottom 9 at a first angle, wherein the first angle is an obtuse angle. In this way, the side walls 10 together with the bottom 9 form a V-shape, or a U-shape. Herein, a V-shape is defined as having a cross sectional shape that comprises two line segments at an angle with respect to each other, either intersecting each other or with a bottom line segment in between. Herein, a U-shape is defined as having a cross sectional shape that comprises two substantially parallel legs connected by a transversal bridge on one end of the legs. The side walls 10 are arranged in such a way that they extend along the wire path. They also extend away from the baffle 7 to beyond the wire path, and thus end above said wire path. The side walls are held in place with two rods 101, that allow adjustment of the first angle between obtuse positions. The distance between the side walls 10 is also adjustable by moving the inwards and / or outwards with respect to each other. The open top box 8 is carried by a set of strips 81, in this example made of metal. The strips 81 allow flexible orientation of the open top box 8, and can even allow the open top box 8 to be replaced by a similar box which is longer or shorter, to account for different lubrication needs. An alternative would be to make the box 8 extendible and retractable in its length measured along the wire path, for instance telescopically. Alternatively, the effective length of the box may be changeable by changing e.g. the position of the rear wall 12 and / or the side walls 10.

[0044] As the wire 4 moves towards the wire outlet 3 at speed, contact between the wire 4 and said bodies 5 will cause the bodies 5 to move around, and sometimes out of the box 8. The bodies 5 can then be replenished by new bodies 5 by the transport mechanism 6. The lubrication device 99 can also include a magnetic filter for filtering the lubricant 98. The lubricant 98 could be contaminated with e.g. mill scale stemming from the wire 4, which can be removed by said magnetic filter. Of course, if desired this filter can also be placed elsewhere in connection with the container 1. As an example, a circuit taking lubrication from the container 1 and feeding it back may be provided with the for example magnetic filter. The same circuit may include a reservoir from which additional lubricant can be added automatically to the container 1, for instance in combination with the monitoring provisions explained above.

[0045] In figures 2 and 3, a top and side wall of the lubrication device 99 are not shown to expose the interior of the container 1.

[0046] As can be seen best in figure 2, one of the side walls 10 (bottom side wall in figure 1) tapers towards the wire path, thereby reducing the transversal cross section of the box 8 in a direction towards the wire outlet 3. Figure 2 also shows more clearly the direction in which the lubricant carrying bodies 5 are discharged from the transport mechanism 6, in this embodiment the direction being substantially transversal to the wire path, but angled slightly towards the wire outlet 3.

[0047] Figure 3 shows a side view of the lubrication device 99, giving a clearer view of the way the transport mechanism 6 ends slightly above the wire 4, in order to ensure that the lubricant carrying bodies 5 actually interact with the wire 4. Furthermore, motor 62 is visible, attached to the top of the Archimedean screw 61 of the transport mechanism 6.

[0048] Figure 4 shows a variation on figure 3, in which the transport mechanism 6 is replaced with a transport mechanism 106 of a different kind. In other aspects, the variation is the same. In this case, the transport mechanism contains a casing 164 which runs obliquely upwards. In the case, a series of links 161 forms an endless loop around a system of pulleys 163. Some of the links 161 have carriers 162 which carry bodies 5 with lubricant on the links 161 upwards, as the links move upwards 161. To effect movement, a motor may be provided, but this is not shown. Similar to figure 3, a guide 14 is used to allow the bodies 5 to move from the transport device 106 to the open top box.

[0049] In figures 5A and 5B yet another variation is shown. This variation differs only from figure 3 and 4 in that its open top box 8 is extendible telescopically. This type of box 8 can be used with different kinds of transport mechanisms (6, 106). For this purpose, no transport mechanism is shown. The open top box 8 comprises a double side wall 10 consisting of two slidable wall parts 50 and 51. The end 52 of the rightmost wall part 51 in figure 5A can be seen relatively far to the left in that figure. In the following figure 5B, the original location of that end 52 has been shown with a dotted line 53. The end 52 itself however has been moved to the right together with the wall part 51 thereby extending the entire side wall 10. A similar construction can be applied for the bottom. As a result, the box 8 is extendible. A total length of the box from front wall 11 to rear wall 12 thus changes between a relatively short length L1 in figure 5A to a relatively long length in figure 5B.

[0050] It is noted that terms like "preferably", "generally" and "typically" are not utilized herein to limit the scope of the claims or to imply that certain features are critical, essential, or even important to the structure or function of the claims. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present disclosure. Likewise, for the purposes of describing and defining the present disclosure, it is noted that the terms "substantially" and "approximately" and their variants are utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement or other representation, as well as to represent the degree by which a quantitative representation may vary without resulting in a change in the basic function of the subject matter at issue.

[0051] While certain representative embodiments and details have been shown for purposes of illustrating the present disclosure, it will be apparent to those skilled in the art that various changes may be made without departing from the scope of the disclosure, which is defined in the appended claims.

Claims

1. Lubrication device for lubricating a metal wire with a preferably liquid lubricant, for instance for facilitating drawing or rolling the wire, wherein said lubrication device comprises: - a container with a wire inlet and a wire outlet at two opposite ends of container so that a wire can be pulled through an interior of the container from the inlet to the outlet, the container being configured to hold a multitude of lubricant carrying bodies therein; and - a transport mechanism configured to transport lubricant carrying bodies from a bottom of the container towards a top of the container, and to discharge the lubricant carrying bodies in the container at a distance from the bottom thereof, characterized by - a baffle arranged between a wire path defined from the wire inlet to the wire outlet on the one hand, and the bottom of the container on the other hand, the baffle being arranged to impede at least some of the lubricant carrying bodies after they are discharged from the transport mechanism.

2. Lubrication device according to the previous claim, wherein the baffle is arranged substantially parallel to the wire path.

3. Lubrication device according to the previous claim, wherein the baffle is arranged substantially horizontally.

4. Lubrication device according to any of the preceding claims, comprising an open top box with a box bottom and at least two opposing side walls, the box bottom comprising the baffle and the at least two opposing side walls extending along the wire path.

5. Lubrication device according to the previous claim, wherein the side walls extend away from the baffle to beyond the wire path.

6. Lubrication device according to the previous claim, wherein the box is open between the at least two opposing side walls to allow ingress and egress of the wire.

7. Lubrication device according to the previous claim, the open top box further comprising front and rear walls opposite each other and extending between the side walls, the front and rear wall each comprising an aperture or slot for the wire to pass through, wherein optionally the front wall and / or the rear wall comprises a reinforced wire inlet or outlet respectively.

8. Lubrication device according to any of claims 4-7, wherein the box has cross section defined in a plane normal to the wire path which decreases in a direction towards the wire outlet, wherein optionally at least one of the side walls tapers inwards on a longitudinal end facing the wire outlet.

9. Lubrication device according to any of claims 4-8, wherein the transport mechanism is configured to discharge into the box.

10. Lubrication device according to any of claims 4-9, wherein one or both of the side walls are arranged at a first angle with respect to the box bottom as measured on the interior of the box, the angle being obtuse.

11. Lubrication device according to any of claims 4 - 10, wherein one or both of the side walls are arranged at the first angle with respect to the box bottom as measured on the interior of the box, wherein the first angle is adjustable, preferably between obtuse positions.

12. Lubrication device according to any of claims 4 - 11, wherein a distance between the side walls is adjustable.

13. Lubrication device according to any of the preceding claims, wherein the transport mechanism is arranged transversal of the wire path.

14. Lubrication device according to any of the preceding claims, wherein the baffle is extendible and / or retractable in a length direction substantially parallel to the wire path, and / or wherein the lubrication device further includes a magnetic filter configured for filtering the lubricant, for example for removing the mill scale from the lubricant.

15. Method for lubricating a metal wire, the method comprising the steps of: a) providing the lubrication device of any of the preceding claims, with a liquid lubricant in the container carried by the lubricant carrying bodies; b) running the transport mechanism to discharge the lubricant carrying bodies over the baffle; and c) pulling the metal wire over the baffle, wherein steps b) and c) are performed simultaneously, wherein optionally the method further comprises monitoring a lubricant level in the container.

Images