High ductility cold rolled ribbed steel bar ( steel wire ) production line

TW3B-800/12-F

Machine Parameters
Rated Power:    Medium frequency: 800KW. Rolling mill: 160KW
Dimension: Length 40m, Wide 5.5m.
Max. speed: 180m/min.
Workpiece size range: Φ5.5-Φ12mm.
Max. vibration intensity: V≤2.8m/s.
Max. temperature rise: 60℃.
Receiving part is available for selection: standard double steel machine is 12 meters, 1.5t plate screw production line.

Equipments of Production Line

Introduction: Processing speed: Φ5.5 mm - Φ7 mm of up to 180 meters per minute (including Φ 7 mm). Φ8 mm - Φ10 mm of up to 150 meters per minute (heating temperature 580 ℃);Φ 10.5 mm - Φ 12 mm up to 130 meters per minute (heating temperature 580 ℃). note: heating temperature > 580 ℃ have influence on wire speed.

Machine Summary
Composition: Cold rolled ribbed bar and wire machine mainly composed of dephosphorization machine, driving and drived rolling mill, medium frequency heat treatment device, CNC fly shear, speed measuring device, automatic steel tilting machine or coiled reinforced bar device, baler etc.
Function: Ordinary carbon steel as material, through reducing the diameter, forming and heat treatment to improve the material grain boundary organization distribution, improve the physical properties, automatically sizing, cutting and baling to storage.

Features
1. Adopting driving and drived rolling mill structural style, one time reducing and one time formaing technical production process; adjustable-velocity, easily change roller, easy operation; solving the old process, poor product quality and hard operation etc problems of traditional cold rolling rebar machine.
2. This production line adopts on line heat treatment, on line control, on line quality inspection etc technology, automatically, high speed continuously operating, the mechanical property of the cold rolled ribbed bar and wire is over national standard GB13788, and achieving hot rolling Ⅲ grade steel standard.
3. Full automatic 10M.
4. Full automatic 12M.
5. Coiled cold rolled ribbed bar production line.

Phosphorus removal machine
1. Reducer adjustmnet to save labour.
2. Adopt the design of full-enclosed protection guard, to guarantee environment clean.
3. Adopt YG8 alloy guide mold and Cr12 alloy guide wheel.
4. The design of optimizing the loading angle guarantees loading smoothly.

Function: Wipe off oxide layer of raw material surface, reduce adhesion of rolling ring surface, protect rolling ring and medium-frequency device, improve surface quality of the products.
Principle: Gear motor drive worm, worm reversing and transfer power to the worm gear, worm gear drive turnplate, guidewheel reversing volume raw material to the "S" type.

Power unit of driving and drived rolling mill
Function: Provide rolling power
Principle: Variable-frequency motor provides two power axis by transformation ratio slow down of gear motor, and drive upper and lower spindle.
1. YVF 132KW three phase variable-frequency motor: Started up by frequency converter low frequency and low voltage, small starting current, small impact to power system; infinitely adjustable-speed, saves the electricity.
2. Motor and gear motor adopt couplings with spring dowel pin, noise reduction and buffer, automatic adjustment of axis center.
3. The features of universal coupling: large angle compensation capacity, transmission efficiency of 0.98, large bearing capacity, smooth rotation, convenient disassembly and maintenance of equipment.
4. Reducer: Adopt air-cooled whole to decrease oil temperature.

Reducer
1. The reducer is machine of decelerate of hard tooth surface, structure and gear parameters through computer optimization; the material adopts high strength low carbon alloy steel(20CrMnMo), and carburizing and quenching process, tooth surface hardness to over 350HBS; The tooth shape adopts CNC gear grinding process, the accuracy of national standard level 6.
2. High transmission efficiency, the transmission efficiency more than 0.9.
3. Smooth running, small noise.
4. Large bearing capacity, easy to disassemle and maintenance.

Rolling mill unit: reducing mill
Function: Rough processing products.
Principle: After finishing mill start-up, operation gear motor drive worm gear and worm, drvie the two screw ratition, drive respectively bearing box near to the appropriate position, then process the raw material.
Structure: Reducing mill mainly consist of base, spindle unit, gear motor, worm gear and worm etc. The base is whole casting, spindle is whole unit and dismantling and loading convenient.

Bearing box unit
1. Spindle unit consist of spindle, rolling ring, upper and lower bearing boxes, three bearings, two nuts with finishing teeth and etc. The spindle unit is a whole structure.
2. The spindle adopts 45# steel a whole casting and through tempering heat treatment, good reliability.
3. Rolling ring adopts WC alloy that is a rolling special use material; Rolling ring lock using nut locking with fine thread, and through the top wire locking structure, avoid rolling ring loosing.
4. Spindle bearings consist of one special steel rolling four row cylindrical roller bearing, one pair thrust ball bearing; Roller bearing mainly bear radial rolling force, thrust ball bearing mainly bear axial rolling force, the force distribution of rolling force can improve the bearings service life.

Rolling mill unit: Spindle 
Structure 
1. The spindle unit mainly consist of spindle, rolling ring, four bearing boxes, four bearings, two nut of fine thread, four oil seal and etc. Upper and lower spindle are the whole structure.
2. Spindle is forged by alloy steel(20CrMo), through the tempering, quenching and heat treatment, high strength surface and good internal flexibility.
3. Rolling ring use WC alloy steel that a kind of special material for roll; Rolling ring lock adopt double nut, resistance to vibration, check back, locking. 
4. Spindle bearings consist of one special steel rolling four row cylindrical roller bearing, one pair deep groove ball bearings; Roller bearing mainly bear radial rolling force, deep groove ball bearing mainly bear axial rolling force, the force distribution of rolling force can improve the bearings service life.
5. The lubrication of spindle bearings use lipid oil at fixed period, can completely meet the demand of working condition of equipment and after period easy maintenance, low maintenance cost. 
Tungsten carbide(WC) alloy forming roller ring: The fit clearance of rolling ring and spindle achieve optimization design at the long term practice, easy disassembly and not wear axis.

The rolling part of driving and drived rolling mill
Function: Finish rolling products.
Principle: Adjust lower spindle to compaction raw material, universal coupling drive upper and lower spindle relative rotation, friction drive the raw material, and continuous rolling products.

The adjustment of roller seam
1. The upper roller is fixed structure, adjusting height of lower roller can achieve adjustment of the roller seam.
2. The adjustment of lower roller: one can handle operation, through motor of reducer driving worm and worm gear, drive the lifting screw up and down to adjust roller seam; another using wrench rotate the worm then adjust the roller seam.
3. Adjust the nut of the side of lower roller can achieve the adjustment of right and left.

Rolling mill unit: Dovetail slide
1. Use 3D coordinate type design, all parts are integrally casting, among sliding plates adopt slide-type connecting structure, can adjust freely spatial orientation of raw material and adjust accurately the seam of guide and roller ring by hand wheel to drive screw and nut.
2. Guide ram and guide body are made of 45# steel forging, guide wheel are Cr12 alloy quenching treatment, to ensure that guide rigidity, reliability and abrasive resistance of guide wheel.

Scramming device

Function: Protect equipment
Principle: When appear production problems, steel bar line by straight to distort and staching, stop device feedback signal to the PLC system, and instructions that alarm and stop immediately issued by the PLC system.
Structure: Nylon sleeve, induction, base, etc.

Medium-frequency Heating equipment
Function: Improve extending performance of steel material
Principle: Through IGBT full solid-state induction heating module to heat products to a certain temperature under Ac1, eliminate stress, refine the grain size, stable size, ensure accuracy.

The features of medium-frequency heating equipment
1. IGBT full solid-state induction heating module, quick heating, little energy, high efficiency, compare the thyistor internediate frequency to save electrical energy about 30%.
2. Come into being rarely higher harmonic, few pollution in power system. Transformer switch is not hot, not interfere with the equipment operation.
3. Medium-frequency water recycling system adopts water exchange, inner loop using distilled water, so all waterway of long-term use equipment have not water scaling and jams, greatly reduce the fault, save the maintenance cost.
4. The circuit structure is simple, complete protection function, complete fault display function, can qucikly find the fault point, easy maintenance.

Speed measuring device
Function: Determination of production line speed and length of product.
Principle: Adjust the spring to compress rebar, friction drive tachometer wheel, wheel drive the encoder, the encoder transfer information to operation station, know speed and length.

Flying shear
Function: Shearing rebar
Principle: According to the length requirement, PLC control servo motor and drive gear deceleration, to achieve shearing tool instantaneous cutting.

Features
1. Flying shear adopts international advanced electronic CAM technology, through the high speed data acquisition external signal, then after a complex operation, finally realizes the high precision control of the actuator, to ensure the online length cutting precision.
2. Flying shear mainly consist of base, box-body, gear mechanism, servo motor, shearing tool, tool plate, pipe, etc.
3. Adopts gear reduction structure, PLC centralized control.
4. Spindle is forged by 40 Cr alloy; Hard teeth surface gears adopt high strength low carbon alloy steel, and carburizing and quenching process; Great stability, high precision, cutting precision is ±5mm.
5. Adopt servo motor, high precision, large torque, reliable, and timely service.
6. Hard alloy shearing tool, wear resistance, strong impact resistance; Tool block use compensation structure, such as tool wear gap, tool block can move up and down, left and right, make full use of tool.
7. Adopt drum-type cog-wheel coupling , large bearing capacity, isolation vibration, low noise.
8. Enhanced base can reduce the fuselage vibration.

Centralized controlled operational cabinet
1. Electrical system of the production line mainly consist of rolling mill and medium-frequency control system, medium-frequency heating system, flying shearing system and steel tilting system.
2. Electrical system of the production line achieve highly automatic and centralization, According to production require, the system can set and adjust all parameters, such as the production speed of production line, medium-frequency tempering temperature, the specified length of flying shear, the number of single bundle, etc.

Steel Bar tilting machine
Function: Cutted rebars into the holder.
Principle: After flying shear cutted, transport products to steel tilting machine by accelerated roller conveyor, products tilted holder, centralized control system met the requirement of the test number, reversing rolled ssteel, continuous, automatic operation; Finally moving packing machine to need of packing, wear steel belt and packing.
Structure: The steel tilting system mainly consist of accelerated roller conveyor, tilting part and packing part, controlled by PLC system, coordination, continuous, automatic operation.
1. Accelerated roller conveyor mainly consist of accelerated motor, guide. Its function is to accelerate the moving speed of rebars, avoid before and after rebar pile of steel.
2. Steel tilting unit mainly consist of stepping motor, tilting shaft, tilting fork, chute, its function is to send rebars to material frame.
3. Packaging part mainly consist of packaging machine, packaging the car, packaging guide, its function: packaging the car with packaging machine arrive the need of packaging to package. One person can complete packaging, save labor.

Small-type coiler
1. In cold rolled ribbed steel bar production line, small-type coiler is a equipment of collection and packaging of coiling rebars, including coiling machine, automatic cycloid and discharging car three parts, auxiliary equipment is packaged rack. The coiling machine adopts two levels of hard tooth suface cylindrical gear transmission, power adopts torque motor, to ensure that keeps stable tension in the process of winding. Coiling block consists of four quadrant, the harmomegathus adopts four connecting rod institutions, coiling block end claw and harmomegathus mechanism achieve linkage, to save time and effort, hydraulic cylinder on the tail provides power. Dimensions: Φ580*Φ850*560mm, weight: 1-1.2tons.
2. Automatic cycloid achieve cycloid wheel automatic reciprocating motion within the width of the winding by stepping motor. The guide device adopts linear bearings, the screw adopts ball screw, small resistance, long service life. Control part is controlled by industrial microcomputer, high degree of automation.
3. Discharging car can realize two kinds of motor function of lifting and horizontal, it is responsible for the finished packaging and pull away from the coiling block so that the hoisting. Packaging frame is equipment that fix packaging belt and packaging machine, packaging machine hang in the packaging frame through counterweight device, move easily and convenient.