straighthening machine for steel wire

Invention: Straightening Steel Wire Machine Before Making Wire Buckles

1. Overview

The Straightening Steel Wire Machine Before Making Wire Buckles is a specialized piece of equipment designed for the pre-processing of steel wire used in buckle production (e.g., 32 x 7 mm wire buckles). It straightens and conditions the wire to remove residual stresses, bends, and surface imperfections, ensuring that the wire is in optimal condition for forming into high-quality buckles. This invention addresses common issues in buckle manufacturing, such as inconsistent buckle shapes, reduced tensile strength, and production delays due to wire defects.

• Purpose:
  • Straighten steel wire to a high degree of precision before buckle forming.
  • Improve the quality and tensile strength of wire buckles (e.g., 32 x 7 mm buckles with system strength of 1125–2400 daN, as previously discussed [Previous Artifact ID: 44ba4daa-b1e5-4f8d-8a1f-958e0b12d5ed]).
• Application: Ideal for industries producing steel wire buckles for strapping applications, such as securing steel strapping (e.g., 9mm blued steel strapping) or steel pipes for export to Ecuador or Algeria.

2. Design Specifications

2.1 Structural Components

• Base Frame:
  • Material: Heavy-duty steel with a welded construction for stability [Web ID: 4].
  • Dimensions: 2.5 m x 1.0 m x 1.2 m (L x W x H), compact design for integration into production lines [Web ID: 12].
  • Weight: Approximately 500 kg (1102 lbs), ensuring stability during high-speed operation.
• Wire Feeder:
  • Inlet Guide: Adjustable guide rollers to accommodate wire diameters from 3 mm to 10 mm (e.g., 7 mm for 32 x 7 mm buckles) [Web ID: 3].
  • Feed Mechanism: Motorized feed rollers with a variable speed drive (0–50 m/min) to control wire input [Web ID: 12].
• Straightening Module:
  • Roller Configuration: Two sets of straightening rollers (7 rollers per set, 14 total) arranged in a staggered pattern to apply multi-axis straightening forces [Web ID: 1].
    • Roller Material: Hardened steel (HRC 58–62) for durability and wear resistance.
    • Roller Diameter: 50 mm, with adjustable spacing to handle different wire diameters.
  • Straightening Precision: Achieves straightness within ±0.05 mm/m, ensuring uniformity for buckle forming [Web ID: 3].
  • Tension Control: Integrated tension sensor to prevent over-stretching, maintaining wire tensile strength.
• Surface Conditioning Unit:
  • Wire Brushing System: Two rotating wire brushes (brass bristles) to remove surface rust, scale, or debris from the wire, improving surface quality for buckle forming [Web ID: 12].
  • Optional Polishing: Micro-abrasive belt (grit 600) for a smoother finish, reducing friction during buckle forming.
• Output Guide:
  • Exit Rollers: Adjustable rollers to guide straightened wire into the buckle-forming machine.
  • Cutting Option: Integrated shear (optional) to cut wire into pre-set lengths (e.g., 150–200 mm for 32 x 7 mm buckles) before forming [Web ID: 12].

2.2 Technical Features

• Wire Diameter Compatibility: 3 mm to 10 mm, covering common buckle sizes (e.g., 7 mm for 32 x 7 mm buckles) [Previous Artifact ID: 44ba4daa-b1e5-4f8d-8a1f-958e0b12d5ed].
• Wire Material Compatibility:
  • High-strength steel wire (galvanized or phosphated, as used in buckles) [Web ID: 0].
  • Tensile Strength Range: 600–1200 MPa (typical for buckle wire) [Web ID: 8].
• Speed:
  • Straightening Speed: 0–50 m/min, adjustable to match the downstream buckle-forming machine [Web ID: 12].
• Power Supply:
  • 380V/50Hz, 3-phase (adjustable to 120/240V, 60Hz for Ecuador) [Previous Artifact ID: da2846a0-29ac-4791-ae42-ff246e25bb9c].
  • Power Consumption: 3 kW (1.5 kW for feed motor, 1 kW for straightening rollers, 0.5 kW for brushing/polishing).