Automatinė plieninės vielos pervyniojimo ir rišimo linija: pervyniojimo laikas, rišimo viela ir AGV išdėstymas

Santrauka

Automatinė plieninės vielos pervyniojimo ir rišimo linija paima ritę iš tempimo zonos, pervynioja vielą į sunkesnę, tvarkingesnę ritę ir suriša ją plienine viela per ritės kilpą. Automatiškai valdomos transporto priemonės perneša ritinius tarp stočių, todėl niekas jų nekelia ir nestumia rankomis. Mūsų lygiavertis sprendimas sujungia plieninės vielos vyniojimo mašiną (360 m/min., φ2–φ4 mm viela, 50–1,000 kg ritės) su vielos susukimo ir rišimo įrenginiu. Žemiau pateikiame pervyniojimo laiko, rišimo vielos kiekio vienoje ritėje ir AGV išdėstymo duomenis.

A low-profile round AGV platform transfers the heavy steel wire coil between processing cells and docks precisely beneath the gantry frame. Overhead positioning arms lower over the coil core while wire stock feeds through precision guides and tensioning rollers directly into the binding head for automated shaping and cutting. An integrated industrial control console with HMI touchscreen and emergency stop oversees the station sequence, interlocking line start strictly with confirmed AGV docking position.

Turinys

Kodėl reikia automatiškai atsukti ir įrišti

Wire from drawing machines typically discharges in smaller coils containing multiple joint welds. Downstream processing plants require fewer, heavier, continuous coils because each wire joint creates an interruption or downtime stop on high-speed forming lines. Rewinding consolidates drawn wire into a single dense coil, while automated binding secures its mechanical geometry during heavy crane lifting and intermodal transit.

Both operations are labor-intensive, hazardous, and situated near moving wire running under high tension, making them the primary targets for mill automation. Within our integrated manufacturing framework, coiling and packaging are built as a unified line family (differentiating integrated winder-binding systems from standalone secondary packaging equipment [manufacturer rating]).

Linijų srautas, stotis po stoties

The continuous automation sequence operates across five sequential stations:

  1. Tiekimas: The AGV conveys the raw source coil from the drawing zone to the dedicated pay-off station and docks beneath the overhead gantry.
  2. Atsukimas: The wire feeds through linear guide dies and tensioning rollers onto the expanding reel. The coiling head adjusts vertically to locate wire ends, while servo-driven profiling ensures tight, level layer winding under constant back-tension [manufacturer rating].
  3. Perkėlimas: An automated mechanical clamp securely grips the dense, finished coil, transferring it directly from the doffing rack to the binding position.
  4. Įrišimas: Binding wire is driven through the open coil eye, formed around the annular coil cross-section, tensioned, and twisted closed.
  5. Krovimas: An automated overhead crane or transfer arm collects the secured coil for transport to the finished inventory storage bay.

The central PLC system interlocks every station: each sequence step commences only when the preceding station returns a positive cycle-complete handshake.

Pervyniojimas: greitis ir ritės svoris

The rewinding system utilizes an elephant-trunk vertical winder with the core reel positioned eye-to-sky. The trunk connecting plate routes continuous wire directly down to a vertical doffing rack, allowing substantial coil mass accumulation without creating intermediate wire joints.

Parametras Reikšmė
Apvijos ritės skersmuo ~ 560 mm
Apvijos greitis 360 m / min
Vielos skersmuo φ2–φ4 mm
Paruošto ritės svoris 50-1,000 kg
Rišimo medžiaga plieninė viela, PET arba PP, pagal ritės svorį

Heavier coils utilize steel wire ties through the eye for maximum tensile containment; lighter wire bundles can be processed with high-strength PET or PP strapping.

Atsukimo laikas vienai ritei

Wire cross-sectional mass per linear metre is determined by steel density: Mass per metre: 7,850 kg/m³ × π × (wire diameter ÷ 2)² Rewinding cycle time is calculated by: Rewinding time: Coil weight ÷ Mass per metre ÷ Winding speed

(Calculations below represent illustrative engineering reference models):

Vielos skersmuo Mass per Metre Total Length in 1,000 kg Coil Rewinding Time at 360 m/min
~ 4 mm ≈ 0.0987 kg/m² ≈ 10,100 m ≈ 28 min
~ 2 mm ≈ 0.0247 kg/m² ≈ 40,500 m ≈ 112 min

Because mass scales quadratically with diameter, thin wire (φ2 mm) requires four times the rewinding duration of φ4 mm wire for an identical 1,000 kg bundle. In contrast, the automated wire binding cycle operates at a fixed mechanical speed regardless of wire gauge. Consequently, on thinner wire lines, a single through-the-eye binding station easily services multiple upstream winders without causing line bottlenecks.

Pririšimas per akį plienine viela

The through-the-eye binding unit integrates two synchronized mechanisms: a wire feed track and a rotating twisting head. The feeding track extends through the open eye of the vertical coil, encircling the coil wall cross-section before returning the wire end to the twisting head. The mechanism grips both wire leads, pulls radial tension, twists the wire knot to a specified turn count, and shears the tail cleanly.

Two system layouts support dual radial strapping (two ties per coil):

  • Dual twisting heads: Two binding heads cycle simultaneously, completing two ties in a single fast stroke to match high-volume output.
  • Single twisting head with indexing turntable: The head applies the first tie, an integrated turntable rotates the coil (e.g., 90° or 180°), and the unit applies the second tie. This configuration lowers capital investment while fitting lines with longer rewinding cycles.

Binding with standard wire stock eliminates specialized consumable strap costs, as compatible steel wire inventory is already produced and maintained on-site.

Įrišimo viela vienoje ritėje

The wire loop length required per tie depends on the coil’s physical annular envelope: Loop length: 2 × (Radial width + Coil height) + Twist allowance where: Radial width: (Coil OD − Coil ID) ÷ 2

The coil internal diameter (ID) corresponds to the φ560 mm expanding mandrel. For a package with 900 mm outer diameter (OD), 400 mm package height, and an engineered 100 mm knot twist allowance (illustrative example):

Inžinerinis parametras Skaičiavimas Pasekmė
Radialinis plotis (900 − 560) ÷ 2 170 mm
Loop length (single tie) 2 × (170 + 400) + 100 1,240 mm
Du kaklaraiščiai viename ritinyje 2 × 1,240 2,480 mm

Target strap counts, twist node allowances, and overall machine binding cycle times are confirmed during initial project sizing. AGV payload ratings and floor-level docking alignments are finalized during layout engineering.

AGV transportavimas ir prijungimas

Automated guided vehicles eliminate erratic forklift handling and high-maintenance crane transfers between wire drawing, rewinding, and packing sectors. Each heavy-load AGV supports a dedicated steel coil centered on a low-profile round deck, following magnetic floor tracks, optical paths, or laser guidance.

Precision docking repeatability is critical: the vehicle must align centrally beneath the gantry frame to ensure overhead pay-off clamps and stabilizing mandrels enter the coil eye without mechanical scuffing. Station safety interlocks restrict gantry arm lowering until optical proximity and laser docking sensors verify full zero-speed station lock. The required fleet size depends directly on plant travel distance, speed profiles, and winder cycle duration, verified during site engineering.

Atrankos kontrolinis sąrašas

To size the rewinding winder, binding head, and AGV fleet, verify the following inputs:

  1. Drawn wire diameter range, tensile strength, and steel grade.
  2. Source coil dimensions, inner/outer diameters, and incoming bundle weight.
  3. Target rewound coil weight (50–1,000 kg), final OD, and stack height.
  4. Binding specification: steel wire gauge, number of radial ties (2 or 4), or alternative PET strapping.
  5. Required throughput (finished coils per 8-hour shift).
  6. Facility footprint, floor condition, transport distance, and designated AGV travel corridors.

Saugumas

The integrated line complies with international industrial safety directives:

  • EN ISO 12100:2010: Rizikos vertinimas ir rizikos mažinimo inžinerija.
  • EN 415-10: General safety requirements for automated packaging and coiling machines.
  • EN 60204-1: Electrical safety, earthing, and industrial machine control architecture.
  • ISO 3691-4: Functional safety and obstacle detection for driverless industrial trucks (AGVs).

Primary mechanical hazards include running high-speed wire strands, rotating vertical mandrels, and automated hydraulic/electric twisting cutters. Heavy steel perimeter fencing encloses the winder and strapping sectors. Overhead gantries feature access interlocks, control stations integrate Category 0 emergency stop pushbuttons, and AGV corridors are marked and monitored by dual safety laser scanners. Complete CE conformity documentation and guarding layouts are delivered per project specification.

Inžinerijos DUK

Q: What wire diameter range does the 360 m/min winder accommodate? A: The standard vertical elephant-trunk winder processes φ2 mm to φ4 mm drawn steel wire at continuous line speeds up to 360 m/min.

Q: What is the maximum finished coil payload? A: Finished packages range from 50 kg up to 1,000 kg, supported by the φ560 mm mandrel and the vertical doffing rack.

Q: When should our mill select steel wire binding over PET strapping? A: Heavy, springy, or oil-coated steel wire coils (especially approaching 500–1,000 kg) require through-the-eye steel wire ties to prevent hoop-stress failure and snap-back during transit. Lighter or coated wire products can utilize PET or PP strapping with friction-weld joints [manufacturer rating].

Q: Can one central binding station service multiple rewinding machines? A: Yes. Because standard automated strapping cycles run in ≤35 seconds per coil (supporting 20–40 coils/hour across an integrated line [manufacturer rating]), and rewinding a 1,000 kg coil of φ4 mm wire takes ≈ 28 minutes (up to ≈ 112 minutes for φ2 mm), a single wire-twist binding station coupled with AGV distribution comfortably balances multiple upstream winders.

Q: Are AGVs mandatory for coil transfer? A: No. Walking beams, powered roller conveyors with polyurethane (PU) protective roller sleeves, or standard overhead cranes can link the cells. AGVs provide the greatest layout flexibility for facilities with long travel routes or changing footprint layouts.

Kitas žingsnis

  1. Send your technical parameters (wire diameters, target coil weights, cycle rates per shift, and floor plan) to info@fhopepack.com.
  2. Our engineering team will calculate the winder configuration, binding cycle balance, and AGV routing requirements.
  3. Receive a formal technical proposal and quotation per 24 valandas.

Šaltiniai

  • FHOPE Product Specification: Automatic Steel Wire Winding and Binding Machine
  • FHOPE Equipment Family: Automatic Steel Wire Coiling & Strapping Machine (FPCL-W500)
  • FHOPE Packaging Systems: Master Wire Coil Packaging Line
  • Standards: EN ISO 12100:2010, EN 415-10, EN 60204-1, ISO 3691-4

Paskutinį kartą peržiūrėta: 2026-10-19

Paskutinį kartą atnaujinta: 2026-10-29

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