Copper coating line is a crucial working procedure for the solid steel welding wires.
WELDING WIRE CHEMICAL COPPER COATING LINES
Copper coating line is a crucial working procedure for the solid steel welding wires, This working procedure has two functions: one is to improve the surface protection of the welding wires, and the other is to raise the electric conduction of the welding wires surface .In the CO2-gas shield welding, the electricity is conducted through the direct contact between the welding wires and the current contact tube .A good coat can reduce effectively the sparkle wear of the contact tube .The copper element is not suitable in welding, and the national standard of the copper content is less than or equal to 0.5%.The gloss of the copper coat of the welding wires is the direct factor of the welding wire quality. A simple copper coating facility can never meet requirements of the high quality of coated copper.
Copper coating facilities include two categories: electroplating and chemical copper coating. The electroplating is traditional while the more mature technique is the cyanides electroplating, which is steady and easy for operation, and is rarely used in new welding wires plants. The chemical copper coating is firstly widely used in Europe and America and was introduced into China in late 1980s.It is now more mature because of more than 20 years improvement, and is adopted by all the welding wire manufacturers in China.
THE ARRANGEMENT OF THE CHEMICAL COPPER COATING LINE
The arrangement mainly contains: reciprocating copper coating line and expanded copper coating line.
1. The reciprocating copper coating line is applied to producing welding wires in small scale or in limited areas where longer wires can not be arranged. The large-scale manufacturing is rarely adopted.
2. Expanded copper coating line: It means the welding wire is in straight line in the tank without contacting any pulleys. In this way, it reduces damages and the corresponding fault rate. which will lead to lightest damage to the copper coat of the welding wires. and many wires will pass through the tank at a time. Expanded copper coating lines always take up larger area. However, they are still used by most manufacturers.
COMPOSITIONS OF THE EXPANDED COPPER COATING LINES:
Bobbin Pay-off, Degreasing Machine, Hot Water Rinsing Tank, Electrolytic Alkali Tank, Rinsing Tank, Hot Water Rinsing Tank ,Electrolytic Pickling Tank, Rinsing Tank, Acid Activation Tank ,Copper Plating tank, Rinsing Tank, Neutralizing tank ,Rinsing Tank, Hot Water Rinsing Tank After plating, Drying Channel, Skin pass, Drawing Machine, Bobbin Take-up, Electrical Control , Information Display System.
Pay-off machine adopts auto-inhibition wire paying off, and the constant tension of wire drawing can be ensured without any power.
All the tanks are divided to the upper tank and the lower tank,and the lower tank, the upper tank is for the passing of wires while the lower tank is for storing liquid that will be circulated to the upper tank by the vane pump and returns into the lower tank. This ensures the uniform density of the liquid and the stability of the copper plating.
The hot water rinsing ,electrolytic alkali rinsing, and hot water rinsing after plating adopt steam heating technology to lower the cost.
Water rinsing applies the water circularly. Fresh water is only required for the last working procedure to save water.
The electric heating air duct cycle is used in drying process, and the temperature can be controlled automatically.
Oily lubricants are used in finishing not only for drawing finish, but for forming an oil film on the surface of the welding wire, which will be in favor of the welding wire storage.
The material of the capstan is ZG45 spray painting tungsten carbide. The surface is mirror-surface treated and is rigid and wear-resistant without damaging the surface of the welding wire. The dragging adopts inverter control AC motor and steady speedup and speeddown.
Taking up applies speed controller with tension feedback to ensure constant tension for taking up to reduce distortion and extend the life of the bobbin.
Taking up and paying off are controlled by the PLC and operated separately. Operation buttons are provided to the paying off and taking up of each machine. The drawing machine is equipped with foot switch. Each line can be operated and shut down separately. These devices have the function of wire broken automatically stop, and the LED will display the faulty information.
