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Ting, 1STCD-600x4B+500x7B, Straight-Line Wire Drawing Machine, 11-Block Capstan, 246 Tons/Month Capacity (New)

Ting, 1STCD-600x4B+500x7B, Straight-Line Wire Drawing Machine, 11-Block Capstan, 246 Tons/Month Capacity

Description

  1. Overview
    1. Wire drawing machine.
    2. Monthly production 246 tons by straight-line type wire drawing machine.
    3. Running time: 16 hours / 2 shifts / 25 days / 75% production efficiency (for conventional die drawing).
    4. For die drawing: capacity 60 tons (for outlet wire Ø1.37mm) - 12 days.
    5. Capacity 186 tons (for outlet wire Ø2.32mm) - 13 days.
    6. Total output capacity: 246 tons (for 1 production drawing line) - 25 days.
    7. Material: high carbon steel (1800MPa).
  2. Machine Equipment
    1. Pay off: horizontal type pay-off 2 set.
    2. Model: TPF-2000W.
    3. Drawing: straight-line type wire drawing machine 1 line.
    4. Ø5.5mm - Ø1.37mm (11-block capstan w/ dancer system).
    5. Ø6.0mm - Ø2.32mm model: 1STCD-600x4B + 500 x7B.
    6. Take up: non-stop coiler w/ die holder 1 set.
    7. Model: FCDA-500 x1B.
  3. Optional Equipment
    1. Industry 4.0 hardware & software: 1 set.
    2. w/ Mitsubishi PLC & control system + Ethernet networking transmodule.
  4. Buyer's Scope of Work
    1. Kindly note that the following shall be to the buyer's account:
    2. A. The wiring of the electrical system:
    3. 1. Power supply cable from power.
    4. 2. From the control cabinet to the control console and to the machine, signal cable, and power supply cable.
    5. B. The piping of water:
    6. 1. The circulatory cooling tank.
    7. 2. The water piping from the circulatory tank to the machine.
    8. 3. The cooling tower, etc. (cooling system).
    9. C. The piping of air pressure:
    10. 1. Air compressor.
    11. 2. Piping from air compressor to the machine.
    12. D. The placement and installation of the machinery & equipment.
    13. E. Coordination of machinery with civil engineer.
    14. This quotation does not include installation.
  5. Machine Equipment for Drawing Part
    1. All pictures are for reference only and may vary slightly from model-to-model and improvement updates.
  6. Horizontal Type Pay-Off
    1. Horizontal type pay-off model: TPF-2000W.
    2. A picture containing indoor Description automatically generated
    3. Consistent horizontal feeding for high tensile wire.
    4. Double pay-off for non-stop feeding with shorter production downtime.
    5. Automatic stoppage mechanism for snarls and trouble wire.
    6. Allows simple loading of wire rod via forklift.
    7. Max. load per arm: 2,000kgs.
    8. Quantity: 2 set
  7. Straight-Line Type Wire Drawing Machine
    1. A picture containing text Description automatically generated
    2. Model: 1STCD-600x4B + 500 7 B
    3. Motors & drives: 60 HP AC inverter Siemens motor (3 phase) + Mitsubishi inverter x 4 (Ø600 drum).
    4. 60 HP AC inverter Siemens motor (3 phase) + Mitsubishi inverter x 7 (Ø500 drum).
    5. Drawing range, inlet diameter - to - outlet diameter: (refer to "1STCD list").
    6. Final max. speed: 600 m/min.
    7. Voltage: 380V / 50Hz / 3 phase.
  8. Drawing Machine — Control Method
    1. Synchronization from capstan blocks 1st - last are controlled by the dancer system.
    2. By-pass capability with all capstan blocks; each capstan block can act as exit blocks.
    3. Speed adjusted via PLC's automatic control programme.
    4. Adopts linking, jogging, and foot pedal control mode.
    5. Hydraulic disc brakes mounted on each capstan block.
    6. Automatic detection for electrical and mechanial issues such as snarls and wire break to prevent machine damage.
    7. The HMI control interface can display all fail-safe alarms and detections.
  9. Drawing Machine — HMI Main Control Console
    1. HMI control console includes a touch display monitor with keyboard interface for set input and output parameters of each individual block.
    2. The HMI console will display all various statuses and parameters, not limited to but including line speed, frequency & current, the reduction per draft, individual capstan speed, and all possible warnings & errors.
    3. Memory of errors and alarms are recorded on the system's history log for analysis and troubleshoo.
    4. Optional equipment - the PLC system can be linked to a network through a modem transmodule allowing for remote assistanc and troubleshoo including data collection on a local network by MIS system (data collection requires own data server).
  10. Drawing Machine — Blocks
    1. 1st block - Ø600mm capstan drum x 4.
    2. 5th to last block consist of Ø500mm drum x 7.
    3. (Last capstan drum shall be double-deck version with straightening rollers implemented on the exit).
    4. Material: cast iron (FCD-45) with a hardness of 40 HRC ± 2.
    5. The drum surface is mirror-polished to prevent wire and surface abrasion.
    6. Precision tungsten carbide coa on all block surface from the entry root and upwards to a minimum of 150mm.
    7. After high precision tungsten carbide treatment; the surface hardness will reach 68 HRC ± 2.
    8. Block set-up: vert i cal axis type for first & last block, while the remaining will be tiltled type.
    9. Block lifetime is approx. 5 - 8 years (dependant on maintenance).
  11. Drawing Machine — Cooling System
    1. Capstan water cooling (spiral type) with uniquely designed gap system. All internal capstan made of corrosion resistant material.
    2. Water flow is adjustable at the machine front of every capstan block.
  12. Drawing Machine — Die Holders (Diebox)
    1. Fixed die holder: 1st to last capstan block.
    2. Patented design adop double pressure dies providing uniformed lubrication and prolonged die life.
    3. Elongated diebox / holder to provide better lubrication and roundness during drawing.
    4. Side loading cartridge type; suitable for single die or double pressure die.
    5. Cartridges implemented with quick tool-free removal allowing for a quick change of die. Suitable for single and double pressure dies.
    6. Die type: JIS W105 / W104 / W103 single or double pressure die.
    7. Die holder adjustment: up & down, left & right.
    8. Water cooling implemented for all die holder (diebox).
  13. Drawing Machine — Further Features
    1. Anti-vibration rollers: implemented on each individual capstan block.
    2. Pressure switches: installed on the machine to prevent wire break during pressure cut-off.
    3. Pressing wire roller by pneumatic cylinder: to prevent wire slippage on drum, during machine stoppage, the pressing roller located on the hindside of each individual capstan block will steadily push and hold the wire in place to prevent slippage during restart.
    4. Wire entry direction: (to be advised by buyer).
    5. Stop & halt times - normal stop time: programmable by user.
    6. Quick stop: without wire break.
    7. Emergency stop: 0.5 sec. - 3 sec. w/ additional wire breaking.
    8. Length counter: digital meter mounted on the last final pulley of the drawing machine.
    9. Noise level: below 80 dBA.
    10. Capstan block control panel: a control panel is foreseen for each individual capstan block which includes all the basic push-buttons and selectors for opera the machine.
    11. Water valves for all die holder and capstan block; and a manometer for the tuner arm's pneumatic cylinder.
  14. Equipment for Industrial Safety
    1. Equipment guardrail and safety lock to prevent opera personnel from entering the dangerous area.
    2. Frame is equipped with protection warning lights that are synchronized to a timer and the control system.
    3. Safety protection adopts general international yellow warning. Other color samples adopt the national color standard (buyer can provide own color samples).
    4. Conforms to C.E & SGS ISO-9001 quality standard.
  15. Non-Stop Coiler w/ Die Holder
    1. A picture containing indoor Description automatically generatedA picture containing device, miller Description automatically generated
    2. Model: FCDA-500 x1B
    3. Motors & drives: 60 HP AC inverter Siemens motor (3 phase) + Mitsubishi inverter drawing range:
    4. Finished wire range: (refer to "1STCD list ").
    5. Inlet diameter - outlet diameter: (refer to "1STCD list").
    6. Final max. speed: 600 m/min.
    7. Power
    8. Capstan block: 1x block of Ø500mm / double-deck construction.
    9. Coa of tungsten carbide on block surface.
    10. Die type: JIS W103 / W102.
    11. Cooling system: water cooling for capstan.
    12. Air cooling for block (air blower: 1/2 HP).
    13. Electrical control method: the speed of the non-stop coiler will be automatically synchronized to the outlet block of the drawing machine.
    14. Speed is adjusted automatically by the PLC's control programme.
    15. Capable of linking, jogging, and foot pedal control mode.
    16. Machine control method:
    17. Straightening rollers: on the flyer - X (7 pcs) & Y (6 pcs) - (quantity may change due to customization) goose neck guider:
    18. Wire accumulation system by elevation of goose neck via pneumatics.
    19. Winding direction: (to be advised by buyer).
    20. Goose neck direction corresponding to the desired coiling direction should be confirmed by the buyer.
  16. Electrical
    1. AC motor (3 phase) from Siemens, top quality assurance Mitsubishi inverters from Japan with initial high breakaway torque and smooth running at low speeds (1Hz @ 200% torque).
    2. PLC control cabinet with dust prevention and constant voltage regulator to avoid electrical damage.
    3. Electrical components are of quality products with national license. The power supply shall be of three-phase four-wire system with low-voltage control circuit consis of 24V.
    4. When voltage of the power grid fluctuates within ± 5%, the equipment is required to ensure that operations will function normally.
    5. Safety measures: overload protection, messy line protection, overheat protection.
    6. Main control console (operator station): operable by both touch monitor or physical push-buttons & selectors.
    7. The high-precision sensor imported from France; fine ouptut of 20M / M / 4000 instructions.
    8. Mitsubishi PLC control programme.
  17. Mechanical
    1. All buttons with dust protection.
    2. Material: forged SNCM alloy steel, after hardness treatment, reaches HRC59°± 2°. The gears have been processed with high precision German machinery with secondary grinding of JIS standard for the tooth surface treatmeant, producing a quality lifetime of up to 10 years. This type of the gear is suitable for long operations under high loads.
    3. Gearbox is equipped with an oil level controller to prevent the gears and bearings from damages due to oil loss.
    4. In addition to the tapered bearing, the bearing design is implemented with ball bearings for up and down movement to prevent the tapered bearing from long-term wear due to off-centered gear meshing. (Patent pending).
    5. Bearings of SKF or similar precision quality. Oil seals are from renowned Japan NOK brand or similar quality.
    6. Exceptional quality disk brakes from with electrical type braking system from "LENZE" Germany or of similar quality.
    7. Material of the gears are made of SNCM alloy steel with material of transmission mandrel from Japan.
  18. Gearbox Protection System (Patent Pending)
    1. An oil level controller is installed in the gearbox to prevent the gears and bearings from damage due to oil loss, insufficient oil level, oil entry clog, high temperature; the machine will automatically stop and notify the operator via the HMI interface to prevent gearbox damage.
    2. Gearbox cooling system with magnetic filtering to prevent iron residual generated by the lubrica oil due to 24 hours long-term operation and high friction; purpose for protec the gears, bearings, and oil seals to achieve a longer service life and lower cost of maintainence.
  19. Included Accessories for Model: 1STCD (Per Line)
    1. A. Wrench 1 pc
    2. B. Pulling-dog 1 pc
    3. C. Stop-block 2 pcs
    4. D. Powder clipper 11 sets
    5. E. Outlet wire carrier stand 2 sets
    6. F. Tool box 1 set
  20. Drawing Die List

    1. 1STCD List (Drawing Die)

      Inlet Diameter φ M/M

      Outlet Diameter φ M/M

      Total A.R.R %

      Avg A.R.R. %

      Speed Max. M/Min.

      Capacity

      Mts/Hr.

      Die

      Nos.

      Total

      HP

      Winding Weight Mts/Pc

      1

      Model: 1STCD-600x4B + 500 x7B

      5.50

      1.43

      93.2

      21.68

      600

      0.45

      11

      0

      Model: FCDA-500 (speed will automatically be synchronized)

      1.43

      1.37

      8.2

      8.20

      600

      0.42

      1

      721

      0.5 - 1.5

      2

      Model: 1STCD-600x4B + 500 x7B

      6.00

      2.42

      83.7

      15.20

      600

      1.30

      11

      0

      Model: FCDA-500 (speed will automatically be synchronized to draw line speed)

      2.42

      2.32

      8.1

      0.00

      600

      1.19

      1

      721

      0.5 - 1.5

    2. The above data is derived from customer's requested outlet product wire of Ø1.25mm & Ø2.32mm using the respective inlet wire rod of Ø5.5mm & Ø6.0mm.
    3. The above date is for reference only.
  21. Notes
    1. As a prerequisite for this machine line, the high carbon wire rod needs to be pickled + phosphated before drawing to prevent wire breakage or surface abrasion, especially more so when runned at continuous max. production speed.
    2. Roundness tolerance will be dependent on the die quality used by the customer.
  22. Remarks
    1. Finished product can be effected by the following factors:
    2. The quality of the wire rod.
    3. Drawing dies.
    4. Pretreatment of wire rod; such as pickling & coa.
    5. The type of lubrication used and its quality.
    6. Opera skill.
    7. Specification of final product.
    8. Other auxiliary and third-party equipment used.
    9. Environment condition such as temperature and humidity can effect production speed and quality of product.
  23. Trial Run Service
    1. 2 engineers - 10 days.
    2. For the delegation to Seller's technicians for machine tes & operational training.
    3. A. We will provide 2 engineers (mechanical & electrical) to check alignment, to set cast and helix, and to mechanically start up the machine and produce wires at customer specifications.
    4. B. We will provide 10 days of trial run service and training including the day of departure and arrival.
    5. C. The following items are included in this quotation:
    6. 1. Flight tickets for the engineer(s).
    7. 2. Engineer(s) wage.
    8. 3. Meals for the engineer(s).
    9. D. The following items shall be arranged and borne by the buyer:
    10. 2. Transportation to the place of work.
    11. E. Expense of extended service stay due to buyer set-back / postponement or request, shall be borne by the buyer; including meals, lodging, transportation, airline re-booking, and engineer wage.
  24. Industry 4.0 Hardware & Software
    1. A. Industry 4.0 hardware & software for 1STCD type:
    2. All software programs are designed and written in-house to provide ease-of-use and ease-to-read interface; by being fully first party, effectively eliminates any troubleshootng downtime from third-parties and is able to provide immediate first-line response.
    3. HMI console provides all possible monitoring; including but not limited to line speed, reduction rate, power consumption, power ratio, output capacity, dancer position, signals & alarm, alarm history log and more depending on options and model.
    4. HMI will display all possible errors and notification and if deemed necessary will automatically stop the production line to prevent further damage to the drawing machine.
    5. Allows for 30 programmable sets of wire drawing data recipe.
    6. Graphic data to provide quick analysis of production output relative to the time and day.
    7. Ethernet networking transmodule to enable LAN connection for remote diagnosis and troubleshoo. Together with an industrial computer or data server (customer is responsible for said equipment implementation), a data management system can be implemented to allow for Level 0 to Level 2 monitoring.
    8. Please note that the HMI interface shown above may be subject to changes from regular improvement and updates.