Copper Plating Line for Solid Wire
Components
Dancer
Mechanical polishing machine
Alkali degreasing device
Pickling tank
Washing tank
Copper coating tank
Neutralization washing tank
Drying device
Skin pass machine
Electrical control system
Technical Data
Max speed: 18m/s.
Wire diameter: Φ0.8-1.6mm.
Tensile strength of inlet wire: ≤1250MPa.
The Drying device’s heating with induction heating coil, heating source is 37KW inverter.
Die box of Skin pass machine using Oil-based lubricant. Synchronous motor 15KW.
Water pressure: ≥0.2MPa, air pressure: ≥0.5MPa.
Total power: about 79KW.
Floor space: 22430×3000×1850mm (Length × Width × Height).
Main Functions
Each tank is short and has winding wheels.
Wire is round the wheel many times to ensure that the time wire stay in the liquid is long enough to achieve a high plating speed.
The line length is about 20-25m, and the working speed can achieve 18m/s.
Each tank is provided with water throwing device to prevent different liquid mutual mixing.
No air blowing device required and needn’t configure air blower.
Heating with induction heating coil. The drying power varies with the speed of wire, ensuring that the wire can be dry and not overheated at any speed to achieve high drying efficiency.
Drum diameter of skin pass machine is 400mm, die box using Oil-based lubricant, antirust effect is good and the wire feeding performance is better.
Accord with the requirement of energy saving and cost reduction.
Main Equipment
Dancer
5 wheels, material is HT200.
Tensioning manner of Dancer: cylinder.
Be installed non-contact displacement sensor.
Mechanical Polishing Machine
The lubricant on the surface of the welding wire is wiped by rotating steel wire ball.
The steel wire ball scrapes the lubricant on the surface of the welding wire, which is conducive to reducing the pressure of the subsequent alkaline cleaning.
2 * 0.75KW AC motor drive.
Alkali Degreasing Device
The temperature of the wire drawn out is higher so it is easier to remove the lubricant at the same time.
No heating is necessary after normal production and the higher temperature of the wire drawn out will be enough to heat the lye.
While lye needs preheating if restart it after a long shut down.
Removing lubricating on the surface of welding wires with alkaline and scouring pad achieves a better treatment effect.
Tank is made of 304 stainless steels and divided into upper and lowers.
The upper tank has mechanical wire polishing device and two groups of winding wheel components, polishing with scouring pad. Electric heating 12KW.
The wheel is made of cast iron and the wire is 8 times round the wheel. The length of the collecting wire is about 35 meters.
1 piece of 5KW pump enables liquid circulation between the upper and lower tanks.
Outline dimension: 2900×1200×1500mm(Length × Width × Height).
Pickling Tank
Tank is made of PP and it has upper exhaust pipe interface.
The frame is made of 304 stainless steel square tube to prevent tank deformation.
2 groups of winding wheels are in the tank and the wire is 5 times round the wheel.
The length of the collecting wire is about 12 meters.
The wheel is made of polymer.
1 piece 0.75KW pump to realize the upper and lowertank liquid circulation.
Outline dimension: 1810×1210×1400mm(Length × Width × Height).
Copper Coating Tank
Tank made of PP and upper exhaust pipe interface is set.
Electric heating is 6KW.
The frame is made of 304 stainless steel square tube to prevent tank deformation.
2 groups of winding wheel are in the tank and he wire is 8 times round the wheel.
The length of the collecting wire is about 35meters.
The wheel is made of polymer.
1 piece of 1.5KW pump is to realize the upper and lower tank liquid circulation.
Outline dimension: 2650×1300×1400mm(Length × Width × Height).
Neutralization Washing Tank
Tank is made of PP and divided into 3 parts of first washing, neutralization and cleaning .
304 stainless steel pipes are used for high pressure washing.
3 pieces of 0.75KW pump are to realize the upper and lower tank liquid circulation in each part.
The cleaning tank needs to add clean water and excess water overflows into the washing tank for recycling and saving water.
The exit port is provided with 2 swing wheels with each part, which are used to get rid of the water on the surface of the wire.
The swing wheels are made of 304 stainless steels.
Outline dimension: 4900×1200×1320mm(Length × Width × Height).
Drying Device
The wire is heated by the unique principle of non brush resistance heating and ready to use at any time without preheating.
High equipment utilization with low energy consumption.
Compared with the common electric heating tube and the energy consumption is reduced by 70%.
The device has the advantages of small volume, simple and convenient installation.
The equipment has a separate control system so it can be connected with the front and the back working equipment on-line.
The speed of the wire is measured by non-contact speed sensor, and the PLC is used to control the heating current.
The drying power varies with the speed of wire to ensure that the wire can be dried and not overheated at any speed.
The running speed of the wire, the fault code and other data can be shown on the display screen.
Temperature parameter can be adjusted according to the drying effect to ensure the wire is thoroughly dried.
The front door is with square holes, and the top is provided with a fan which is favorable for the distribution of water vapor.
Inovance (made in China) inverter is provided for heating source and the power is 37KW (Power in actual use about 8KW).
Outline dimension: 1850×900×2000mm(Length × Width × Height).
Skin Pass Machine
The horizontal type drums avoid any torsion with wire and ensure the good quality for the wire.
The capstan diameter is Φ400mm and material is ZG45 steel with TC (tungsten carbide) spraying on the working surface，which is hard and wear-resistant to avoid damaging the surface of the welding wire.
In the inner of the drum there is spiral groove, which can effectively increase the cooling area and ensure the cooling effect of the wire.
Oil-based lubricant is used on die box and it achieves good antirust effect and better wire feeding performance .
AC motor power is 15KW.
Outline dimension: 1200×1000×1200mm(Length × Width × Height).
Dancer
5 wheels, material is nylon.
Tensioning manner of dancer is cylinder.
Installed non-contact displacement sensor.
Spooling Machine
Outside diameter of bobbin in the wire spooling machine can be designed as customer’s requirement.
The wire winding with constant tension controlled by inverter.
Wire tension stability, effectively reduce uneven wire tension cause deformation to the bobbin.
Bobbin clamping by cylinder, and have a check valve to avoid the bobbin falling off when the air pressure suddenly reduced.
The brake: by cylinder.
Traverse unit: timing belt.
AC motor power is 22KW.
