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0102030405
Integrated Flat Wire Rolling and Pulling Machine - Top China Suppliers | Reliable Factory Solutions
Product Description
Equipment configuration (supply list)
| Equipment composition | |||
| Configuration items / Item | quantities | ||
| Rotary arm type double-station payoff frame | 1 unit | ||
| BAOC-LLS500 Vertical double-wheel wire drawing machine with tension control | 6 units | ||
| BAOC-ZJ-220 Horizontal two-roll active rolling mill with tension control | 1 unit | ||
| BAOC-ZJ-180 Horizontal two-roll active rolling mill with tension control | 1 unit | ||
| BAOC-LLS500 Vertical double-wheel wire drawing machine with tension control | 2 units | ||
| BAOC-400T High-speed induction annealing machine for flat wire | 1 unit | ||
| BAOC-LLS500 Vertical double-wheel wire drawing machine with tension control | 1 unit | ||
| BAOC-WS800 horizontal bobbin winder with disc movement | 1 unit | ||
| Roll cooling system | 1 unit | ||
| ZJ430 Head Rolling Machine | 1 unit | ||
| Drawing fluid supply station (4 water pumps + 35 sq. exchangers + 6 cu. ft. tanks (customer's own)) | 1 set | ||
| Wire Drawing Electrical Control System | 1 set | ||
| Connection lines, signal lines, control lines (except power inlet lines and motor lines) between electrical cabinets and equipment | 1 unit | ||
| Device Colour | |||
| Main components | Color Specification | Supplier color code | |
| main body of machinery | Blue, RAL5015 | Colour: Blue; Colour code: RAL5015; |
|
| electronic control cabinet | Off-white, supplier's standard colour | Colour: Beige; Colour code: RAL7035; |
|
| Protective doors, covers and rotating parts | White or yellow, according to the supplier's requirements | Colour: Yellow; Colour code: RAL1026; |
|
| Stainless steel parts | Primary colours. | ||
| Others shall be executed according to the factory standard of the supplier. When choosing the international colour standard, the supplier will make a plate according to the colour standard and provide it to the demander for confirmation, and the spraying will be carried out according to the colour plate confirmed by both parties. The demander understands and agrees to accept that colour difference variations are allowed. The Demanding Party shall confirm the colour plate with the seal of the Supplier and send it back to the Supplier within one week from the date of receipt of the colour plate provided by the Supplier, after which the delivery period will be postponed. | |||
| Operating Directions: | Right-facing, the operator faces the drawing mainframe, feeds the wire from the left and receives the wire from the right. | ||
1. Basic Parameters
- Scope of production: Suitable for rolling and drawing copper flat wire with rounded corners, width to thickness ratio ≤ 5.
- Finished section: 4-20mm²
- R angle and tolerance of conductor: GB/T 5584
- Width: 3-13mm (Tolerance: ±0.005 mm)
- Thickness: 1-3mm (Tolerance: ±0.005 mm)
- Finished product conventional specifications: 2.65 × 4, 1.7 × 3.4, 1.6 × 3.8
- Feed material: oxygen-free copper rod, low oxygen copper rod
- Inlet diameter: uniform φ8mm copper rod
- Processing passes: 6 passes for drawing, 2 passes for rolling, 2 passes for drawing, 1 pass for annealing, 1 pass for drawing
- Running speed: Designed maximum line speed 300m/min. (Actual speed determined by wire process parameters, rolling and drawing process).
2. Demand Supply
- Power of the whole machine: about ???? ?KW
- Compressed air: For pneumatic tension wheels, supplied by Party A, air pressure 4-6 kg, dry, free of impurities, oil and water.
- Requirements: The ground must be level and well ventilated. The installation workshop length must be at least 28 meters, ensuring sufficient space for installation, loading/unloading, transport, and maintenance.
- Emulsion: Emulsion to be supplied by Party A.
Description of each functional unit of equipment
1. Vertical over-the-horizon payoffs (one set)
Used for the uplift and release of round lines.
2. Wire drawing machines (six sets)
For pre-drawn round billets.
Ingredients:
- Six sets of double roller wire drawing machines (with die box)
- Six sets of tension
Technical Parameters:
- Drawing machine roller diameter: φ500mm
- Drawing machine power: double roller double power
- Wheel width: 160 mm
- Drawing wheel material: ZG45
- Surface treatment of drawbar wheel: sprayed tungsten carbide
- Roll radial runout: ≤0.1mm
- Transmission motor: inverter motor
- Tension wheel lowering method: pneumatic
- Tension wheel diameter: Φ420 mm
- Tension wheel material: wear-resistant nylon
- 1 mould box mounted in front of the traction sheave
- The traction wheels are double-driven, i.e. both traction wheels are powered; Overload protection is provided
- Tractor wheels with internal water cooling
3. Tension devices (two sets)
Used for the linkage adjustment of rolling mill and rolling mill, rolling mill and mould pulling machine one.
Technical Parameters:
- Tension wheels: 3
- Tension wheel lowering method: pneumatic
- Tension wheel diameter: Φ200 mm
- Wheel width: 20 mm
- Tension wheel material: 304
4. Chassis, sheet metal enclosure (1 set)
Rack base with flush guard doors. The machine is operated from the outside, leaving enough space inside for threading and removing rolls.
5. Horizontal two-roll mill ZJ-220, ZJ-180 (one set each)
Roller slit adjustment: Adopting screw to push to achieve, only the upper roll can be adjusted, the lower roll is fixed. The main drive adopts servo motor + reducer and universal joint, the upper and lower rolls drive. Roll cooling adopts external emulsion cooling.
Composition:
- 1 set of horizontal two-roll mill stands
- 1 roll gap adjustment device, driven by servo motor
- 1 main drive: motor + gearbox, fixed to the frame
- 1 guides with symmetrically adjustable guide widths
- 1 fixing bracket for fixing the mill to the base
- 1 set of manual roll transverse reciprocators
Technical parameters:
- Roll bearings: mill bearings lubrication: grease lubrication
- Roll diameter: Φ220 mm, Φ180 mm
- Roll width: 150 mm
- Main Drive: Inverter Motor + Hard Gear Reducer + Universal Joints
6. Cleaning device (one set)
With mounting bracket, 2 sets of tightening felts, felts to be supplied by Party A.
7. Moulding machines (three sets)
It is used for fine drawing of copper flat wire, with double traction wheels and double drive structure. The drawing mould is provided by Party A.
Ingredients:
- 1 mould box mounted in front of the traction sheave
- The traction wheels are double-driven, i.e. both traction wheels are powered; Overload protection is provided;
- The traction wheels have internal circulating water cooling.
Technical parameters:
- Drawbar diameter: Φ500 mm
- Wheel width: 160 mm
- Drawing wheel material: ZG45
- Surface treatment of drawbar wheel: sprayed tungsten carbide
- Roll radial runout: ≤0.1mm
- Transmission motor: inverter motor
8. Vertical tensioning device
It is used for controlling the speed and tension between mould pulling machine 1 and mould pulling machine 2, and between mould pulling machine 2 and take-up machine, and the tension size is adjusted by pneumatic, and the pressure adjustment range is 0~0.6MPa, and the air source is provided by Party A.
Technical Parameters:
- Tension wheels: 3
- Tension wheel diameter: Φ420 mm
- Wheel width: 20 mm
- Tension wheel material: wear-resistant nylon
9. BAOC-400T High-speed induction annealing machine for flat wire
Annealing machine composition: induction annealing machine includes: mechanical parts, electrical parts, steam protection part, cooling part. Compressed air source and cooling water source are not included.
Technical parameters:
- Scope of production: Applicable to copper flat wire. Finished section: 4-12 mm², max. width: 12.0 mm, max. thickness: 2.5 mm.
- Feed material: Oxygen-free or low-oxygen copper rod (SCR or equivalent).
- Annealing speed: 4-8 mm², 320m/min; 8-12 mm², 160-320m/min; (See table below for details).
| Serial number | Cross-sectional area (mm²) | Speed (m/min) | Run | Annealing power | Tonnes of electricity consumption | Note |
|---|---|---|---|---|---|---|
| 1 | 4~6 | 320 | approximate 1000kg | Approx. 80kw | Approximately 80 degrees. | |
| 2 | 6~8 | 320 ~250 | ||||
| 3 | 8~ 10 | 250 ~200 | ||||
| 4 | 10~ 12 | 200~ 160 |
- Speed automatic tracking: annealing performance can reach the national standard and no oxidation.
- Elongation: 30%-40% continuously adjustable;
- Power supply configuration capacity: 150kVA/380V;
- Anti-oxidation method: Steam (the equipment comes with a steam generator);
- Drying method: compressed air blowing dry (air compressor configured by the user);
- Inlet/outlet height: 1200/1800mm;
- Cooling method: circulating water, flow rate 20-50L/min;
- External dimensions: 1100 x 2200 x 2200.
- Demand supply: Compressed air: used for blowing, air source provided by Party A, air pressure 3-5kg, dry, no impurities, no oil, no water. Product cooling water: the temperature of the circulating water used to cool the product does not exceed 45 °C.
Take-up machine (one set)
The spooling machine adopts lifting structure, which can ensure the constant tension of spooling wires, the row of wires adopts servo motor and ball screw, driving the reciprocating motion of the I-beam wheel to achieve, the row of wires distance according to the width of the finished product system customised, can also be manually corrected, the I-beam wheel installation adopts the double-top axle-less structure, which can be automatically clamped.
It is only necessary to place the discs in the specified position on the equipment by other devices or manually, and to disc the torque-transferring pin to the disc hole position. With automatic loading and unloading interface.
With metre counting function, to set the length of the early warning speed reduction, to reach the required length of the stop and alarm. Individual HMI with all operating functions. For example: disc tool size, top and bottom start position, wire pitch, etc.
Technical Parameters
- Take-up speed: 250 m/min MAX
- Maximum load: 1200 kg
- Maximum outer width of take-up reel: 540 mm
- Maximum line width: 550 mm, infinitely adjustable
- Thread pitch: 15mm max.
- I-wheel clamping: pneumatic Take-up reel
Size Specifications
| Take-up disc type | Outer diameter (mm) | Barrel diameter (mm) | Total width (mm) | Maximum gross weight (kg) | Centre shaft hole (mm) |
|---|---|---|---|---|---|
| 1# | 800 | 448 | 540 | 1200 | 127 |
Description: After getting the reversing signal, the reversing servo stops and determines the angle at which the pallet turns by calculating the spindle encoder, and when it reaches the set angle, the reversing servo starts the reversing operation quickly. The basic parameters of the line can be set on the man-machine interface. Fast and accurate steering.
Roll cooling system system (one set)
With non-woven filtration, automatic level detection, automatic non-woven panning.
Electrical control system (one set)
For automatic control of rolling mills.
Technical parameters
- Power supply: 3 x 380V+N+PE, A.C., 50 Hz
- Motor: AC maintenance-free
- Control cabinet: Rittal type electric cabinet
- Wiring: profinet bus connection with cable routing slots outside the rear side panel of the device
- Main control system: Siemens
- Controls include: Inverter for take-up and pay-off control
- Servo control: roll gap adjustment
- Other devices: the internal control cables of the electrical cabinet and the cables from the electrical cabinet to the various control units of the equipment are all provided by Party B. The power cable from the power distribution cabinet to the electrical cabinet is provided by Party A (i.e. Party A only needs to provide external power supply to the electrical cabinet of the equipment).
- Human-machine interface: a main control cantilever box, 10 inch colour screen, for controlling and adjusting the production line. A spooler control cantilever box, 10 inch colour screen, for controlling the spooler. The main control panel is installed on the right side of the rolling mainframe. Auxiliary control panels, which are distributed in different locations of the mill according to their functions. Each auxiliary control panel is equipped with an emergency stop button.
Overview of PLC and electronic control unit functions
- Safety Control Functions: All functions are realised by the PLC, which checks the safety locking status and thus guarantees the safety of the operator and prevents possible damage to the mill components.
-
Automatic control function is realised by the PLC control program:
- Acceleration to set rolling speed
- Deceleration control and stop control
- Checking of all manual and automatic control movements
- Automatic press-down positioning
- Automatic stop when reaching the preset length
- Abnormal alarm control and display during mill production
-
Other control functions:
- Calculation, output and display of the relative value of the speed of each station of the rolling mill
- Position control of each station's undercut
- Calculation of the length of the rolled product
- Synchronised control of rolling speed at each station of the mill
Frequently Asked Questions (FAQ)
Q1: What is the production scope and finished product specifications of this line?
A1: It is suitable for rolling and drawing copper flat wire with rounded corners (width to thickness ratio ≤ 5), finished section of 4-20mm², width of 3-13mm, and thickness of 1-3mm.
Q2: What is the maximum designed operating speed of the machinery?
A2: The designed maximum line speed is 300 m/min, with actual speed determined by the wire process parameters.
Q3: What are the power and utility requirements for installation?
A3: It requires compressed air of 4-6 kg (dry, free of impurities, oil, and water), a level, well-ventilated workshop floor of at least 28 meters in length, and emulsion supplied by the user.
Q4: How does the BAOC-400T high-speed induction annealing machine prevent oxidation?
A4: It utilizes steam for anti-oxidation, and the equipment comes equipped with its own steam generator.
Q5: What are the key features of the take-up machine?
A5: It features a lifting structure for constant tension, a servo motor and ball screw for wire row alignment, a double-top axle-less structure for automatic clamping, and automatic loading/unloading interfaces.
Q6: What control system is used for the electrical control cabinet?
A6: It uses a Siemens main control system, Profinet bus connections, AC maintenance-free motors, and 10-inch color touch screens on the main and spooler control cantilever boxes.