拉丝机连续退火操作过程注意事项
Wire drawing machine continuous annealing process matters needing attention
（内部培训教材）
（Internal training materials）
为了提高产品品质和产能，降低能耗，现在线缆行业逐渐用连续退火方式代替原有的罐式退火。连续退火的工作原理是利用一定长度的铜线把两个正负电极的铜轮直接短路，因为铜线的电阻相当低，在低电压状况下也能产生很大的短路电流。利用这个低电压大电流，就能达到把铜线烧软目的。在现场操作中，会造成退火后线径变细、表面划伤、铜线发红、铜线变色、铜线氧化等一些现象。现根据现象，结合退火原理来解释、解决操作上的一些失误。
In order to improve the product quality and productivity, lower energy consumption, now cable industry gradually continuous annealing mode instead of the original tank annealing. Continuous annealing working principle is to use a certain length of copper wire the two positive and negative electrode copper wheel directly short circuit, because the resistance of the copper wire is quite low and in low voltage condition can also produce a lot of short circuit current. Use this low voltage large current, can achieve the copper wire burning soft purpose. In the field operation, can cause annealed wire diameter necked, surface scratch, red copper wire, copper wire color, copper wire oxidation and so on some phenomenon. According to phenomenon, combined with annealing principle to explain and solve operational some mistakes.
1.退火后线径变细：铜线在硬态时，出口模就是定径模，张力大小不至于把线径拉丝。但是在连续退火时，铜线发热使线材变软，线本身就有一定的延伸。为了把线延伸的部分及时送出，不至于把铜轮的导电镍环摩擦起槽，现在退火一般都结合了国外先进经验做成三角退火结构。三角结构的外层导电铜轮分内外两沟，铜线经内沟引入，完成退火。从外沟引出去到达收线。为了不使镍环起槽，外沟直径比内沟大，这在结构上解决了镍环起槽问题。为了补偿退火线径变细的问题。一般连续退火出口模要选择比实际需要线径大0.0015—0.0035比较合适。多出部分正好被自然延伸掉。
When annealed wire diameter necking: copper wire in hard state, export module is sizing die, tension size not the wire diameter wire drawing. But in the continuous annealing, copper wire heating make wire become soft, line itself has certain extension. In order to put the line extended part timely send out, and not the copper wheel of conductive nickel ring friction tank, now annealing generally combined with foreign advanced experience into triangular annealing structure. Triangular structure of the outer conductive copper wheel points inside and outside two groove, the copper wire inside groove introduced, complete annealing. From the ditch derivation to accept line. In order not to make nickel ring up tank, outside groove diameter ratio inside groove is big, this on the structure solved the nickel ring grooving problem. To compensate for annealed wire diameter necking problem. General continuous annealing export should choose to die than actual need wire diameter 0.0015-0.0035 more appropriate. More than just part of the natural extension off.
因为退火后的线已经很软了，对应不同的的线径要采用合适的张力重量，如果线径小张力大，就会把线径拉细了。张力的调节在退火方面要求是相当高的。不能任何线都用一个张力的。
Because after annealing line is very soft, corresponding to different wire diameter to use appropriate tension weight, if wire diameter small tension is big, will be the wire diameter and thin. Tension control in annealing demand is very high. Not any line with a tension.
2. 表面划伤：一连续退火是利用铜线在导电轮上连续接触引出，来完成正负极间短路，达到退火目的。理论上讲铜线和铜轮间有相对运动，就会产生一定的划伤，再者线在铜轮上也是连续电击的过程。细线因为接触面小，看上去不是很明显，粗线因为接触面积大，看上去要明显的多。为了降低线和导电轮间摩擦和电击产生的划伤，一要让冷却水有一定的润滑作用，（建议使用烧炖油，按0.1%的浓度添加或直接使用含有一定抗氧化功能拉丝油，按1-3%的浓度添加）减轻线和导电轮之间的摩擦。二要在不至于把铜线拉细的情况下尽量加大张力，让线和导电轮之间滑差降低，最大程度减少擦伤。三是检查各过线导轮、瓷孔等有没有破损粗糟的地方。四是尽快解决主机和退火之间传动难调的问题。（单独电机控制退火部分，在退火入线端加装张力架，退火部分自主构成一路PID闭环控制，这样就解决了主机和退火部分因线径不同造成滑差，解决主机和退火之间的滑差，让铜线和镍带之间因滑差造成电击点降低到最低。
Surface scratch: continuous annealing is the use of copper wire in conductive wheel on continuous contact eduction, to complete the positive and negative electrode short circuit, achieve annealing purpose. In theory copper wire and copper round there is relative motion between, will produce a certain scratches, and furthermore, line in copper wheel is the process of continuous electric shock. Fine line because the contact area is small, the look is not very obvious, thick line for large contact area, appears to be more obvious. produced scratches, one to make cooling water have certain lubrication, (suggest using burn stew oil, according to the concentration of 0.1% add or directly use contain certain antioxidant function drawing oil, press 1-3% concentration add) reduce the wire and the electric conduction of the friction between the wheel. Second, we need to be in the copper wire fine-drawn cases try to increase the tension, let the line and conductive wheel slip between reduced, minimize bruises. Three is to examine each thread guide roller, porcelain hole, etc have damaged coarse bad place. control annealing part, in the annealing into terminal adding tension frame, annealing parts constitute the independent PID closed-loop control, this would solve the host and annealing part for wire diameter difference slip, solve the host and annealing between the slip, let copper and nickel belt for slip between caused by electric shock point down to a minimum.
3. 铜线退火后发红：连续退火分三个段：预热段，工作段、冷却段。预热段因线的长度比较长，温度不会超过250度，不至于让铜线变色的。工作段电流大，铜线温度高（550度左右），如果工作段内有空气存在，铜和氧气在加热的条件下就产生氧化铜。在这段最容易氧化发红。工作段一般是采用蒸汽（或水）保护的，如果蒸汽量不够（或水位太低），在这段就已经发红了。解决的方法一是加大蒸汽量（或提高水位）。二是让下铜轮的水位提高，确保工作段没有空气存在。 After annealing copper red: continuous annealing three sections: preheating section, the work piece, cooling section. Preheating section for line length is longer, the temperature is not more than 250 degrees, and not let the discoloration of copper wire. Work period of current is big, copper wire high temperature (550 degrees), if the working section has air exist, copper and oxygen in heating conditions produce copper oxide. In this section of the most easy oxidation is red. Work period of it is to use steam (or water) protection, if steam enough (or water level is too low), in this section will have the red. The solution is to increase a steam (or improve water level). The other is to make the water level of the bronze wheels to improve, guaranteed that the work period there is no air.
注意：利用蒸汽保护的场合，冷却水位不能高出蒸汽出口，否则蒸汽变成直接加热循环冷却水，这样会吸收大量蒸汽，导致蒸汽压力为零（蒸汽发生器加热灯显示，表示一直在加热，可蒸汽就是压力为零。很多时候都会让人产生蒸汽发生器加热管烧毁或蒸汽发生器功率不够的假象，在生产过程中要注意这个现象，以免被误导。工作段如果没蒸汽保护，铜线出来就变色。解决的方法就是适当调小冷却水进水压力。不要太大。同时要保证回水口处出水有一定的压力，不能让空气从回水口进来。
Note: using steam protection occasions, cooling water can't more than steam outlet, or steam into direct heating cycle cooling water, so that can absorb a large number of steam, steam pressure to zero (steam generator heating lamp display, says it has been heating, steam pressure is zero. A lot of times can make the person produces steam generator heating pipe burn or steam generator power not enough illusion, in the process of production should pay attention to this phenomenon, so as not to be misled. Work DuanRuGuo didn't steam protection, copper wire them will change color. The solution is appropriate adjustment small cooling water feed water pressure. Don't be too big. At the same time to ensure that the water back to the opening place has certain pressure, can't let air come in from the back gate.
4. 铜线变色（暗红或发白）：连续退火在工作段把线烧软，还要经过冷却段冷却后才能达到引出线不烫、不带水。为了解决大规格线连续退火后冷却不够，引出线太烫，导致铜线暗红或发白，在冷却段有两个进水口：冷却下进水、冷却中进水。在做小规格线时，只要冷却下进水打开就可以了。如果做大的规格线，两个出水口都要打开，这样加强铜线的冷却效果。引出线就不会太烫，也不容易产生暗红或发白了。连续退火冷却不够一般出现在退规格比较大的铜线，因为以前都是用蒸汽来保护退火，工作段和冷却段又是个连通器，这样冷却段水位不可能高于蒸汽入口位置的，否则水就把蒸汽口堵住，但是冷却段水位不高，又不能有很好的冷却效果。真是很矛盾的事情。为了解决这样的难题，我们改进了退火设计，从根本上解决了这样的矛盾。根据线径的不同，随便调节冷却段水位。达到冷却的目的。
Copper wire color (dark red or white) : continuous annealing in the work period of the line burn soft and pass cooling section after cooling can achieve lead not hot, without water. In order to solve large size line continuous annealing cooling is not enough, lead is too hot, resulting in copper wire dark red or white, in cooling section has two inlet: cooling down water, cooling water. Doing small specification line, as long as the cooling water open it. If do big specification line, two outlet open, so that strengthen the cooling effect of the copper wire. Lead is not too hot, also is not easy to have a dark red or white with. specifications larger copper wire, because before is steam to protect annealing, working section and cooling section is a communicating vessels, such cooling section water could not higher than the steam inlet position, or water to steam mouth stopped, but cooling section water level is not high, also cannot have a good cooling effect. Really contradictory things. In order to solve this problem, we improve the annealing design, fundamentally solve this contradiction. According to the different wire diameter, literally adjust cooling section water level, to achieve the purpose of cooling.
5. 铜线变色：两种情况，一种是铜线退火出来就变色了，还有一种是退火出来当时很好，但保存不了多久就氧化变色。
Copper wire color: two kinds of circumstances, one kind is copper wire annealing them will change color, still have a kind of is annealing out at that time is very good, but not as long as you keep oxidation color.
针对前一种情况，主要是注意工作段内有没有空气，解决方法同上。还有就是冷却水太脏或水质变坏，需要更换干净的冷却水。第二种情况一般是带水造成的，主要是解决吹干的问题。如果空气吹不干，考虑加装一个刮水模来解决，效果也很好。让铜线出来不带水是最终的解决目的。
In the former case, mainly pay attention to work in period without air, the solution as above. There is water too dirty or water quality change bad, need to replace clean water. The 2nd kind of circumstance is usually caused by with water, mainly is to solve the problem of dry. If air blow not stem, consider adding a wiper die to solve, the effect is very good also. Let the copper wire out without water is the final purpose of solving.
6．注意事项：因为拉丝带连续退火，在操作上要注意的事情比较多，一个环节不注意，就能到来生产的麻烦，以上只是介绍了现场比较典型的故障案例，在实际生产中，为了在源头就解决隐患发生，在设备外围的配备上要注意几点1：中拉拉丝油池的体积不能小于7个立方/台，中拉冷却油池不能小于3个立方/台，油池尽量长和宽，不要太深，那样有利于散热。2：铜线在退火过程中产生的热量全部让冷却水带走，这样冷却水会连续加热，当冷却水温超过70度时，冷却效果就不理想了，铜线就会发红。所以冷却水池不能太小，冷却水量也必须足够，建议冷却泵电机选用三相0.75KW以上，出水口径在1寸的自吸泵。不建议使用单相水泵。管道在铺设时尽量少弯头，保证出水流量和压力。3：高速拉丝机的模具要和设备的减面率相符合。配的太大比较好开机，但是塔轮寿命会减短。配的太小，拉丝困难，速度一快就容易断线，但是因滑差小，塔轮就不容易起槽。根据现场的经验，一般模具配比上在设备的减面率基础上加2-3个滑动系数就可以了。高速拉丝模具要求定径区比土拉丝机的短，喇叭口要圆整。定径区长了，模具寿命会长，但是压缩区长，相应的线速度也加不起来，高速特别容易断线。针对拉丝机来说，过桥模一般选用聚晶就可以了，出口模因为是定径模，要选用钻石的。最好在最后几个靠近出口模的三四个模具都选用钻石最好了。国产模具质量稳定的也很多。天长的和河北的模具也可以选用，价格比较低廉，性价比很高吧。4：铜材的质量问题，这方面是最难查的故障了，一般表现为经常莫名其妙的断线，大规格和小规格都差不多，给一线工人带来最大的头痛。并且还查不出原因。也只有更换好几批母线后，才能总结出经验了。我们生产厂家也无能为力。5：穿线方法的问题，为了减小塔轮上的线滑动系数，尽量多在塔轮上绕圈，一般在塔轮上绕圈不能小于4圈，绕圈少了，塔轮更容易起槽。绕圈太多也不好，容易互相压线。6：张力气压调节的问题，一般情况下，在不退火时张力气压要越大越好，只要不至于大到把线拉断。因为双变频控制，收线变频的快慢主要靠张力杆后面的精密电位器分压取中间电压来得到收放平衡，如果张力气压达不到线径规格所需要的气压值，就会造成收线速度慢，滑差变大，有客户反应不退火时，机器速度达到1300M/MIN以后，铜线都会烧红现象，这就是典型的张力气压太低，造成主机速度快，收线速度严重不足，铜线在主机的定速轮上摩擦产生大量的热，把铜线都给退火了。这样情况出现，客户的主机定速轮都会起槽（一般拉丝机的定速轮是不会起槽）。在连续退火时，张力气压要注意了，不能太大，否则会把线拉细很多，造成束丝现象严重。调节上根据不同线径现场调节，铜材的厂家不同，相应的退火气压也不一样，最好现场摸索出配合固定铜材的经验数据。理论数据不可靠。有的时候在连续退火的厂家，又需要退火和不需要退火，现场工人在退火时调好张力气压，在不退火时没有及时调大，就会造成张力气压太低，拉丝出问题了。这点要特别注意。7：现在的控制系统越来越先进，不象以前的接触器继电器控制系统，越先进的东西要更专业的人员来护理，现场出现操作工随意调节变频器参数和退火板电位器现象，调了不知道怎么调回来了，就会造成不必要的设备投诉。在没有专业电气人员在场时，要严禁操作工擅自玩变频器和退火控制板，在设备安装调试期间要和客户说明清楚。
Note: for drawing with continuous annealing, in operation should pay attention to things more, a link to pay no attention to, it can come production of trouble, the scene is more than just introduced the typical fault cases, in the actual production, in order to solve the hidden danger source will occur, in the peripheral equipment with the attention should be paid to some: 1: the wire drawing oil tank volume can not less than 7 cubic/table, pull cooling oil pool not less than 3 cubic/station, oil pool in length and width as far as possible, don't be too deep, that is beneficial to the heat dissipation. 2: copper wire in the annealing process of heat all let cooling water away, so that cooling water will continuous heating, when the cooling water temperature over 70 degrees, the cooling effect is not ideal, copper wire will be red. So cooling pool cannot too small, cooling water must also be enough, suggest cooling pump motor selection three-phase 0.75 KW above, outlet diameter in 1 "self-priming pump. Don't suggest using single phase water pump. Pipeline laying in the elbow less as far as possible, to ensure that the water flow and pressure. 3: high speed wire drawing machine mould and equipment to reduce surface rate consistent with. With too much better boot, but cone life will be cut short.
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