How to enhance the operability of water tank wire drawing machines with VFD?

The water tank wire drawing machine is a crucial device for processing coarse metal bars into fine metal wires. Its working principle is based on the gradual drawing of metal to achieve the desired fineness and specifications. Here is an overview of the process and an explanation of the key stages:

Drawing Process

• Gradual Drawing: The metal bar is stretched through multiple drawing heads in stages, with each drawing head responsible for a certain degree of refinement. These drawing heads are usually placed in a water tank to use water for cooling, thereby reducing the accumulation of heat during the metal processing.
• Line Speed Adjustment: During the drawing process, as the diameter of the metal wire decreases, it is necessary to adjust the working line speed of each drawing head accordingly to maintain the constant volume flow rate of the wire passing through the drawing die. This is achieved by controlling the line speed of the incoming and outgoing wire, based on the formula where D and d represent the diameters of the incoming and outgoing wire, respectively, and v1​ and v2​ are the respective line speeds.
• Mechanical Transmission: The entire drawing process requires only one electric motor to drive, distributing power evenly to each drawing head through mechanical transmission or a gearbox.

Synchronous Operation and Control System

• Synchronous Operation: Ensuring all drawing heads operate synchronously is key, achieved by relying on the speed difference of the drawing wheels and the tension on the line. The entire system’s synchronized coordinated work depends on this precise speed and tension control.
• Cooling Requirement: Since the drawing process generates a large amount of heat, cooling fluid is needed for dissipation, to protect the equipment and ensure the quality of the metal wire.
• Winding Control: The winding part is driven by a low-power electric motor, requiring constant tension on the line. Control of the tension is crucial for ensuring the wire is evenly wound on the spool. If the tension fluctuates, it will lead to uneven winding, thereby affecting the quality of the wire.

Quality Impact

The design and control system of the water tank wire drawing machine directly affect the quality of the final metal wire. From precise control of the drawing speed to stable tension during winding, each stage requires careful management to ensure product uniformity and quality.

Through this detailed processing, the water tank wire drawing machine can efficiently process coarse metal bars into fine metal wires widely used in daily life and industry, including various applications such as woven art pieces.

What are advantages of suing VFDs?

Therefore, the use of a variable frequency drive (VFD) is very important for the wire drawing machine, as it can significantly enhance the operational performance and safety of the machine. Here are a few main advantages of VFDs and their impact on the drawing process:

1. Emergency Stop Protection and Swing Arm Position Control
   • In case of an emergency stop or wire break, the VFD can ensure a quick halt of the wire drawing machine. During stopping, the VFD control system can also adjust the swing arm automatically to the middle position, avoiding equipment damage or difficulties in starting due to improper swing arm position.
   • This enhances the safety and reliability of the equipment, preventing mechanical damage or additional burdens during startup due to sudden stops.
2. Quick Response and High Stability
   • The application of VFDs in wire drawing machines, especially for torque control, allows for quick responses and high precision in speed control. Whether during startup, operation, or load changes, the VFD can ensure the stability of the swing arm position, avoiding oscillation.
   • This is crucial for maintaining the continuity and high quality of the drawing process. The ability to quickly reach a balanced position at startup and adapt to different line speeds and spool diameters during operation ensures the uniformity and stability of the drawing.
3. Quick Response and High Stability
   • The application of VFDs in wire drawing machines, especially for torque control, allows for quick responses and high precision in speed control. Whether during startup, operation, or load changes, the VFD can ensure the stability of the swing arm position, avoiding oscillation.
   • This feature greatly reduces damage caused by continued operation after a wire break, also protecting the safety of operators. Auto-stop ensures issues can be addressed timely before causing greater loss.

Conclusion

The use of VFDs greatly enhances the performance of the water tank wire drawing machine, with significant improvements in safety, stability, and operational convenience. These control advantages not only reduce downtime in production, lower maintenance costs but also ensure the consistency and reliability of product quality. Additionally, VFDs offer the extra benefit of energy saving, as they allow the equipment to operate at optimal speeds, reducing unnecessary energy consumption.