Advanced Wire Cleaning Equipment: SHJLPACK Shot Blasting Technology
Wire shot blasting equipment is a highly efficient method for cleaning wire surfaces. It utilizes high-speed abrasive particles to remove rust, scale, and oxides, preparing the wire for further processing and enhancing its properties like tensile strength and corrosion resistance. SHJLPACK's shot blasting machines ensure a clean, uniform, and durable wire surface.
Understanding Shot Blasting Technology for Wire Cleaning
Shot blasting is a cold working method used for processing metal surfaces. It involves impacting the metal with small, spherical particles under high pressure. This process leverages the kinetic energy of abrasives to effectively remove surface contaminants and achieve a desired material condition.
The high-pressure abrasive stream in shot blasting efficiently eliminates greasy deposits, scale, and rust from metal surfaces. It can also create a matte finish and provide the necessary surface roughness for subsequent coating or finishing processes. Importantly, shot blasting removes corrosive elements and loose particles, improving the overall surface quality of the wire.
Key Applications of SHJLPACK Shot Blasting Equipment
SHJLPACK shot blasting machines are designed to enhance wire production through several key applications:
- Corrosion and Oxidation Removal: Effectively removes rust and oxide layers from the wire's outer surface, ensuring a clean base material.
- Uniform Surface Roughness: Achieves a consistent surface texture across the wire, which is crucial for subsequent processes like coating and drawing.
- Internal Stress Reduction: Helps to relieve internal stresses generated during the wire drawing process, improving material stability.
- Enhanced Material Properties: Increases tensile strength and resistance to stress corrosion cracking, leading to a longer service life of the wire.
Technical Specifications of SHJLPACK Wire Shot Blasting Machines
SHJLPACK shot blasting equipment is engineered for robust performance and efficiency. The following table outlines the main technical parameters:
| Feature | Specification |
|---|---|
| Processed Material | High-speed tool steel |
| Wire Diameter Range | Ø6.0-32.0 mm |
| Feed Speed | ≥50m/min (dependent on drawing/retracting machine) |
| Impeller Head Abrasive Flow | 4 × 250 kg/min |
| Elevator Lifting Capacity | 80 t/h |
| Separator Capacity | 80 t/h |
| Separator Wind Speed | 4-5 m/s |
| Screw Conveyor Capacity | 80 t/h |
| Feeding System | QM pneumatic valve, 4 sets |
| Dust Removal Main Air Volume | 13000 m³/h |
| Dust Removal Power | 11 kW |
| Dust Removal Method | Bag dust removal |
| Total Power Consumption | Approx. 62 kW |
Operational Principle and Design of SHJLPACK Shot Blasting Machines
SHJLPACK shot blasting machines are designed for continuous, high-efficiency wire cleaning. The process begins with wire traction, feeding the wire into the cleaning chamber after a coarse straightening. Within the chamber, powerful shot streams from multiple turbines bombard the wire surface. This abrasive action effectively removes scale, rust, and dirt, leaving a bright and clean surface with optimal roughness.
Key Functional Components:
- Cleaning Room: The enclosed area where shot blasting occurs, designed for durability and safety.
- Wire Guide Device: Ensures smooth and consistent wire movement through the blasting zone.
- Shot Blasting Device: Consists of high-speed turbines that propel abrasive particles.
- Projectile Circulation System: Recovers and recycles abrasives, including an elevator, separator, screw conveyor, and flow adjustment mechanisms.
- Purging Mechanism: Removes residual abrasives from the wire surface after blasting.
- Dust Removal System: Captures and filters dust generated during the process, maintaining a clean working environment and ensuring environmental compliance.
- Electrical Control System: Manages and monitors all machine functions for optimal performance and safety.
The projectile circulation system is crucial for efficiency. A screw conveyor collects the used abrasive and debris mixture, transferring it to a bucket elevator. The elevator lifts the mixture to a separator, which efficiently separates reusable abrasives from dust and debris. Purified abrasives are then returned to the shot blasting system, while dust is directed to the dust removal system.
Key Components and Structural Features
SHJLPACK shot blasting machines are constructed with high-quality components to ensure durability, efficiency, and ease of maintenance.
Blasting Chamber
The blasting chamber is a robust, box-shaped welded structure lined with wear-resistant plates. This enclosed design ensures safe and contained shot blasting operations. The wear-resistant lining protects the chamber walls and extends the equipment's lifespan. The chamber is designed to maximize projectile bounce, enhancing cleaning efficiency. A large maintenance door with a safety interlock switch allows for easy access and safe maintenance.
Shot Blast Impeller
The machine features four high-performance impeller heads. The impeller is designed to accurately meter and accelerate the shot stream onto the wire. Key components like blades, pellet wheels, and control cages are made from hardened tool steel for extended durability.
Spiral Conveyor
The spiral conveyor, driven by a cycloidal gear reducer, efficiently transports collected projectiles from the hopper to the bucket elevator. The screw blade is constructed from durable 16Mn material, processed with precision technology to ensure accurate pitch and dimensions, maximizing its service life.
Bucket Elevator
The bucket elevator uses a flat belt and centrifugal gravity for efficient vertical transport of abrasives. A squirrel cage roller design enhances belt friction, preventing slippage and extending belt life. This design also prevents projectile jamming and belt run-off.
Pneumatic Valve
Pneumatic valves precisely control the flow of abrasive media, preventing motor burnout and blockage issues. This system ensures accurate and consistent shot blasting intensity.
Dust Removal System
SHJLPACK's dust removal system is a two-stage design featuring a settling chamber and a pulse bag filter. The pulse bag filter, with over 99% dust removal efficiency, utilizes pulse counter blowing for effective soot cleaning and minimal gas consumption. This system maintains air quality, with emissions kept below 30 mg/m³.
Shot Sand Separator
The BE full screen separator efficiently separates reusable abrasives from dust and debris. Utilizing gravity air separation, it ensures that only clean abrasives are recirculated, maximizing cleaning effectiveness and reducing waste. Adjustment baffles allow fine-tuning for optimal separation efficiency, reaching up to 99%.
Electrical Control System
The electrical control system allows operators to sequentially start and test each functional component. Safety interlocks prevent operation with the maintenance door open and ensure the shot blasting device only operates when the shot feeding brake is active. The system includes a current display and overcurrent protection for enhanced safety and control.
SHJLPACK: Your Partner in Advanced Wire Cleaning Solutions
SHJLPACK wire shot blasting equipment represents a significant advancement in wire cleaning technology. By delivering efficient, reliable, and environmentally conscious solutions, SHJLPACK is committed to enhancing the quality and productivity of wire manufacturing processes.
