-Introduction of Equipment
Lead Strip Caster
It is a high efficient auto-production line for lead strip manufacturig. It can work continuously for 24 hours and its productivity is up to 2 tons per hour. With high degree of auto control and man-machine interaction, dynamic monitoring to the machine is realized. The encoders are equipped on main motors so that the equipment speed of whole production line will match with each other. Each machine can be single controlled or linkage controlled to ensure simple installation, debugging & maintenance. The sensors on key parts will ensure timely information feedback so that a continuous production and equipment & personal safety can be guaranteed.
1.1.1 Lead Supply System: This system includes hogs feeding machine & melting furnace. Melting furnace is for alloy hogs melting. 1.1.2 Caster: this machine adopts steel belt sealing and cast wheel casting structure. The lead liquid will be sealed by steel belt to prevent overflow after it flows into groove of cast wheel. At the same time, it will be cooled down by air cooling and water cooling mechanism inside & outside the wheel, then the lead plate with uniform thickness will be formed. PLC and closed-loop system composed by a series of shut off Valve & regulator valve will ensure a sustained and steady high quality lead strip casting.
1.1.3 Horizontal Cutting Machine: normally, horizontal cutting will be started at the beginning & ending of each casting process. In case of an emergent situation, if rolling needs to be stopped for a limited time, casting process will not stop thanks to horizontal cutting. The machine has two cutting mode: Manual/Auto.
1.1.4 Rolling Stands: this machine has seven double-shaft rolling unit (6+1 type), the first 6 rolling stands were driven by an independent motor. The machine can be started via console at caster. There are four types of working mode to meet maintenance & production requirement.
1.1.5 Dryer: the function of this machine is to eliminate emulsion liquid residue on the surface of lead strip by strong air flow. Without moisture and oil, the strip quality can be assured even if it has been stored for long time.
1.1.6 Trimming Machine: the lead strip will be cut into required width by this machine, its scrap was also cut and sent back to furnace. Belt broken device are equipped on this machine. In case of a winder failure, emergency processing will be will carried out by the device.
1.1.7 Auto-Winder: this machine includes two sets of independent winding unit which will continuously wind up the lead strip into a roll , after that, the roll was unloaded and stored by an unloading device. The switching, conveying and winding of lead strip are all auto controlled. Alternating between winding machines is controlled by the program automatically to ensure a continuous production of the whole production line.
1.1.8 Electric Control System: the full-automatic control system consists of following components: programmable controller (PLC) and man-machine interface as central control component, inverter, servo motor, pneumatic system as executive component, approach switch and speed detector.
Main Technical Parameters:
Lead Strip Production Line
A- Main Items:
1- Melting Furnace(2* Capacity:15T/PC).
2- Lead Plate Casting System.
3- Rolling Stands(6+1 Type).
4- Cleaning System.
5- Trimming System.
6- Guide Rail.
8- Operation Platform & Electrical Control Components.
B . Technical parameters:
Width Range of Lead Strip:65-120mm.
Power:120KW(Lead Pot is not included).
Working Pressure of Pneumatic System:0.3-0.4Mpa.
Total Weight: About 45T.
The following document contains technical data and description regarding a line of production for automotive plates for lead-acid batteries is composed by:
-N°1 Vertical Double decoiler .
-N°1 Welding strip machine.
-N°1 Expander machine.
-N°1 Scrap conveyor.
(Standard direction of production is from left to right (under request is right to left).
18.104.22.168 PRODUCTION CHARACTERISTIC:
Following the data requirement for the material witch will be processed by the line and the characteristics of the plates at the exit of the line:
Composition laminated strip alloy: Al=0,005%±0,002, Sn=0,3-1,2%±0,05
Ca=0,06-0,095% ± 0.005
Strip Thickness: From 0,7mm to 1mm
Strip Width: From 60mm to 90mm
Moisture: From 9% to 14%
Density (Cube Weight): From 3,8 to 4,8 g/cm3
Plasticity (Penetration): From 330 to 420 (Humboldt)
Fiber Additives: From 1,5mm
Max Temperature: 45°C
22.214.171.124 Plate Production*
* to have a better estimate of the number of molds and the type of equipment, provide the complete drawings of the plates to be produced.
126.96.36.199 Plate Tolerance
Weight (wet): Nominal +-3g
Cutting tolerance: at the nodes.
188.8.131.52 Production Parameters
Line can run up to 32m/min.
184.108.40.206 Line Composition
The machines are equipped with all necessary safety guard and dust extraction hoods, locking doors and inspection doors, pneumatic system electrical system, and security system in accordance with the European Machinery Directive 2006/42/EC. Are provided Manual of use and maintenance with the EC declaration Language: English
A. Vertical Double Decoiler:
Decoiler with two mandrels witch permits to the operator to load the new strip reel meanwhile the line is working.
• Max weight: 1000 kg + 1000kg.
• Electrohydraulic expansion of the spindle.
•Manual turret rotation; • Loop control.
B. Welding Strip Machine:
This station permits to the line operator to safely and certain weld together the tail of one coil with the head of a new coil thereby eliminating line down time due to strip reel changeover. The operation is straight forward through the use of cold welding of two parts. The station is supplied with all necessary controls for a safe, constant and reliable operation. It is composed principally of the following parts:
• Chassis Made by aluminium profiles where are installed all the system equipment of the machine. In the rear part there is the slot for a scraps cassette. While on the left side there is a large shelf to store the tools needed.
• Mould unit; Complete with reaction springs, pneumatic cylinder and plate detaches sheet, is placed in the upper part of the frame and is used to make a cut perfectly orthogonal. The orthogonal position is guaranteed by reference pins.The mould is equipped with safety guards and a slide for scraps evacuation.
• Welding unit; This station is positioned in the lower part of the frame and includes two registry guides with a blocking system of the laminate In the central part is placed a block of cast iron resistors controlled by a thermocouple and a system of water cooling. The cast iron has the task to bring the 2 sides of laminate at the ideal temperature and then, melt the solder wire which weld the laminate. Once the welding is done, by a selector the solenoid valve will open the cooling circuit.
• Electric Panel; Including the following controls:
ON/OFF cooling system;
Instrument for temperature control; General switch;
C. Expanding Machine:
The expander consist of:
• Feeding system.
• Expanding and punching unit.
• Sharper press.
• Output system.
• Electrical and electronic equipment.
• Soundproof cabin.
Strip insertion system, vertical adjustment, complete with pivoted rollers for the inertial damping of the strip. Adjustable guides for the introduction of the strip in roller. The preload between the upper and lower roller is performed by an hydraulic system with calibrated push.
Expanding and punching unit :
Composed by: Working axes as follows: No. 2 main axes for controlling mold expansion tape. Each axis is activated by a motor and a series of toothed pulleys which, by means of a rigid torsional coupling, rotates the eccentric shaft, which, being in contact via the connecting rods and a slide wedge, poses the head of the mold in reciprocating motion causing the expansion phase of the tape. The punching step is performed by cams with a special profile, which acts on a dedicated wheel.
Shape press :
with the following characteristics: System to prevent theof failure in case
of overload. Mold lined up in 4 positions with side rails for quick change
dimension grids. Stemheads crushing grid provided with spacers of
different heights according to the geometry of the end plate.
C. Expanding Machine:
The roller pressure is pneumatically regulated. Guide support from the sh arper flattening the mouth of the lower roller. Output slide vertically adjus table.
Electrical and electronic equipment :
For complete control of the machine. Consists mainly of: Electrical panel where are inserted electrical protection and safety for the operator and the machine. Hand control with cable wire that all ows the interface between the user and the machine.
Soundproof cabin ?
Integrated and comprehensive of Cabin made in two pieces with longitudinal opening sliding on rails with wheels. Walls and ceiling made of sound-absorbing modular panels of 80 mm. Entrance doors by sliding closure. Inspections windows opening by shock absorbers. Limit switch lever 4 security. Interior lighting. Notes: Bench provided with “T” slots for insertion of hydraulic lifting plan ks and quick changeover of the mold. Automatic lubrication grease system centralized.