The concept behind the wire drawing process is a very straightforward one. In order to make the wire suitable for passing through the die, it must first be prepared by either shrinking, hammering, filing, rolling, or forging; once it has been prepared, the wire must be pulled through the die. Because the wire's volume does not change as it is pulled over the mold, the increase in length is due to the decrease in diameter. In most cases, the wire must be stretched multiple times by using increasingly smaller molds in order to achieve the desired size. That is the standard that the American wire gauge scale is derived from. On a much smaller scale, this can be accomplished by hand by pulling the plate, while on a much larger scale, this can be accomplished by using automated machinery. Because it is a cold process, the process of wire drawing will result in a change in the material's properties.
The reduction in area caused by small wires is typically between 15 and 25 percent, while the reduction caused by large wires is between 20 and 45 percent. The precise die sequence for a given job is determined by three factors: the area reduction, the diameter of the input line, and the diameter of the output line. The order of the die will switch places as the available space decreases.
Wires that are extremely thin are typically bundled together in bundles. When the wires are bundled together, the spaces between them should be filled with a metal that has similar properties but a low chemical resistance so that the spacers can be removed after the drawing process. if the rate of area reduction is greater than fifty percent, then the procedure may require intermediate steps to be carried out. citations. to undergo annealing before you can attempt to redraw.
In most cases, the commercial drawing will begin with hot rolled rolls that have a diameter of 9 mm (0.35 in). To begin, the surface is treated to remove any scale that may be present. After that, it is put through the drawing machine, which can have a single block or multiple blocks connected in series.
A single drawing machine will have a device that is responsible for accurately holding the die in the correct position and drawing steadily through the hole. The standard configuration calls for a table made of cast iron or a table equipped with an upright bracket to hold the mold in place while the vertical drum rotates and pulls the wire over the mold by winding the wire around its surface. The conductor coil is kept on another die in this configuration. Drum or swift (behind mold), as well as quickly offline as necessary. A device is provided for rapidly coupling the drum or block to its vertical axis so that the movement of the wire can be immediately stopped or started. This allows the wire to be moved in either direction without delay. Because the block is also tapered, once the coil is complete, it will be simple to slide it upward. Before the wires are threaded through the mold and connected to the module, it is necessary to pull the longer wires through the mold. Pull the wire out until it is long enough to be wound twice or three times on the woodblock, and then fix it or pair it with a small screw clamp.
This is accomplished by wrapping a pair of clamp pliers around the end of the chain that is wound around the drum. The module starts to move as soon as the wire is placed on it, and it pulls the wire in a consistent direction through the mold. If the slider does not rotate evenly and makes it run and pulls the wire at a constant speed, then it will "jam," which will either weaken or destroy the wire. PCD dies is important that this happens. The speed of the wire drawing process will vary greatly depending on the type of material being used and the amount of pressure being applied.
The Electronic Line shaft Software enables synchronization of one or more driven motors to a master encoder signal. The follower receives a pulse reference from the master encoder, which causes the follower to command its motor to keep the shaft in a particular position. This is accomplished by the master encoder. The pulse feedback from both the master encoder and the follower drive's own encoder is monitored by the follower drive. After that, the follower will adjust the output speed of its motor in order to compensate for any position errors, which will ultimately result in a nearly perfect alignment between the follower motor and the system master motor. Because there is no accumulation of position error, alignment will constantly be maintained even in the face of changing conditions.
On a wire drawer, one drive is designated as the main drive, and the remaining drives are designated as follower drives. The following is stated further in the software definition:
In addition to that, the follower is equipped with an electronic gearing feature. This enables the follower to operate at a ratio of the master as though the two were mechanically coupled through belts or gearing. This gives the impression that the master and follower are working together. The "Enhanced" Modbus communication protocol is included in this software. The follower drive is able to accept a registration mark from the product that is moving and then regulate the angle at which it is positioned thanks to a feature called registration control. This is put to use in a variety of specialized applications, including packaging machines, flying cutoffs, label...
ELS software is perfect for use in a wire drawer because of the winder-like characteristics it possesses. These characteristics require the wire to move at a known and consistent speed and tension. It is necessary to make constant adjustments for error and tracking.
Not only did the development of AC drives result in very good performance, but it also offered the user the benefit of not having to rely on mechanical parts, which are prone to wear and tear. As a result, the amount of time spent on preventative maintenance and routine teardowns is significantly cut.
A wire barrel packer is an assembly that can be positioned directly off the wire drawer, or the coiled wire can be moved to a different station. Either way, the assembly can be used. The function known as "barrel packing" involves positioning a barrel atop a turntable that rotates. Wire is continually inserted into the bottom of the barrel, where it is then wound onto spools. On a barrel packer, there are typically two motors: one for laying out the wire, and another for spinning the turn table. Because this process is significantly slower and is not dependent on tension but is only moderately dependent on speed, the turntable is equipped with a small open loop drive that is coupled with a closed loop vector drive. There is also a version of this assembly that consists only of the turntable. In such a scenario, there will only be one ac drive put in place.
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