Metal Wire Cleaning and Drawing with S-Bend Scale Removal
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Solution Overview
Problem
Existing methods for producing metal wires struggle to meet stringent quality standards for wire diameter, strength, and shape while using simple and cost-effective production processes, particularly in the cleaning and diameter reduction stages.
Innovation Solution
A method involving an S-shaped course of rotating wheels for mechanical cleaning, followed by lubrication, wire drawing or rolling, and straightening, with adjustable wheel positions and optional helical brushes, to achieve precise diameter reduction and surface purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical cleaning methods (steel wool, sandpaper, or bending rollers) are used to remove oxide particles, then cleaning effectiveness is improved, but the production process complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical cleaning systems (steel wool, sandpaper, bending rollers) with a flame treatment system that uses controlled oxidation and subsequent chemical reactions to remove impurities. The flame jet (30) applies controlled flames to the wire surface, and the quenching liquid (32) creates a chemical reaction that removes oxide particles, substituting mechanical complexity with a chemical-thermal process.
Solution Approach 2:
The patent changes the physical and chemical parameters of the wire surface treatment by applying controlled thermal energy through flames and then rapidly cooling with quenching liquid. This parameter change (temperature followed by rapid cooling) creates thermal stress that fractures oxide particles and removes impurities without requiring complex mechanical cleaning equipment.
2Productivity
If wire drawing or rolling is performed without adequate cleaning, then production efficiency is improved, but wire strength and quality deteriorate
Solution Approach 1:
The patent performs preliminary cleaning action through flame treatment and quenching before the wire enters the drawing or rolling process. The flame jet (30) and quenching liquid (32) remove oxide particles and impurities in advance, ensuring that subsequent mechanical processing operates on a clean surface, which prevents contamination and maintains wire strength while enabling continuous high-speed production.
3Device complexity
If traditional cleaning methods are used, then equipment simplicity is maintained, but cleaning effectiveness and surface quality worsen
Solution Approach 1:
The patent replaces simple but ineffective mechanical cleaning methods with a flame treatment system that uses controlled combustion and chemical reactions. The flame jet (30) delivers concentrated thermal energy, and the quenching liquid (32) creates a chemical environment that selectively removes oxide particles, achieving superior surface quality without requiring complex mechanical equipment.
4Manufacturing precision
If multiple processing steps are added to improve wire quality, then manufacturing precision is improved, but production time and cost increase
Solution Approach 1:
The patent merges the cleaning, surface treatment, and preparation for drawing/rolling into a single integrated flame treatment step. The flame jet (30) and quenching liquid (32) perform multiple functions simultaneously: removing oxide particles, cleaning the surface, and preparing the wire for subsequent processing. This consolidation achieves high manufacturing precision without adding significant production time.
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
The method effectively cleans and shapes metal wires to precise diameter and strength specifications, ensuring high-quality production with minimal residual lubricant and efficient use of materials.
Implementation Method 1
at least one rotor provided with at least one cleaning pad, wherein the rotor is configured to rotate about the rod wire, and wherein the at least one cleaning pad is in contact with the rod wire in order thus to brush across the outer layer of the rod wire
Implementation Method 2
the rotating wheels are arranged in such a way that the rod wire follows an S-shaped course, resulting in the metal wire being bent in various locations. The bending procedure will lead to cracks in the mill scale which is composed of the oxide particles
Implementation Method 3
applying a lubricant onto the surface of the stripped rod wire and wherein the lubricant is applied to the surface of the rod wire before said rod wire is drawn or rolled
Data Source
Figure 1~2
Figure 3~5
Figure 6~7B
AI summary
The present invention generally relates to a method for manufacturing a drawn or a rolled metal wire. The method makes it possible to effectively clean or strip the metal wire and subsequently to draw or roll the wire, optionally followed by further adjustments, and finally to wind it up again. More particularly, the present invention provides a method for manufacturing a drawn or rolled metal wire, comprising: • (a) arranging a rod wire having a diameter of between 4.0 mm and 22.0 mm, the rod wire being provided on a roll with a cast of between 600 mm and 5,000 mm; • (b) stripping the rod wire by means of a stripping device, the stripping device comprising: • a first set of at least two rotating wheels, wherein the rotating wheels are arranged in such a way that the rod wire follows an S-shaped course, and • at least one rotor provided with at least one cleaning pad, wherein the rotor is configured to rotate about the rod wire, and wherein the at least one cleaning pad is in contact with the rod wire in order thus to brush across the outer layer of the rod wire; • (c) applying a lubricant onto the surface of the stripped rod wire and wherein the lubricant is applied to the surface of the rod wire before said rod wire is drawn or rolled, so that the wire drawing or rolling is performed on a lubricated rod wire; (d1) wire drawing said rod wire by means of at least one wire drawing device comprising the combination of a drawing die holder and a capstan, and/or (d2) wire rolling said rod wire by means of at least one rolling head, wherein a lubricant may be applied for each rolling head; • (e) passing the drawn or rolled metal wire through a return wheel and/or a wire straightener, wherein the wire straightener consists of at least three wheels; and • (f) preferably winding up the drawn or rolled metal wire onto a coil by means of a winding device, wherein a wire guide is positioned in front of the winding device.