In the metallurgical industry, the wire drawing machine is an important piece of equipment for the production of metal wire. Its main function is to draw various types of wire into fine wires of required specifications. For products with different precision levels and specifications, as well as for different types of metals, different specifications of wire drawing machines can be chosen. For most steel wire manufacturers, considering the characteristics of steel, the direct-in type wire drawing machine is more commonly used.
1.Unwinding: The unwinding process of the wire in the wire drawing machine does not require high precision control for the entire draw ing process. The wire drawing machine with dual frequency inverter control utilizes the wire tension during the drawing process to stretch the wire through the circular disk, meaning the unwinding is automatically controlled by the tension from the subsequent drawing process.
2.Wire Drawing: The wire drawing process varies significantly depending on the type of metal material, the product precision, and the specific requirements. The drawing process is controlled by a main motor (referred to as the main machine). The metal wire is guided through a series of tower wheels and progressively drawn through molds of various sizes to achieve the desired specifications. During the drawing process, coolant is applied to cool the molds.
3.Winding: Winding is the most critical process in a dual-frequency wire drawing machine, having a decisive impact on the performance of the drawing machine. It is also an important criterion for evaluating the performance of the machine's electrical system.
The winding process is driven by a motor that powers the winding reel. The wire comes out from the drawing section and passes through a tension rod. The tension rod's job is to send the current tension signal to the control unit. The control unit adjusts the output frequency based on the difference in the signal, ensuring the tension remains constant during the winding process.
The wire passes through a tension rod and rises to a guide wheel, then is pulled to the guide wheel of a payoff machine. The payoff machine is driven by a small motor, which moves it back and forth. Its function is to lay the wire evenly onto the winding reel. The winding motor drives the winding reel to rotate, automatically winding the wire, guided by the payoff machine, onto the reel. This completes the entire winding process. If a wire break occurs during winding, the system automatically stops and activates the brake to quickly halt the winding reel.
Water Tank Type Wire Drawing Machine: This type of wire drawing machine uses a water tank to cool and lubricate the metal wire during the drawing process. It is suitable for drawing soft metal wires such as copper and aluminum. Its technical characteristics include continuous operation, high production efficiency, and excellent protection of the surface quality of the wire. It is suitable for medium and fine gauge wires, including high, medium, and low-carbon steel wires, galvanized iron wires, alloy wires, etc. The advantages include high production efficiency and good cooling effect, while the drawbacks are its complex structure and relatively high maintenance costs.
Straight-Line Wire Drawing Machine: This machine is suitable for drawing hard metal wires, such as steel wire. Its technical features include precise control of tension and speed during the drawing process, ensuring stable drawing quality. The straight-line wire drawing machine is typically equipped with multiple drawing wheels, allowing for multiple passes in the drawing process. It is suitable for high, medium, and low-carbon steel wire, stainless steel wire, copper wire, and other materials. The advantages include good cooling effect, high transmission efficiency, and a high level of automation, while the drawback is the higher equipment cost.
Drum-Type Wire Drawing Machine: This machine uses multiple drums to stretch the wire, making it suitable for processing various metal wires. Its technical features include a simple structure, easy operation, and low maintenance costs, making it ideal for small-batch and multi-variety production needs.
CNC Wire Drawing Machine: This machine is controlled by a computer, enabling high automation and intelligence in the wire drawing process. Its technical features include precise control of tension, speed, and temperature during drawing, ensuring high quality and consistency of the drawn products.
The water tank-type wire drawing machine typically consists of the main machine, drawing die, tension balance bar, take-up machine, and wire laying machine, as shown in the diagram below:
Generally, the pay-off reel does not require motor control and is free to unwind. The drawing machine adjusts the speed using an external potentiometer. The take-up reel controls the inverter which receives a combination of the frequency signal output by the drawing machine and the position signal from the tension rod to adjust the tension. The wiring diagram is shown below:
The straight-line wire drawing machine consists of a take-up main unit and multiple tower reels. The number of tower reels varies depending on the machine, typically ranging from 4 to 8 reels. Each tower reel is equipped with a cylinder swing arm for feedback control to prevent wire breakage. The pay-off is generally free unwinding. The diagram is shown below:
The straight-line wire drawing machine requires interlocking control during wire threading. The start signal for each tower reel is controlled by the PLC. The speed of the tower reels is controlled by a combination of the frequency signal output from the take-up main unit and the feedback signal from the cylinder swing arm, ensuring smooth operation of the system. The reference wiring diagram is shown below:
he start-up of the straight-line wire drawing machine requires the PLC to provide signals, as interlocking control between different tower reels is necessary during wire threading. Additionally, in the event of a wire break, the entire machine needs to be stopped. However, the FR500L can support a simple wiring method without the need for a PLC. The reference wiring diagram is shown below:
In a water tank type wire drawing machine, some equipment simplifies wiring and debugging by using a torque method for wire winding. A potentiometer is used to adjust the torque, thereby controlling the tension of the wire. Typically, the torque winding inverter only needs to receive the operation signal and the potentiometer signal. Its connection with the main wire drawing inverter is minimal, essentially functioning as an independent system, making the debugging process easier. The wiring diagram for the torque winding inverter is shown below:
