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China Wire Rod Pickling & Phosphating Line Suppliers: High Efficiency, Low Emissions & Advanced 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, production has been automatically. The process is stable, especially suitable for large-volume, centralized production.
Low production cost
Automatic control of process parameters, the production process can be optimized, with reasonable and effective production media circulation. Ring utilization, while automated production can effectively reduce personnel costs. These factors make the automated pickling equipment. The operating cost of equipment is much lower than that of traditional pickling.
Low environmental pollution
The automated pickling equipment can be equipped with advanced waste water and waste gas treatment devices, combined with the characteristics of its own equipment, Achieve relatively low emissions and minimal pollution to the plant and its surroundings. Especially for acid mist treatment and water treatment. On the other hand, if equipped with suitable acid regeneration and wastewater treatment equipment, zero emissions can even be achieved.
Technological Advancement & Industry 4.0
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.
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, with 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, with large output.
Straight type
Suitable for manufacturers with compact plant structure and low 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.
Note: The rinsing process after pickling is very important in the entire pickling and phosphating process, which directly affects the subsequent phosphating treatment; poor rinsing effect will shorten the service life of the phosphating solution. After the residual acid is brought into the phosphating solution, the phosphating solution is easy to turn black, and the service life is significantly shortened; incomplete rinsing will also cause poor phosphating quality, red or yellow surface, short storage time, and poor drawing performance. Metal products manufacturers with higher requirements use a comprehensive flushing system.
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 primary benefits of automated pickling compared to traditional methods?
Automated pickling offers excellent surface quality, continuous automatic production with high efficiency, lower production costs through optimized media circulation and reduced labor, and significantly reduced environmental pollution via advanced waste treatment devices.
How do I choose between Circle, U-type, and Straight type pickling equipment layouts?
Circle type is ideal for high and low carbon wire rod materials with similar process requirements, offering high efficiency and fault tolerance. U-type is best for varied wire rods and stainless steel with different processing needs and high output. Straight type is suitable for manufacturers with compact plant layouts and lower output requirements.
What makes the new generation of manipulators highly reliable and safe?
They feature corrosion-resistant electric hoists, synchronous four-wheel drive control (where a single motor failure does not stop operation), absolute value lifting encoders, and linear positioning sensors with 0.8mm resolution for precise positioning.
What is tank external circulation filtration technology and its benefits?
It is a patented technology that removes heating elements from the tank. It uses dynamic turbulent pickling to improve efficiency by 10-15%, online residue removal to increase hydrochloric acid lifespan by over 15%, and significantly reduces maintenance labor.
Why is the rinsing process after pickling so critical?
Incomplete rinsing allows residual acid to contaminate the phosphating solution, turning it black and shortening its service life. This leads to poor phosphating quality, red or yellow surfaces, reduced storage times, and poor drawing performance.
Can the automated pickling control system integrate with factory management software?
Yes, the advanced control system features a reserved MES system interface for seamless integration. It also supports RFID/barcode tracking, wireless industrial Ethernet, IoT interfaces for remote mobile monitoring, and customizable process reports.