The SHJLPACK horizontal type wire drawing line is engineered for efficient and high-volume steel wire production. This advanced system integrates several key components to streamline the wire drawing process, from unwinding the wire rod to spooling the finished wire. Designed for continuous operation, this system emphasizes productivity and precision, making it a valuable asset for wire manufacturing. It is a system designed for drawing steel wire, starting from a larger diameter and reducing it to a smaller, specified diameter through a series of controlled drawing steps, ensuring consistent quality and output.
Components of the Horizontal Wire Drawing Line
The SHJLPACK horizontal wire drawing line is composed of several integrated machines working in tandem to ensure a seamless wire drawing process. Key components include:
- Vertical Wire Unwinder (RGT-3100A): This component initiates the process by vertically unwinding the wire rod, preparing it for subsequent stages.
- Combined Descaler (RG-SB7): Equipped with descaling rollers and steel brushes, this unit mechanically removes scale from the wire surface, enhancing the wire's quality and extending the lifespan of drawing dies.
- Straight Line Wire Drawing Machine (RGTD): The core of the system, this machine reduces the wire diameter through a series of capstans and dies (traditional monolithic or cassette roller dies). The number of capstans is customized based on client requirements.
- Horizontal Spooler (RGT-2000): This unit precisely spools the drawn wire onto spools or bobbins, ready for further processing or shipment.
- Optional Sharpening and Welding Devices: For enhanced operational efficiency, optional devices for wire sharpening and welding are available.
Straight Line Type Wire Drawing Machine RGTD-670×1B + 550×8B (9-Block Capstan w/ Dancer System)
Straight Line Type Wire Drawing Machine RGTD-670×1B + 550×6B + 600×1B (8-Block Capstan w/ Dancer System)
Technical Specifications of the Drawing Machine
The drawing machine model RGTD-670×1B + 550×8B, when paired with the spooler RGT-2000, offers impressive performance metrics.
Specification of drawing machine RGTD-670×1B + 550×8B with spooler RGT-2000
| Model | Inlet Diameter | Outlet Diameter | Total A.R.R | AVG A.R.R | Capstans | Capstan Motor | Drawing Speed Max. | Capacity, MTS/HR | Number of Drawing Dies | Winding Weight, MTS/PC | Total Power Consumption |
|---|---|---|---|---|---|---|---|---|---|---|---|
| RGTD-670×1B + 550×8B | Ø6.5 mm | Ø1.6 mm | 93.9% | 26.71% | Ø550 mm×1 pcs, Ø670 mm×8 pcs | 60 HP×9 pcs | 900 m/min | 0.85 | 9 | - | 628 HP |
| RGT-2000 | Ø1.6 mm | - | - | - | - | - | 0.5 - 1.5 |
Key Features of the Horizontal Wire Drawing Machine
The SHJLPACK horizontal wire drawing machine is packed with features designed for optimal performance and ease of use:
- Versatile Wire Drawing Range: Capable of handling inlet wire diameters up to Ø6.5 mm and reducing them to an outlet diameter as fine as Ø1.6 mm.
- Powerful Drive System: Each of the 9 capstans is powered by a 60HP AC Inverter SIEMENS motor, complemented by MITSUBISHI Inverter Drives, ensuring robust and reliable operation.
- High-Speed Operation: Achieves a maximum drawing speed of 900 m/min when equipped with roller cassettes, significantly boosting productivity.
- Advanced Control System: Features a Dancer System for synchronization between capstan blocks, along with Linking, Jogging, and Foot Pedal Control Modes. A PLC automatic control program manages speed adjustments.
- Safety and Monitoring: Equipped with hydraulic disc brakes, automatic fault detection for wire snarls and breakages, and a comprehensive HMI control interface that displays alarms and system statuses.
- HMI Control Console: A user-friendly touch screen interface allows operators to set parameters, monitor performance, and access error history for efficient troubleshooting. Remote assistance and troubleshooting are possible through optional network connectivity.
- Durable Capstan Blocks: Constructed from Cast Iron (FCD-45) with a hardness of 40 HRC±2, the capstan blocks feature a mirror-polished surface with precision tungsten carbide coating for enhanced durability and reduced wire abrasion.
- Efficient Cooling System: A water-cooling capstan system with a spiral design and corrosion-resistant internal components ensures optimal temperature control.
- Flexible Die Holder System: Accommodates both Rotary Die Holders for the first block and Roller Cassettes for subsequent blocks, with quick tool-free cartridge removal for die changes.
- Anti-Vibration Rollers: Minimizes vibrations during operation, contributing to smoother wire drawing and improved wire quality.
- Comprehensive Safety Features: Includes safety guards, warning lights, hydraulic pinch rollers, and C.C.E. & ISO-9001 safety certifications, ensuring operator safety.
Cassette Roller Die Technology: Enhancing Efficiency
SHJLPACK’s integration of Cassette Roller Die technology represents a significant advancement in wire drawing. Compared to traditional monolithic dies, roller cassettes offer reduced friction, leading to energy savings and improved wire quality.
Advantages of Cold Rolling with Cold Rolling Cassettes:
- High Precision: Ideal for producing small diameter wires with a roundness tolerance of approximately Ø0.02 mm.
- Increased Speed and Productivity: Roller rolling technology allows for higher drawing speeds and greater output.
- Extended Tool Life: Roller rings can process approximately 3000 tons of wire before regrinding is needed, minimizing downtime.
- Reduced Lubricant Use: Significantly reduces the need for lubricants, contributing to cleaner wire and lower operational costs.
- Lower Power Consumption: Requires about 10% less power than conventional die drawing.
- Cleaner Output Wire: Produces a bright, clean wire with minimal lubricant residue, beneficial for post-processing treatments.
- Improved Working Environment: Eliminates dust and drawing powder particles, creating a healthier workplace.
![Cold Rolling Cassette]()
Cold Rolling Cassette Features:
- Diameter Range: Suitable for inlet to outlet diameters from Ø5.5 mm to Ø1.6 mm.
- Oil Cooling Design: Six pins with oil cooling ensure optimal bearing temperature control.
- Tungsten Carbide Rollers: Equipped with six pure tungsten carbide roller rings for durability and performance.
- Adjustable Rollers: Features individual axial and radial roll adjustment for precise wire drawing.
- Integrated Lubrication: Internal circulation and lubrication network for roller holder bearings.
- Protection Measures: Includes oil cooling circulation and recovery systems with automatic machine stop and alarms for oil loss or pump failure. Maintenance reminders for consumables are also integrated into the HMI.
Performance Comparison: Roller Cassettes vs. Drawing Dies
| Drawing with drawing dies | Drawing with roller cassettes | Features and benefits of drawing with roller cassettes | |
|---|---|---|---|
| Inlet Diameter | 8.00 mm | ||
| Outlet Diameter | 3.00 mm | ||
| Total A.R.R | 85.9% | ||
| AVG A.R.R | 21.72% | ||
| Drawing Speed Max. | 4 m/sec (250 m/min) | 5.83 m/sec (350 m/min) | 30% speed boost |
| Hourly output | 0.83 MTS/HR | 1.17 MTS/HR | |
| Monthly productivity (25 days × 24 hours) | 299 MTS | 562 MTS | Productivity increase by 263 MTS |
| Productivity factor | 60% | 80% | 20% increase in productivity factor |
| Number of Drawing Dies | 8 Dies | 1 Rotary Die + 7 Roller Cassettes | |
| Total power consumption | 704.5 HP | ||
| Winding Weight | 0.8 - 1 MTS/PC | ||
| Tool life | 1 set for 10-15 tons | 1 set for 9000 tons | Increasing the service life of the tool (rollers can be re-sanded 3 times) |
| Operation and cost of drawing powder for 9000 tons | NT$115,200 | NT$4,800 | Savings NT$110,400 |
| The need to stop equipment for 3000 tons of products | 1600 times | 200 times | 8 times fewer equipment stops |
| Operating safety | Lung infection risk | No dust or powder | Reducing worker and environment protection costs |
| Environmental pollution | Waste neutralization needed | No waste neutralization | Savings on wastewater treatment |
| Degreasing process | Required | Absent | Savings on degreasing |
| Staff training | Time-consuming | Easy and fast | Cost reduction in training and commissioning |
Mechanical Type Bending & Brushing Descaler RG-SB7
The RG-SB7 Mechanical Type Bending & Brushing Descaler efficiently prepares wire rod for drawing by mechanically removing scale. This process involves bending the wire in multiple planes between rollers and then cleaning it with steel brushes.
Equipment Features:
- Dual Descaling Action: Combines mechanical bending and brushing for effective scale removal.
- Automated Brush Control: PLC-controlled steel brushes delicately remove scale without damaging the wire surface, with automatic brush replacement notifications.
- High Cleaning Efficiency: Achieves up to 90% wire cleanliness, prolonging the life of drawing dies and other consumables.
- Pre-Pickling Elimination: Reduces or eliminates the need for pre-pickling, saving on acid and waste treatment costs.
- Working Diameter: Suitable for wire diameters from Ø5.5 mm to Ø 7.0 mm (medium and low carbon steel), with custom sizes available.
Mechanical Cleaning Unit with Brushes:
- Uniform Brushing: Guiding and straightening rollers ensure consistent brush contact.
- Powerful Drive: 12 HP drive power for effective brushing.
- Alloy Steel Brushes: Four sets of alloy steel brushes and motors.
- Automatic Adjustment: PLC-controlled automatic brush adjustment via electromagnetic switch sensor and HMI monitoring.
- Synchronized Speed: Brush cleaning unit speed synchronizes with the drawing line speed.
- Long Brush Life: Alloy steel brushes last for approximately 3000 tons of use.
Bending Descaler:
- Tungsten Carbide Rollers: Bending descaling rollers made of pure tungsten carbide with a 5-year lifespan.
- Optimized Roller Alignment: Rollers aligned horizontally and vertically for maximum descaling effect.
- Mill-Scale Collection: Integrated chute for collecting mill scale into a waste disposal bag.
Vertical Type Pay-Off RGT-3100A and Horizontal Spooler RGT-2000
The RGT-3100A Vertical Pay-Off and RGT-2000 Horizontal Spooler are crucial for the beginning and end of the wire drawing process, respectively.
Vertical Type Pay-Off RGT-3100A:
Equipment Features:
- Overhead Sheave: Mounted on a 5.2m high column for smooth wire feeding.
- Pneumatic Tilting Column: Column can be tilted for easy threading.
- Automatic Stop System: Inlet sensor detects wire snarls or breaks and automatically stops the machine.
- Durable Sheave Surface: Sheave surface has a special coating for increased hardness.
Horizontal Spooler RGT-2000:
Design Features:
- Take-up Range: Handles wire diameters from Ø1.6 to Ø5 mm.
- Powerful Motor: 75HP AC inverter SIEMENS motor with MITSUBISHI inverter drive.
- Synchronized Speed: Take-up speed is synchronized with the outlet capstan block.
- Spool Handling: Accommodates DIN-800 spools with an elevation mechanism for easy loading and unloading. Maximum take-up weight of 1000 kg (excluding spool weight).
- Traverse Mechanism: Adjustable traverse width and lay with inverter-controlled speed.
- Straightening Rollers: Two sets of hardened SKD-11 steel straightening rollers.
- Synchronization Capability: Can be linked and synchronized with other machine lines.
- Disc Brake System: Suntes (Japan) or equivalent quality disc brake system for reliable stopping.
- Safety Guard: Protective steel guard with a sliding door for access.
Electrical and Mechanical Components
SHJLPACK prioritizes quality and reliability in the electrical and mechanical components of its wire drawing lines.
Electrical Equipment Components:
- High-Quality Motors and Inverters: SIEMENS AC motors and MITSUBISHI inverters ensure smooth and powerful operation.
- PLC Electrical Cabinet: Dust-filtered cabinet with constant voltage regulator and high-quality, licensed electrical components.
- Safety Measures: Overload, snarl, and overheat protection systems.
- User Interface: Touch monitor and physical buttons on the main control console.
- Precision Sensors: High-precision sensors from France.
- PLC Control System: Mitsubishi or SIEMENS PLC control system.
Mechanical Components:
- Dust Protection Buttons: All buttons are dust-protected.
- Taiwan-Made Gearboxes: Helical (bevel) gearboxes and hypoid gears made in Taiwan with high-quality forged alloy steel, hardened to HRC59°±2°. Precision-machined gears with secondary grinding for long life under heavy loads.
- Gearbox Monitoring: Oil level controller to prevent damage from oil issues, with automatic machine stop and HMI notifications.
- Gearbox Cooling and Filtering: Cooling system with magnetic filtering to maintain oil cleanliness and extend component life.
- Premium Bearings and Seals: SKF bearings or equivalent and Japan NOK oil seals or equivalent.
- High-Quality Brakes: Taiwan-made disc brakes with Lenze (Germany) or equivalent electrical braking system.
- Japanese Steel Mandrels: Transmission mandrels made of Japanese SNCM alloy steel.
HMI Main Control Console and Industry 4.0 Features
The HMI Main Control Console provides a comprehensive interface for operators to monitor and control the wire drawing line.
HMI Main Control Console Features:
- Touch display monitor with keyboard interface for parameter setting.
- Real-time display of line speed, frequency, current, reduction rate, capstan speeds, and warnings/errors.
- Error and alarm history log for troubleshooting.
- User-friendly interface with various monitoring screens (examples shown below).
Appearance of the HMI Main Control Console
Production data monitoring screen
Programmable sets of wire drawing data recipe
Graph of change in drawing speed over time
Alarm history screen
Wire Tension System Status Display Screen
System monitor screen
Basic settings screen
Screen for displaying the state of drawing line nodes
Oil tank operation parameter setting screen
Equipment maintenance period setting screen
Screen for monitoring wear of drawing line units
Screen for monitoring wear of drawing line units
Screen for monitoring wear of drawing line units
Screen for monitoring wear of drawing line units
Industry 4.0 Hardware & Software (Optional):
- Comprehensive HMI monitoring of line speed, reduction rate, power consumption, output, and alarms.
- Automatic machine stop for error prevention.
- Storage for 30 programmable wire drawing data recipes.
- Graphic data analysis of production output.
- Optional PLC ethernet networking for remote diagnostics and data management system integration.
Auxiliary Equipment
SHJLPACK also offers auxiliary equipment to complement the horizontal wire drawing line, including roller type wire sharpening machines and electric butt welding machines.
For more information or inquiries, please contact SHJLPACK using the details provided.
