Multi-wire drawing machine, continuous annealing and annealer machine
sponsored by Pan-Pioneer Co., Ltd.
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A. DM Multi-Wire Drawing Machine
1.] Main specification:
1.1.) Type: Wet type multi wire Drawing Machine ;In-Line Continuous annealing machine machine with Twin-Motor quick-change functionality
1.2.) Application:
1.2.1.) For copper wire Mass-Production (wire harness for example) purpose , 7/8 wires in-line bunched (no accurate bunching pitch needed) and go to extrusion directly.
1.3.) New Features:
1.3.1.) Twin-Motor system with both quick-change / high-speed mode selectable
1.3.2.) Constant Slip rate.
1.3.3.) 13dies X 8 wires (custom-design)
1.3.4.) Two-step speed gear box (high/Low speed selectable)
1.3.5.) In-line annealing machine machine with CCCS annealing machine machine control technology
1.3.6.) Final capstan slip rate adjustable (CCCS functionality)
1.3.7.) Die sequence database can save up to 200 set of die sequences, operator can recall the die sequences from database for operation.
1.3.8.) A automatic die sequence correction functionality, automatic slip rate calculation to avoid Human errors
1.3.9.) Fin-tuning annealing machine curve functionality, improve the annealing machine power-control accuracy under low line speed. (CCCS)
1.3.10.) CCCS will base on the base die sequence and the multi-wire drawing machine mode being select (quick die-change or high speed multi-wire drawing machine mode) schedule and calculate the corresponding die schedule for Operator. This feature will save the number of dies User have to buy for different finishing wire sizes. Please refer to the following references.
|
|
RD Ratio (%) |
Pan-Pioneer (2.0-0.4mm) |
Pan-Pioneer (8.0-1.3mm) |
Other company (2.0-0.4mm) |
Other company (2.0-0.4mm) |
|
Inlet(13) |
30.0 |
1.67 |
|
1.67 |
|
|
12 |
25.0 |
1.45 |
|
1.45 |
|
|
11 |
25.0 |
1.25 |
1.67 |
1.25 |
1.67 |
|
10 |
20.0 |
1.12 |
1.45 |
1.12 |
1.45 |
|
9 |
20.0 |
1.00 |
1.25 |
1.00 |
1.25 |
|
8 |
20.0 |
0.90 |
1.12 |
0.90 |
1.12 |
|
7 |
20.0 |
0.80 |
1.00 |
0.80 |
0.79 |
|
6 |
20.0 |
0.72 |
0.90 |
0.72 |
0.70 |
|
5 |
20.0 |
0.64 |
0.80 |
0.64 |
0.63 |
|
4 |
20.0 |
0.57 |
0.72 |
0.57 |
0.56 |
|
3 |
20.0 |
0.51 |
0.64 |
0.51 |
0.50 |
|
2 |
20.0 |
0.46 |
0.57 |
0.46 |
0.45 |
|
Finishing |
Variable |
0.42 |
0.42 |
0.42 |
0.42 |
Remarks : You waste more money on purchasing dies.
1.3.11.) Variable inlet wire sizes and finishing wire size just by ken-in the wire sizes then the CCCS system will calculate and display the correct and corresponding die sequences on the TFT Touch screen.
1.3.12.) Human Error Free functionality: Any Error due to operator Key-in the data , for instance, data out of range , slip ratio incorrect , or try to change parameters while machine is running, CCCS will discard the instruction from operator and warning on the TFT monitor.
1.3.13.) Adjustable Slip ratio: There are two situations you may get advantage from special slip ratio setting.
a.) In case of special situation, CCCS allow operator make special setting to overcome it. For example, if the finished wire is 1.3mm for example and which is far from the capacity of normal operation, To achieve this goal, operator can do the special setting as follows:
|
|
RD Ratio (%) |
Pan-Pioneer (2.0-0.4mm) |
Traditional Setting(Fail) |
Special Slip Ratio setting |
||
|
Inlet(13) |
35.0 |
1.61 |
1.61 |
1.95 |
||
|
12 |
30.0 |
1.35 |
1.35 |
1.53 |
||
|
11 |
20.0 |
1.21 |
Spare |
1.30 |
||
|
10 |
20.0 |
1.08 |
Spare |
1.32 |
||
|
9 |
20.0 |
0.97 |
Spare |
Spare |
||
|
8 |
20.0 |
0.86 |
Spare |
Spare |
||
|
7 |
20.0 |
0.77 |
Spare |
Spare |
||
|
6 |
20.0 |
0.69 |
Spare |
Spare |
||
|
5 |
20.0 |
0.62 |
Spare |
Spare |
||
|
4 |
20.0 |
0.55 |
Spare |
Spare |
||
|
3 |
20.0 |
0.49 |
Spare |
Spare |
||
|
2 |
20.0 |
0.44 |
Spare |
Spare |
||
|
Finishing |
variable |
0.40 |
1.28 |
|||
|
|
|
Base Line |
|
|
||
b.) Remark: For traditional quick-change mode, not enough torque to draw the over size wire but the special slip mode can achieve this goal by reduce the load of the final capstan motor (the limitation is on final multi-wire drawing machine capstan).
c.) Slip on the final capstan may damage the finishing capstan easily or generate flaws on the surface of copper wire. Without Slip, there is no tolerance for synchronization, Therefore minimize the slip ratio while not break the wire often, CCCS can compromise these situation by control the slip ratio precisely.
1.3.14.) Hybrid Multi-wire drawing machine Mode: This mode is to compromise and take the merit of both High speed multi-wire drawing machine mode and Quick Change multi-wire drawing machine mode. As we realize , the advantage High speed mode is just as its name : Operate the machine at it full speed no matter the finishing wire sizes you set. To achieve this , you have to put a big motor to overcome the worse case ( the max. finishing wire size).
However, as we under that most of time, the products sizes are
between the Max. and Min. wire size this machine is designed for Under such
circumstance, you lose the profit from the cost of a big motor as well as the
electric bill (caused by the bigger motor). The quick-change mode is to
overcome this flaw of high speed (single motor) design as well as changing the
final multi-wire drawing machine die only while change the produces. The
disadvantage of quick die change mode is the line speed of this mode is
relatively slow compare to the High speed mode since it keep the multi-wire
drawing machine dies at the same position and leave spare spaces close to
the finishing die position. Under such considerations, we develop a Hybrid mode
to overcome such condition.
The theory of Hybrid mode is,
generally speaking, is to utilize the maximum performance of this multi-wire
drawing machine by moving the die-sequence a couple position forward until
the system motor maximum capacity. The example is showing follows:
The Driving Motor
capacity need :
Quick Change ¡Õ Hybrid-1 ¡Õ Hybrid-2 ¡Õ High Speed
The Driving Motor capacity need :
Quick Change ¡Ö Hybrid-1 ¡Ö Hybrid-2 ¡Ö High Speed
Moreover , The High speed mode need different die
sequences (part or all) which will cost more for User since User has to buy more
dies for wire multi-wire drawing machine.
Therefore the Hybrid mode can compromise both Quick change and High speed wire multi-wire drawing machine mode.
1.4.) Inlet wire size range: (custom-design)
1.5.) Final wire size range: mm(custom-design)
1.6.) Speed of final capstan: m/min selectable
1.7.) Capstan diameter: mm.
1.8.) Number of Lines: 8 lines/machine(custom-design)
1.9.) Number of multi-wire drawing machine dies draft: 13 dies for each line
1.10.) Machine area reduction
1.10.1.) for intermediate dies
1.10.2.) Variable for final capstan (CCCS functionality)
1.11.) Power supply: 3 phase, 380V, 50Hz
1.12.) Capstan material:
1.12.1.) Main body: Medium carbon steel with hardness process
1.12.2.) Surface: Tungsten-Carbide coating steel
1.13.) Operation direction: From left hand to right hand (R.H. machine)
Driven motor:
1.13.1.) 250HP DC motor for main drawing, 50HP DC for the final capstan and annealing machine device.
1.14.) CCCS: MMI + PLC, monitor key-in the finish die size and some necessary data, the finish capstan will automatically Running at properly line speed without slip.
2.] Machine Composition
2.1.) DC motor with Drive control system............................................................... 1set
2.1.1.) motor with Control unit for Wire multi-wire drawing machine 1set
2.1.2.)
DC motor with Control unit for final multi-wire drawing machine
capstan 1set
and annealing machine device
2.1.3.) 30HP AC motor with inverter and encoder for 630mm take-up 1set
2.1.4.) Control cabinet with accessories ........................ 1set
2.2.) Synchronization control system .................................................................... 1set
2.2.1.) Touch Screen monitor + PLC .............................. 1set
2.2.2.) CCCS motor synchronization software................ 1set
2.2.3.) CCCS Annealing machine control system....... 1set
2.3.) Multi-wire drawing machine Mainframe.................................................... 1set
2.3.1.) Multi-wire drawing machine capstan...... 12X8units
2.3.2.) Aluminum multi-wire drawing machine cover with viewing windows (tempered glass) 1set
2.3.3.) Final multi-wire drawing machine capstan 1X8units
2.3.4.) Cover for final multi-wire drawing machine capstan 1set
2.3.5.) Inching / Jogging pad.............................................. 1set
2.3.6.) Transmission gear box........................................... 1set
2.3.7.) Two step gear box.................................................. 1set
2.3.8.) Gear box oil circulation system with oil lever viewing window 1set
2.3.9.) Internal multi-wire drawing machine lubricant tank 1set
2.3.10.) Internal piping system of multi-wire drawing machine lubricant circulation 1set
2.3.11.) Wire broken detector......................................... 8units
2.3.12.) Operation panel.................................................... 1set
2.3.13.) Forged die holder............................................. 13sets
2.3.14.) Lubricant Spray nozzle for multi-wire drawing machine dies 13sets
2.3.15.) Heat exchanger with pump for multi-wire drawing machine lubricant system 1set
2.4.) In-Line continuous annealing machine device................. 1unit
2.4.1.) Annealing machine Mainframe.......................... 1set
2.4.2.) Nickel alloy contact sheave.................................... 3set
2.4.3.) Annealing machine power control system........ 1set
2.4.4.) Build-in annealing machine tank........................ 1set
2.4.5.) Steam generator..................................................... 1set
2.4.6.) Internal Annealing machine lubricant circulation system 1set
2.4.7.) Heat-exchanger for annealing machine system 1set
2.4.8.) Bakelite / Mc-lon Guide Rollers........................... some
2.4.9.) Cooling Lubricant level control valves................. 4sets
2.4.10.) Built-in Lubricant tank with lubricant lever detectors 1set
2.4.11.) Heat exchanger with pump for annealing machine lubricant circulation 1set
2.4.12.) Thermal couple with temperature controller indicator 1set
2.4.13.) High flow air wiper................................................ 1set
2.4.14.) Annealing machine control Panel.................... 1set
2.4.15.) Annealing machine power controller............... 1set
2.4.16.) Annealing machine power transformer........... 1set
2.4.17.) Locking door......................................................... 1set
2.4.18.) Inching pad............................................................ 1set
2.4.19.) Air-cooling blower for contact shafts................... 1set
2.4.20.) Rotary water Joint for contact shafts internal cooling..... 1set
2.5.) 630mm take-up unit................................................................ 1unit
2.5.1.) Speed control dancer system............................... 1unit
2.5.2.) Shaft-less type with air-reverse (spring engage) lock type 1unit
2.5.3.) AC motor system with encoder close loop control 1unit
2.5.4.) Length counting System......................................... 1set
2.5.5.) Wire broken detector.............................................. 1set
2.5.6.) Safety cover with viewing windows (tempered glass) 1set
2.5.7.) Pneumatic brake system........................................ 1set
2.5.8.) Itching pad................................................................ 1set
2.5.9.) Operation Panel...................................................... 1set
2.5.10.) Motor and belt type
transmission system........... 1set
DM Multi-Wire
Drawing Machine
3.] Detail specifications:
3.1.) Main body of multi-wire drawing machine:
3.1.1.) Type: horizontal type, 13
capstans lay on a tandem line
8 wires drawn simultaneously with 2-step selectable speed gear box.
3.1.2.) Main frame: made of steel plate, annealed after welding and precision machine finishing will be done
3.1.3.) Gears: made of high quality carbon steel, all gear teeth with class 7 well grinded after heat-treatment and nitro-treatment for sound immunity. A dynamic balancing test will be done to avoid machine vibration
3.1.4.) Shaft: made of high quality carbon steel, grinding will be done after heat treatment.
3.1.5.) Gearless type, speed is controlled by CCCS system
3.1.6.) Capstan:
a.) Type: Capstan ring insert type,
b.) No. of capstan: 13 sets total
c.) Arrangement of capstan: 13 sets of capstan installed inside the multi-wire drawing machine chamber and one set of finishing capstan installed outside of the chamber
d.) Capstan ring: 140mm X 8 grooves
e.) Material of capstan: Medium carbon body with a 3mm thickness tungsten-carbide spray coating
f.) Hardness of capstan surface: 65 Hrc
g.) Surface finishing: by machine grinding
3.1.7.) Multi-wire drawing machine Die dimension: 30mm/ODx15mm/W
3.1.8.) Mechanism area reduction ratio:
a.) No.1-No.12 die: 20% constant reduction ratio
b.) No. 13 finish die: variable (Quick die change)
3.1.9.) Mechanism elongation:
a.) No.1-No.12 capstan: 25% elongation.
b.) No.13 finish capstan: variable (Quick die change)
3.1.10.)
Multi-wire drawing machine capacity::
22-25 m/s for 0.7mm or less copper wire (depends on the material of the copper
rod)
17 m/s for 0.7mm and bigger copper wire
3.1.11.) Brake: pneumatic type controlled by the CCCS and compressed air pressure . It is located on the motor transmission shaft..
3.1.12.) Front cover:
a.) Type: Foldable type, made of aluminum with viewing windows (tempered glass) Open and close of door done manually
b.) Two pieces are with handles for manual lift-up.
c.) Limit switches are for safety. Machine will stop automatically while it is opened.
3.1.13.) Gear oil lubrication:
a.) A Gearbox is located on the backside of the multi-wire drawing machine.
b.) All the gears are immerged into oil level.
c.) All the bearings are oiled by circulating oil tube.
d.) Oil cooling: with circulation pump and tube type heat exchanger for oil circulation and cooling
3.2.) Finishing capstan:
3.2.1.) Install at the output of multi-wire drawing machine, same diameter as other multi-wire drawing machine capstans
3.2.2.) Speed: Speed can be adjusted by the CCCS and it operates speed synchronously with main motor. CCCS will calculate the corresponding speed of both main motor and final capstan motor, which is based on the data from operator input via touch screen monitor or recalled from database stored in the CCCS database. CCCS will send the commends to both main motor drive and final capstan motor drive via high speed communication MOD bus which is immunized by noises which D/A A/D traditional communication cannot.
3.2.3.) Multi-wire drawing machine dies arrangement:
a.) CCCS will supply one based line which is stored in its database, operator key-in the product wire size to CCCS and CCCS will calculate the right die sequence and die location for operator, Meanwhile CCCS will show the productivity, the motor speeds of both main motor and final capstan motor as a references for operator.
b.) Operator
can key-in the slip ratio of the final capstan to keep the surface of the
product is perfect condition meanwhile extend the lifetime of multi-wire
drawing machine dies.
ACM-300 In-Line Continuous Annealing machine and
Anenaler machine device
4.] Main specification:
4.1.) Type: 3 phases contact seaves type
4.2.) Line speed: mps Max.
4.3.) Annealed wire range : mm.
4.4.) Transformer: dry type A class.
4.5.) Power surce: External AC power source
4.6.) Annealing machine and Anenaler machine power is controlled by CCCS system which special software which controlled the true RMS ( root-mean-saqure) algorithm with Annealing machine and Anenaler machine curve fine tune functionality rather than the traditional rough control system.
5.] Machine composition:
5.1.) Annealing machine and Anenaler machine Mainframe........................................ 1set
5.2.) Transmission system (from multi-wire drawing machine final capstan motor)..... 1 set
5.3.) nickel alloy contact sheave........................................................................................... 3sets
5.4.) Annealing machine and Anenaler machine power control system...................... 1set
5.5.) Build-in Annealing machine and Anenaler machine tank...................................... 1set
5.6.) Steam generator............................................................................................................... 1set
5.7.) Internal Annealing machine and Anenaler machine lubricant circulation system... 1set
5.8.) Heat-exchanger for Annealing machine and Anenaler machine system............. 1set
5.9.) Bakelite / Mc-lon Guide Rollers.................................................................................... some
5.10.) Cooling Lubricant level control valves.......................................................................... 1set
5.11.) Built-in Lubricant tank with lubricant lever detectors................................................... 1set
5.12.) Expendable fin typeHeat exchanger .......................................................................... 1set
5.13.) A pump for Annealing machine and Anenaler machine lubricant circulation system 1set
5.14.) Thermal couple with temperature controller indicator................................................. 1set
5.15.) high flow air wiper........................................................................................................... 1set
5.16.) Annealing machine and Anenaler machine control Panel.................................. 1set
5.17.) Annealing machine and Anenaler machine power controller............................. 1set
5.18.) Locking door................................................................................................................... 1set
5.19.) Inching pad...................................................................................................................... 1set
5.20.) Air-cooling blower for contact shafts............................................................................ 1set
5.21.) Rotary water Joint for contact shafts internal cooling................................................. 1set
5.22.) Inlet wire tension roller.................................................................................................... 1 set
5.23.) 300KVA transformer...................................................................................................... 1 set
5.24.) Steam generator............................................................................................................ 1 set
5.25.) Built-in Annealing machine and Anenaler machine lubricant sub-tank.............. 1 set
5.26.) CCCS: MMI+PLC Annealing machine and Anenaler machine control system 1 set
5.27.) Water cooling rotation joints for contact-sheaves shaft cooling purpose.
6.] Detail specifications:
6.1.) Annealing machine and Anenaler machine:
6.1.1.) Type: 3 phases, contact sheaves AC electric resistance type
6.1.2.) Contact sheaves:
a.) 140mm diameter. x 8mm grooves
b.) Sheave shaft cooling: a rotary water-cooling joint for shaft cooling circulation system.
c.) Each carbon brush contact chamber uses high flow air blowing cooling
6.1.3.) Sheaves material: copper wheels with Ni-Cr band
6.1.4.) Annealing machine and Anenaler machine speed: Max.
6.1.5.) High-flow air wipers for drying the wire after Annealing machine and Anenal