China Wire Rod Pickling & Phosphating Line | High-Quality Suppliers & Factory Solutions
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, high production efficiency, large output. Various process parameters are controlled by a computer, achieving stable and automated processes especially suitable for large-volume, centralized production.
- Low production cost — Automatic control of process parameters optimizes the production process. Reasonable and effective media circulation along with automated operations reduces personnel costs, making operating costs much lower than traditional pickling.
- Low environmental pollution — Equipped with advanced wastewater and waste gas treatment devices to achieve low emissions and minimal plant pollution. Acid mist treatment, water treatment, and suitable acid regeneration can even enable zero emissions.
- Future Development — With tech advancement, automated equipment will connect seamlessly with logistics tracking, MES, ERP, and Industry 4.0 systems, utilizing machine vision and cloud big data for highly intensive and multi-variety production.
Equipment selection
The difference between various types of pickling lines:
- Circle type — Suitable for high and low carbon wire rod materials with similar process requirements, featuring high efficiency, large output, and good fault tolerance.
- U-type — Suitable for high and low carbon wire rods and stainless steel wire rods with different varieties and processing requirements, offering large output.
- Straight type — Suitable for manufacturers with compact plant structures and lower output requirements. There is no limit to the variety of wire rods.
Typical process configuration
Features
★ New generation of manipulators:
- Specially customized electric hoist for pickling line, with high protection level and corrosion resistance;
- Four-wheel drive control, 4 mobile motors run synchronously, which greatly improves the reliability and fault tolerance of equipment operation;
- The failure of a single motor does not affect the operation of the manipulator;
- The movable pulley frame with bilateral guidance combined with the multi-guiding structure of the robotic arm ensures stable operation and low noise;
- The movable pulley frame adopts a three-way guide wheel mechanism with a 2×2 structure to ensure that the lifting and lowering process is stable and shake-free;
- Multi-group steering mechanism with 2×4 structure, flexible steering, low running noise, and no rail jamming;
- The turning radius of the track can be as small as 3 meters, and the layout is compact. Compared with similar products, it saves 1/3 of the factory space;
- The manipulator does not directly contact the track during walking, and the track is not worn;
- Equipped with an absolute value lifting encoder to precisely control the lifting position and monitor the lifting status at all times to ensure safe operation;
- Each manipulator is equipped with a linear positioning sensor, which always feeds back the current operating position of the manipulator, with a resolution of 0.8mm, ensuring that the manipulator operates accurately;
- Specially optimized mechanical structure, long service life of parts, easy maintenance and repair, and quick replacement of parts.
- Specially customized electric hoist for pickling line, with high protection level and corrosion resistance;
- Four-wheel drive control, 4 mobile motors run synchronously, which greatly improves the reliability and fault tolerance of equipment operation;
★ The failure of a single motor does not affect the operation of the manipulator:
- The movable pulley frame with bilateral guidance combined with the multi-guiding structure of the robotic arm ensures stable operation and low noise;
- The movable pulley frame adopts a three-way guide wheel mechanism with a 2×2 structure to ensure that the lifting and lowering process is stable and shake-free;
- Multi-group steering mechanism with 2×4 structure, flexible steering, low running noise, and no rail jamming;
- The turning radius of the track can be as small as 3 meters, and the layout is compact. Compared with similar products, it saves 1/3 of the factory space;
- The manipulator does not directly contact the track during walking, and the track is not worn;
- Equipped with an absolute value lifting encoder to precisely control the lifting position and monitor the lifting status at all times to ensure safe operation;
- Each manipulator is equipped with a linear positioning sensor, which always feeds back the current operating position of the manipulator, with a resolution of 0.8mm, ensuring that the manipulator operates accurately;
- Specially optimized mechanical structure, long service life of parts, easy maintenance and repair, and quick replacement of parts.
★ Compact layout, factory-made steel structure, high-strength bolt connection, comprehensive anti-corrosion treatment:
- Easy to maintain and save on factory investment;
- The maintenance station is placed inside the production line and does not occupy external space;
- Stronger and safer than traditional welding, completely eliminate stress;
- Stronger and safer than traditional welding, completely eliminate stress;
- The equipment is beautiful and elegant, easy to install, and the construction period is short;
- The surface of the main steel structure is shot blasted to ensure that the subsequent anti-corrosion coating is firm and tight;
- After shot blasting, the surface is treated with anti-corrosion coating, and sprayed with chlorinated rubber anti-corrosion coating, so there is no worry about corrosion.
★ Pickling adopts tank external circulation filtration technology:
- Patented technology;
- No heating elements and coils in the pickling tank;
- Dynamic turbulent pickling of wire rods improves the pickling effect, and the gaps of wire rods can also be pickled well;
- Improve pickling efficiency by 10~15%;
- On-line filter residue outside the tank, online residue removal, increase the service life of hydrochloric acid by more than 15%, and save production costs;
- The cleaning and maintenance cycle of the acid tank is long, reducing labor intensity.
★ Efficient water recycling technology:
- Synchronous countercurrent water cycle cleaning realizes the gradual utilization of water resources;
- Steam condensate is recycled to the warm water tank;
- Water consumption can be as low as 40Kg/ton, reducing production costs.
★ Full Flush System:
- Simultaneous high-pressure flushing of the inner and outer surfaces of the wire rod;
- Cooperating with the wire rod rotating device, it can wash the contact surface of the wire rod and the hook without dead ends;
- Each flushing nozzle is equipped with an individual universal joint, which can be adjusted to the best flushing angle;
- The flushing mechanism is flexible and exquisite, and the maintenance is simple and convenient;
- Double water pump control, the high pressure water pump is responsible for flushing, and the low pressure water pump sprays the surface of the wire rod for protection;
- The rinse water is used repeatedly without worrying about water consumption.
★ Advanced and durable phosphating and slag removal system:
- Fully automatic intermittent operation without manual operation;
- Large area filtration system, automatic slag cleaning and slag discharge;
- The phosphating clear liquid is automatically returned to the phosphating tank, no additional phosphating clear liquid tank is needed;
- The heat loss of phosphating solution is small in the process of circulating filtration, which helps to reduce energy consumption;
- Reliable operation, small footprint, low noise and low energy consumption;
- Simple operation, low operating cost and convenient maintenance.
★ Advanced control system and reliable program design:
- Two-way positioning of linear sensor and proximity switch, combined with software algorithm, to prevent collision accidents;
- Strict safety control and safety sensor configuration to avoid personal accidents and ensure personnel safety;
- High positioning accuracy, positioning error ≤ 5mm;
- The display screen on the HMI is completely consistent with the current position of the on-site manipulator and the lifting position of the hook;
- Users can customize a variety of process procedures;
- According to the type of wire rod, the operator can select the pickling and phosphating process with one key when loading;
- The production process can be adjusted at any time during the production process, with flexible control;
- Track and record the process status of each coil during the pickling and phosphating process;
- BYPASS function, which can realize one-key rewashing;
- Various reports can be customized according to user needs, which is convenient for users to query and record;
- Use the gateway wireless industrial Ethernet to match the gateway PLC to achieve reliable and real-time control;
- Can choose to use RFID or barcode system, automatically match the process, and track the wire rod path at any time;
- You can choose to use the Internet of Things interface, cloud platform control, and mobile phones and tablets can be remotely online;
- The MES system interface can be reserved, and the MES system can be seamlessly connected with this equipment, which is convenient for production management.
★ Strict quality management and manufacturing:
- All steel structures and manipulators are subject to flaw detection;
- All tanks are tested for 24-48 hours of water filling;
- All electric control cabinets and power distribution cabinets comply with 3C certification.
Frequently Asked Questions (FAQ)
What are the main advantages of automated pickling over traditional methods?
Automated pickling retains the superior surface quality of traditional acid pickling while achieving high efficiency and output through continuous computer-controlled processes. It significantly reduces operating and personnel costs, minimizes environmental impact via integrated waste treatment systems, and allows for seamless integration with MES and ERP tracking.
How do I choose between Circle, U-type, and Straight type layouts?
Choose Circle type if you process high and low carbon wire rods with similar process requirements and need high efficiency. Opt for U-type if you handle diverse wire rod varieties and stainless steel with complex processing needs. Choose Straight type if your factory layout is compact and has lower output requirements.
What makes the new generation of manipulators highly reliable?
They feature synchronous four-wheel drive control where a single motor failure won't halt operations, a corrosion-resistant customized electric hoist, and a multi-guiding structure for stable, low-noise lifting. They also incorporate absolute value lifting encoders and linear positioning sensors with a 0.8mm resolution for precise movement.
How does the tank external circulation filtration technology work?
This patented technology removes heating elements and coils from the pickling tank, instead using external circulation to create dynamic turbulent pickling. This method improves pickling efficiency by 10-15%, ensures wire rod gaps are thoroughly cleaned, and extends the service life of hydrochloric acid by more than 15% via online residue removal.
Why is the Full Flush System critical for subsequent phosphating?
Incomplete rinsing leaves residual acid on the wire rods, which deteriorates the phosphating solution, turns it black, and drastically shortens its lifespan. The Full Flush System uses high-pressure, multi-angle nozzles and wire rod rotation to wash all contact areas without dead ends, ensuring optimal phosphating quality and preventing rust or yellowing.
What environmental protection features are integrated?
The system features efficient water recycling technologies, including synchronous countercurrent water cycle cleaning and steam condensate recycling, reducing water consumption to as low as 40Kg/ton. Additionally, it integrates advanced wastewater and acid mist treatment systems, which can achieve zero emissions when paired with suitable acid regeneration equipment.