Adjustable Wiping Die System for Uniform High-Speed Wire Galvanizing

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Solution Overview

Problem

Existing galvanizing processes struggle to maintain consistent coating quality on wires of varying diameters at high running speeds, leading to issues like uneven coatings, oxidation, and increased viscosity of molten metal, which affects production flexibility and efficiency.

Innovation Solution

A method involving adjustable wiping dies positioned at varying distances from the molten metal bath, combined with controlled gas flow rates, to ensure consistent coating quality across different wire diameters and speeds, using a two-part wiping die system with height adjustment capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If wire running speed is increased to improve productivity, then production efficiency improves, but coating uniformity deteriorates and oxidation increases

Engineering Contradiction:

Improvewire running speedVSAvoidcoating uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The wiping die is made adjustable in height, allowing dynamic repositioning relative to the molten metal bath. This enables the system to adapt to different wire running speeds and diameters, maintaining optimal wiping conditions that ensure uniform coating thickness even at high speeds where coating consistency would otherwise deteriorate

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the physical parameters of the wiping process by adjusting the die height and gas flow rate. By modifying these parameters, the system can compensate for the effects of high wire running speed, maintaining coating uniformity despite the increased speed that would normally cause inconsistency

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If wiping die is positioned close to molten metal bath to control coating thickness, then coating precision improves, but oxidation of molten metal increases

Engineering Contradiction:

Improvecoating thickness controlVSAvoidoxidation of molten metal

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

A stream of inert or reducing gas is introduced as an intermediary between the wiping die and the molten metal bath. This gas stream creates a protective atmosphere that prevents oxidation of the molten metal while allowing the wiping die to operate close enough to the bath surface to maintain precise coating thickness control

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention uses an inert or reducing gas atmosphere to protect the molten metal from oxidation. By establishing this protective environment around the wiping zone, the system can position the wiping die close to the molten metal bath for precise coating control without suffering from oxidation harmful effects

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Manufacturing precision

If wiping gas flow rate is increased to reduce coating thickness, then coating precision improves, but energy consumption increases

Engineering Contradiction:

Improvecoating thicknessVSAvoidgas flow energy

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The invention optimizes the gas flow rate parameter to achieve the desired coating thickness with minimal energy consumption. By carefully selecting and adjusting the gas flow rate alongside die height, the system achieves precise coating control without excessive energy use that would result from simply maximizing gas flow

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Maintains consistent coating quality independent of wire diameter and speed, reducing oxidation and turbulence, enhancing production flexibility and efficiency in high-speed galvanizing processes.

Implementation Method 1

a wiping die crossed by a blade of wiping gas emerging from a peripheral slot to said wiping slot at a wiping gas flow rate of between 0.6 and 9 m3/hour

Methodology Applied

Scientific EffectGas flow:

Implementation Method 2

The wires are directed after the galvanizing bath through a wiping die to remove the excess molten metal used to galvanize the wire

Methodology Applied

Scientific EffectSurface tension: Surface Tension

Implementation Method 3

Galvanizing can be done through a bath of aluminum or zinc, or sometimes other metals or alloys such as tin or a tin-based alloy

Methodology Applied

Scientific EffectGalvanizing:

Implementation Method 4

the wires are directed after the galvanizing bath through a wiping die to remove the excess molten metal used to galvanize the wire

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentEP4578988A1Galvanising process of wires in continuous scrolling and system of wire wiping

Publication Date: 2025.07.02 FIB BELGIUM

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AI summary

High speed wire galvanizing process and wiping die system where the die height is adjustable.