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The advantages and development trend of automated pickling treatment
Automated pickling surface treatment equipment has advantages that traditional pickling methods and other acid-free treatment methods can’t compare:
Good surface quality: The medium used is still acid, so the surface quality still retains the advantages of traditional pickling.
Automatic production: Continuous automatic production ensures high production efficiency and large output. Various process parameters are controlled by a computer, making the process stable and especially suitable for large-volume, centralized production.
Low production cost: Automatic control of process parameters optimizes the production process. Efficient media circulation and reduced personnel requirements keep the operating cost of this equipment much lower than traditional pickling.
Low environmental pollution: The automated pickling equipment can be equipped with advanced wastewater and waste gas treatment devices. Combined with unique equipment characteristics, it achieves relatively low emissions and minimal pollution to the plant and surroundings. With suitable acid regeneration and wastewater treatment equipment, zero emissions can be achieved.
With the advancement of technology, automated pickling equipment will gradually realize seamless connection with logistics tracking, MES, ERP and other systems. With industry 4.0, machine vision, cloud big data and other technologies, can achieve a higher degree of intensive, automated, and multi-variety production, bringing huge economic benefits to the enterprise.
Typical process configuration
Features
Advanced and reliable manipulator
- Specially designed special electric lifting device, suitable for the continuous operation of this type of production line;
- Using 4-motor drive device, synchronous operation, quick start and reliable braking;
- The robotic arm adopts a multi-guiding structure, which runs smoothly and with low noise;
- The movable pulley frame adopts a 2×3 structure with 3 guide wheel mechanisms to ensure that the manipulator rises and falls smoothly without shaking;
- Equipped with multiple safety detection sensors to ensure the safe operation of the manipulator and protect the personal safety of personnel;
- Specially optimized mechanical structure, long service life of parts, easy maintenance and repair, and quick replacement of parts.
Compact layout, factory production of steel structure, high-strength bolt connection
- Easy to maintain and save maintenance investment;
- Stronger than traditional welding, completely eliminate the influence of steel structure stress;
- The equipment is elegant in appearance, easy to install and short in construction period.
Pickling adopts external circulation technology
- There is no heat exchange element in the pickling tank, which is convenient for cleaning and maintenance;
- External circulation filtration technology keeps the tank clean and can quickly clean up the residue in the acid solution;
- Dynamic turbulent pickling improves pickling effect and pickling efficiency.
High-efficiency water circulation and water-saving cleaning design
- Invention patent technology;
- Reverse cascade water circulation cleaning;
- High flow rate and swing cleaning can clean the steel pipe surface more effectively;
- Realize dynamic rinsing and improve cleaning effect;
- Less water consumption means lower waste water discharge, improving user economic benefits.
Advanced and convenient control system and reliable program design
- Multiple positioning of photoelectric sensor, proximity switch and positioning sensor, combined with software algorithm, to prevent collision accidents;
- High positioning accuracy, positioning error ≤ 5mm;
- What you see is what you get: The display status and position on the HMI are exactly the same as the status of the field equipment, which is convenient for the operator to understand the operation status of the equipment;
- Strict safety control and safety sensor configuration to avoid personal accidents and ensure personnel safety;
- When feeding, the operator can click on the material loading HMI according to the type of material to automatically match the corresponding production process;
- Technicians can modify and add process procedures to better adapt to the processing of multiple types of products;
- Advanced multi-point WIFI AP function to ensure that the WIFI signal has no dead ends and ensure the normal operation of the device;
- Internet of things interface, cloud platform control, mobile phone and tablet can be remotely online (option);
- The MES system interface is reserved, and the MES system can be seamlessly connected with this equipment, which is convenient for production management.
Frequently Asked Questions
What are the main advantages of automated pickling over traditional methods?
Automated pickling retains the superior surface quality of traditional acid treatment while introducing continuous automatic production, higher efficiency, lower operating costs, and reduced environmental impact through advanced waste treatment systems.
How does the system ensure safety during the manipulator's operation?
The manipulator features multiple safety detection sensors, a 4-motor drive system with reliable braking, a stable multi-guiding structure, and software algorithms designed to prevent collisions and ensure operator safety.
Can the automated pickling line connect with modern factory software?
Yes, the system is built for Industry 4.0. It features reserved interfaces for seamless integration with logistics tracking, MES, and ERP systems, and offers IoT cloud platform control options.
How does the water-saving cleaning design work?
Utilizing patented technology, the system uses reverse cascade water circulation cleaning along with high flow rates and swing cleaning. This achieves superior cleaning results while minimizing water consumption and wastewater discharge.
What is the benefit of the external circulation technology in the pickling tank?
By keeping heat exchange elements out of the tank, the design simplifies maintenance. The external circulation filtration quickly removes residues, keeping the acid solution clean and improving pickling efficiency through dynamic turbulence.