SHJLPACK Single Capstan Inverted Vertical Wire Drawing Machine: Precision and Efficiency in Wire Production
SHJLPACK's Single Capstan Inverted Vertical Wire Drawing Machine is engineered for high-speed production of calibrated wire, essential for manufacturing screws, bolts, nuts, and specialized components. Handling wire diameters from 36mm down to 3mm, this machine boasts robust motors, advanced controls, and safety features, ensuring enhanced efficiency and precision in wire processing.
Introduction to SHJLPACK Wire Drawing Technology
SHJLPACK is a leading provider of advanced wire processing equipment, offering solutions designed for precision, efficiency, and reliability. Among its distinguished product line is the Single Capstan Inverted Vertical Wire Drawing Machine, specifically developed for the production of high-quality calibrated wire. This machine is pivotal in the manufacturing of fasteners and special parts, where dimensional accuracy and consistent material properties are paramount.
Key Features of the Inverted Vertical Wire Drawing Machine
The SHJLPACK Single Capstan Inverted Vertical Wire Drawing Machine is packed with features that enhance its performance and operational efficiency. These features are meticulously designed to meet the demanding needs of modern wire production.
Robust Motors and Drives
- High-Speed Drawing: The machine is capable of drawing wire at speeds ranging from 20 to 120 meters per minute, optimizing production throughput.
- Quality Motors: Equipped with AC motors from reputable manufacturers like SIEMENS and TECO, ensuring reliable and consistent power.
- Advanced Inverter Drives: Features inverters from Rehymebus for precise speed control and efficient energy usage.
- Efficient Gearbox: Utilizes a gear-type gearbox, which is more efficient than traditional worm gears, contributing to reduced energy consumption and enhanced durability.
- Double Pressing Rollers: Incorporates double pressing rollers for improved wire feeding and stability during the drawing process.
- Customizable Power: Operates on a standard power source of AC 380V / 50Hz / 3 Phase, with drawing direction customizable to buyer specifications.
Advanced Capstan Design
- Durable Capstan Material: The capstan is constructed from nodular cast iron FCD-55 or FCD-65, hardened to HRC40°±2° for exceptional wear resistance.
- Tungsten Carbide Coating: Features a Tungsten Carbide coating, further enhanced with mirror polishing, achieving a surface hardness of HRC68°±2° for prolonged lifespan and consistent performance.
- Efficient Cooling: Both the capstan and die holder are equipped with water cooling systems, maintaining optimal operating temperatures and extending the life of tooling.
- Fixed Die Holder: Employs a fixed type die holder for stable and accurate wire drawing.
- Dry Lubrication: Utilizes a dry lubrication system, simplifying maintenance and reducing environmental impact.
Intelligent Control System
- Independent Speed Control: Individual driving motor units control the speed of the capstan and wire carrier, allowing for precise adjustments and synchronization.
- Synchronized Decoiler Control: The speed of the optional mechanized wire decoiler can be synchronized with the drawing machine, ensuring seamless operation.
- Automated Take-Up Control: Features an optional PLC and HMI console that allows users to set the desired wire coil take-up weight, with the machine automatically stopping upon reaching the target weight.
- Meter Recording: Includes a meter recorder for accurate production monitoring.
- Voltage Regulation: Equipped with a constant voltage regulator to protect against electrical damage from power fluctuations.
- Optional HMI & PLC: Offers optional HMI and PLC integration for comprehensive control and monitoring of the entire machine line.
Technical Specifications
The SHJLPACK Single Capstan Inverted Vertical Wire Drawing Machine is available in various models to accommodate different wire diameter requirements. The table below outlines the specifications for each model:
| Model | Inlet Diameter | Outlet Diameter | Total A.R.R | AVG A.R.R | Capstan Size | Capstan Drum Motor | Rotating Carrier Plate Motor | Drawing Speed Max. | Capacity, MTS/Hr. | Dies Amount | Winding Weight, MTS/pcs. | Pressing Rollers |
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| RCD-600 | Ø6.0 mm | Ø5.25 mm | 23.4% | Ø600 mm | 50 HP | 2 HP | 120 m/min | 1.22 | 1 | 0.5 - 2.0 | 2 sets (Double-Rollers) | |
| Ø5.5 mm | Ø4.8 mm | 23.8% | 1.02 | |||||||||
| Ø5.5 mm | Ø4.65 mm | 28.5% | 0.96 | |||||||||
| Ø3.3 mm | Ø2.8 mm | 28.0% | 0.35 | |||||||||
| Ø3.0 mm | Ø2.45 mm | 33.3% | 0.27 | |||||||||
| RCD-800 | Ø14.0 mm – Ø6.0 mm | Ø12.0 mm – Ø5.5 mm | 26.5% - 16.0% | Ø800 mm | 75 HP | 3 HP | 80 m/min | 4.26 - 0.90 | 1.5 - 2.5 | |||
| RCD-900 | Ø22.0 mm – Ø6.5 mm | Ø20.0 mm – Ø5.0 mm | 17.4% - 40.8% | Ø900 mm | 100 HP | 50 m/min | 7.4 - 0.46 | 3 sets (Double-Rollers) | ||||
| RCD-1000 | Ø20.0 mm – Ø12.0 mm | Ø18.0 mm – Ø10.7 mm | 19.0% - 20.5% | Ø1000 mm | 50 m/min | 5.99 - 2.12 | ||||||
| RCD-1200 | Ø30.0 mm – Ø18.0 mm | Ø27.0 mm – Ø16.0 mm | 19% - 21% | Ø1200 mm | 20 m/min | 5.39 - 1.89 | ||||||
| RCD-1400 | Ø36.0 mm – Ø25.0 mm | Ø33.0 mm – Ø23.0 mm | 16% - 17% | Ø1400 mm | 125 HP | 17 m/min | 6.85 (for Inlet Dia. Ø36.0 mm) |
Enhanced Safety Features
SHJLPACK prioritizes safety in its machine designs. The Single Capstan Inverted Vertical Wire Drawing Machine incorporates several safety features:
- Emergency Stops: Strategically placed emergency stop buttons on all control panels for immediate shutdown.
- Wire Rod Detection: Automatic machine stop if no wire rod is detected, preventing dry runs and potential damage.
- Safety Guard: Pneumatically controlled safety guard that automatically stops the machine when opened, ensuring operator safety during maintenance or adjustments.
- Danger Zone Sensors: Sensors detect unauthorized entry into predefined danger zones, automatically halting machine operation.
- Wire-Stop Bar: Adjustable pneumatic wire-stop bar to prevent injury from wire swing in case of breakage.
- Safety Certifications: Certified to C.E. and ISO-9001 safety and quality standards.
Optional Equipment for Enhanced Automation
To further enhance the automation and efficiency of the wire drawing process, SHJLPACK offers optional equipment, including automatic wire rod unwinder and feeder systems.
Automatic Wire Rod Unwinder and Feeder
The automatic unwinder and feeder system significantly reduces wire preparation downtime. It includes:
- Automatic Wire Rod Unwinder: RGO series unwinder with straightening mechanism.
- Sharpening Unit: RGV series sharpening unit for wire rod end preparation.
This system reduces preparation time from approximately 30 minutes (traditional method) to just 6 minutes, automating processes like feeding, pressing, straightening, and wire shaving.
Benefits of Automatic Feeding System:
- Increased Efficiency: Reduces wire rod preparation time by up to 5 times.
- Automated Shaving: Automated wire shaving process eliminates manual handling and reduces operator risk.
- Semi-Automatic Operation: Streamlines the entire wire feeding and preparation process.
Automatic Large Diameter Wire Feeding & Shaving Machine Specification:
| Model | RGO/RGV-20 | RGO/RGV-30 | RGO/RGV-36 | RGO/RGV-45 |
|---|---|---|---|---|
| Wire Range | Ø22 mm ~ 9 mm | Ø32 mm ~ 10 mm | Ø36 mm ~ 25 mm | Ø45 mm ~ 37 mm |
| Power Source | AC 380 V / 50 Hz / 3 Phase | |||
| Feeding Machine Motor | 7.5 HP AC Motor + Inverter | |||
| Shaving Machine Motors | 3 HP + 1 HP Motor with Inverter Drive | |||
| Lubricating Motor | 1/2 HP | |||
| Hydraulic Pump | 5 HP | |||
| Polearm Wire Capacity | up to 3,000 kgs |
Industry 4.0 Integration and Software
SHJLPACK's commitment to innovation extends to Industry 4.0 compatibility. The wire drawing machine can be equipped with advanced software and networking capabilities:
- HMI Console Monitor: Displays real-time production data, including gearbox oil level, temperature, production speed, and alarm history.
- Error and Warning System: Provides pop-up warnings for system errors and can automatically stop the production line to prevent damage.
- Production Data Analysis: Graphic data for quick analysis of output production trends.
- Custom Software: User-friendly software designed in-house for easy operation and interface.
- Optional Networking: Optional ethernet networking transmodule for LAN connection, enabling remote diagnostics and troubleshooting.
- Remote Monitoring: Optional software for smartphone-based production monitoring.
- Programmable Setups: Software allows for up to 30 programmable wire drawing setups.
Conclusion
The SHJLPACK Single Capstan Inverted Vertical Wire Drawing Machine represents a significant advancement in wire production technology. With its robust construction, advanced features, and focus on safety and efficiency, it provides a reliable solution for manufacturers seeking to enhance their wire drawing capabilities. Whether for producing standard fasteners or specialized components, this machine delivers the precision and performance required in today's demanding industrial environment.
