HYDRON-UNIPRESS, Ltd.

Transcription

HYDRON-UNIPRESS, Ltd.
Manufacturer of the equipment
for the tin/lead industry
ul. Wólczańska 257, 93-035 Łódź, Poland
fax:+4842-684 75 06, tel.: +4842-640 25 46
hydron@infocentrum.com
www.hydrononline.com
REMARK :
Hydron-Unipress, Ltd., of Lódz , Poland, is a corporation organized and existing under
the laws of Poland.
All information presented in this paper should be considered as an offer for further
discussion and negotiation between all concerned parties on the principle of equality
and mutual benefit.
The technical data given in this offer may undergo modification as a result of technical
improvements.
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
OFFER'S SCOPE
If your desire is to start your own manufacturing program in the field of solder making
business the HYDRON-UNIPRESS Ltd. is happy to offer you :
COMPLETE TECHNOLOGICAL LINE for manufacturing of FLUX CORED and
SOLID SOLDER BARS, ANODES and WIRES starting from the process of solder
alloy preparation and with an annual output of 200ton, 400ton or more
HiTech, specialized, INDIVIDUAL EQUIPMENT for manufacturing of FLUX CORED
and SOLID FINE and ULTRAFINE SOLDER WIRES from 0.118"/3.0mm down to
0.002"/0.05mm in diameter for electronic, microelectronic, electromechanic,
automotive and lighting industries, non-toxic, LEAD-FREE SOLDERS for drink water
piping soldering, LEAD PROFILES for stained-glass windows and Tiffany art,
ANODES and BARS for galvanic bath and wave soldering, and many others
applications
Participation in JOINT VENTURES for solder making business
Any other form of COOPERATION desired being of the mutual interest.
We GUARANTEE TECHNICAL AID throughout the implementation period.
APPLIED TECHNOLOGY
HYDRON's manufacturing line developed to produce solders in form of a continuous
wire with one, three, four or five cores filled with high quality flux, close to the
circumference of the wire throughout its length, see Fig.1, is based on the drawing and
extrusion technology, namely conventional and hydrostatic extrusion supported by wire
drawing.
Conventional and hydrostatic extrusion processes allows for production of the submillimeter gauge solders from the starting billet of tens of millimeters, see Fig.2.
In the case of ultrafine flux cored solder wires, see Fig.3, the hydrostatic extrusion
process has been introduced and proved to be superior to other methods, as for
example wire drawing due to its distinguished features, i.e.:
Gives very high reduction ratios in one single pass.
Produces no tension forces acting on the product, therefore ultrafine gauges can be
manufactured.
Assures high dimensional accuracy and surface finish.
Gives more reliable products.
Consumes less energy.
Requires smaller floorspace.
Allows for high production flexibility what makes simultaneous manufacturing of
variety of alloys and gauges possible.
Technical data may be modified as a result of technical improvements
ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
4
Fig.1 FLUX CORED SOLDER RODS and WIRES made by HYDRON's MACHINERY
5
Fig. 2
HYDRON'S HOT (left), COLD (middle) and HYDROSTATIC
(right) EXTRUSION CONCEPTS applied for SOLDER
MAKING
6
Fig. 3
ULTRAFINE FLUX 5-CORED WIRES made with
the HYDRON's HYDROSTATIC EXTRUDER (HTU-112);
wire diameters : (top left) 0.049mm; (top right) 0.059mm;
(middle left) 0.093mm; (middle right) 0.123mm;
(bottom line) their cross-sections; (courtesy Nihon Handa Co.,Ltd.)
7
HYDRON'S BACKGROUND
Extrusion technology has been creatively developed by the High Pressure Research
Center of the Polish Academy of Sciences UNIPRESS in many areas. This technology
has appeared as a result of research works done in UNIPRESS on plasticity of solids
and metalforming under pressure. UNIPRESS' research equipment is known in many
laboratories all over the world, as IBM Research Center, University of Tokyo, Bell Lab,
MIT, Cambridge University and many others. UNIPRESS is also well known as a
Center where the modern, highly efficient technology for solders making has been
developed, tested and introduced as an industrial, highly effective process. Finally,
UNIPRESS has founded two companies in Poland : the HYDRON-Unipress, Ltd. and
the CYNEL-Unipress, Ltd. where the machinery for solders making is manufactured
(HYDRON) and which uses these machines for mass solders production (CYNEL).
CYNEL's solders made with HYDRON's machines are well known to almost 1500
industrial users, including : computer producers, electronic component manufacturers,
TV an radio makers, instrument, meter and lamp producers, and others.
HYDRON's units have been already installed and are succesfully operated in USA,
Germany, France, Italy, England, Russia, Thailand, Malaysia, Singapore and Poland.
Solders made with HYDRON's machinery meet world-wide standards and
specifications.
MANUFACTURING STAGES
HYDRON's solder making line involves the following four manufacturing stages, see
Fig.4 :
STAGE I Continuous Casting (round anodes or solid billets for further extrusion)
STAGE II Hot Conventional Extrusion
large gauges
STAGE III Wire Drawing (mass production) or Cold Conventional Extrusion (small
batch production)
medium gauges
STAGE IV Wire Drawing or Hydrostatic Extrusion (Thinning)
fine and ultrafine
gauges
The HYDRON's System is driven and controlled electro-hydraulically, thus it is reliable,
simple in operation and energy-saving.
PRODUCTION STRUCTURE
The HYDRON's machines permit to produce both, the standard, pure tin-lead solders,
as well as high- and low-melting, and special purpose solder alloys. Pure tin and pure
lead can be also processed.
All flux-cored and solid solders between 100mm(4"") and 0.1 mm(0.004") (or for some
alloys even 0.03 mm( 0.0012") in diameter being in world-wide use can be manufactured.
Production profile can be selected arbitrarily upon the Customer's demand, and can
include both, round and complex cross sections of anodes, bars, rods, tapes, wires,
etc., see Fig.4
8
Fig. 4
Various Products
made by Hydron's
Machinery
9
metal components
MELTINING
CONTINUOUS CASTING
round anodes &
solid billets
HOT EXTRUSION
BAR SHEAR
flux
flux-cored & solid
anodes, bars, rods,
strips, wires
solid bars
(one, two,etc. pounds)
large gauges
CUTTING
WIRE DRAWING I
COLD EXTRUSION
flux-cored & solid
wires
flux-cored & solid
wires & cross-sections
WIRE DRAWING II
medium gauges
flux-cored & solid
wires
WIRE DRAWING III
fine gauges
flux-cored & solid
wires
HYDROSTATIC EXTRUSION
ultrafine gauges
flux-cored & solid
wires
INSPECTION
SPOOLING & PACKING
Fig.4 Solder Making Concept by Hydron
10
Hydron set - up for wire manufacturing
CCU-112
Ingots
Melting
Furnace
4000kg/sh
ift
BILLET CASTING
Up to 1200 kg/h
Metal
Pumping
Billets
WIRE & BAR
EXTRUSION up to
400kg/h solid 12 mm wire
HEP 112
12
12 mm
mm
WIRE
WIRE
for
for drawing
drawing
THICK WIRE
DRAWING
400 kg/h
MWD-112/3/12
THICK WIRE
SPOOLING
400 kg/h
SW-212/2
3 mm wire
for spooling
3 mm
WIRE
for fine
drawing
FINE WIRE
DRAWING
FINE WIRE
SPOOLING
Fine wire
for spooling
SW-112
MWD-112/3/12
11
SOLDER GRADES
The alloys which can be succesfully manufactured with HYDRON's equipment as fluxcored solder wires include full range of two component tin-lead grades and many multicomponent one, as tin-lead alloys with antymony, copper, silver, etc.. The HYDRON's
machines are also capable to run pure elements, i.e.: lead and tin. Other alloys can be
manufactured on the particular Customer's request after throrough examination.
Generally, the HYDRON's process permits a variety of the solder compositions and wire
gauges to be produced simultaneously.
All solder grades being use worldwide in the LIGHTING, AUTOMOTIVE,
REFRIGERATING and FREEZING, CANS and PACKING industries, for ROOFING,
WAVE
SOLDERING,
ELECTROPLATING,
in
ELECTRONICS
and
ELECTROTECHNICS, for COPPER DRINKING WATER PIPES SOLDERING (hot and
cold), for RADIATORS, HYDRAULIC and ELECTRICAL SYSTEMS, for AUTOMATIC
or HAND SOLDERING, by ELECTRICAL or GAS METHODS can be manufactured
with use of the HYDRON's SYSTEMS (COMPLETE LINES) and/or INDIVIDUAL UNITS.
FLUXES
In general, any high-quality, non-corrosive, non-hygroscopic and non-conductive
protection flux can be introduced into the solder with use of the HYDRON's machinery.
However, to obtain the high-quality, flux-cored solders and high productivity of the plant
it is desirable to apply special grades, which can be supplied by CYNEL, manufactured
on site at the Customer's plant or purchase on the market.
An average amount between 2.0 and 3.0 wt% of flux in flux-cored solder is the world
standard. It means that for the output of 200tons of solders the required quantity of flux
is between 4tons and 6tons. However, HYDRON's machinery is very flexible as far as a
flux content is considered. CYNEL's range varies between 0.5 wt% and 7.0 wt% of flux
content, for commonly known FSW21, FSW24, FSW26, FSW31 and FSW32 fluxes
(and their modifications) according to DIN 8511.
12
MANUFACTURING SYSTEM
The HYDRON's process is realized by the following, individual units, see Figs.6:
Hihg Pressure Continuous Casting Unit HP CCU-112
Horizontal Hot Extrusion Press HEP-112
Bar Marking and Shear BMS-112 (optional BMS-212 with packing system)
Heavy Multiple Wire Drawing Machine MWD-112/3/12
Light Multiple Wire Drawing Machine MWD-112/3/12
Vertical Cold Extrusion Press CEP-112
Hydroextrusion Thinning Unit HTU-112
Spool Winders SW 212/2 or /and SW-112 (optional for commecial spooling)
Central Hydraulic Supply System HSS-112 (optional, when a few HYDRON's Units
are set in a line)
One Continuous Caster, one 200ton Hot Extrusion Press and three Wire Drawing
Units can approximately produce in a year (one shift per day) :
1,060,000lbs/480tons of solid solder wire 0.06"/1.5mm in dia.
or
925,000lbs/420tons of solder flux-cored wire 0.061"/1.55mm in dia. +
353,000lbs/160tons of solder flux-cored wire 0.035"/0.9mm in dia.
or
when supported with the one Bar Marking & Shearing Device it will give
2,650,000lbs/1,200tons of 1lb/0.5kg and 2lbs/1kgs solid bars alone
In case of mixed products this line will give annually approximately :
190,000lbs/85tons of solid solder wire 0.06"/1.5mm in dia. + 330,000lbs/150tons of
solder flux-cored wire 0.061"/1.55mm in dia.,
or
130,000lbs/60tons of solder flux-cored wire 0.035"/0.9mm in dia. + 460,000lbs/210tons
of 1lb/0.5kg and 2lbs/1kgs solid bars
13
Hydron set - up for wire manufacturing
CCU-112
Ingots
Melting
Furnace
4000kg/sh
ift
BILLET CASTING
Up to 1200 kg/h
Metal
Pumping
Billets
WIRE & BAR
EXTRUSION up to
400kg/h solid 12 mm wire
HEP 112
12 mm
WIRE
for
drawing
THICK WIRE
DRAWING
400 kg/h
MWD-112/3/12
THICK WIRE
SPOOLING
400 kg/h
SW-212/2
3 mm wire
for spooling
3 mm
WIRE
for fine
drawing
FINE WIRE
DRAWING
FINE WIRE
SPOOLING
Fine wire
for spooling
SW-112
MWD-112/3/2
TEchnical data may be modified as a result of technical improvements
14
HP CCU 112
HEP 112
MWD 112/3/12
SW-212/2
BMS 212
SW-112
MWD 112/2/3
Fig. 6 HYDRON's
SOLDER
MAKING
LINE
Our references :
USA, RUSSIA, CHINA,
GERMANY, FRANCE,
ITALY, MALAYSIA
SINGAPORE, THAILAND
CEU 112
HTU 112
15
CCU-112 CONTINUOUS CASTING UNIT
APPLICATION
HYDRON's CCU-112 Continuous Casting Unit has been designed for continuous
casting of a variety of soldering alloys, see Figs.7(1). The casting is continuously(2)
pulled out by the double-sided pulling cylinder coupled with the clamping grip. The
alloy feeding pump pumps the molten alloy into the Caster holding tank.
Beginning from pure tin and pure lead, through all standard 2-component Sn-Pb
alloys and finally many special, multi-component soldering alloys as all alloys with
copper, e.g.: Sn97Cu3; Sn60Pb38.5Cu1.5, and many others : Sn95Ag5;
Sn59.6Pb38Bi2.4; with low content of Sb (0.2%); Sn50Pb32%Cd18, etc. can be
easily cast with HYDRON's Continuous Caster.
The alloys have to be prepared separately and to be provided in a molten state.
However, the melting pot is not a matter of supply, it can be delivered to the
Customer on special request.
HYDRON's CCU-112 Continuous Caster is programmable controlled, and at present
is the only one in the world which can cast continuously at 842oF/450oC.
If you have any specific alloy you want to try give us and we will test it.
Billet size(3):
Production capacity(4):
Supply working pressure:
Supply voltage:
Control system voltage:
Heating power:
Buzz saw power:
Saw blade size:
Hydraulic supply system power:
Cooling water consumption:
(pressure min. 2bar, free drain)
Overall dimensions (LxWxH):
Total weight:
TECHNICAL DATA
Model 72mm/2.835" Model 140mm/4.5"
72mm;2.835"
140mm;5.5"
1000kgs/h;2200lbs/h 1500kgs/h;3300lbs/h
30MPa;450psi
30MPa;450psi
60MPa;900psi
3x380V 50Hz
3x380V 50Hz
24V (220V)
24V (220V)
10kW
15kW
1.5kW;2H.P.
5.5kW;7.5H.P.
1.5kW;2H.P.
50liters/min
13.5U.S.gallons/min
4150x980x1420mm
13.6x3.2x4.7ft
850kgs;1870lbs
2.2kW;3H.P.
100liters/min
26.5U.S.gallons/min
4600x1050x1700mm
15.1x3.5x5.6ft
1050kgs;2310lbs
(1)
(2)
unit does not include the melting furnace and the melting pot with the agitator
stroke length and the dwell between strokes of the pulling cylinder is set by the operator depending on the alloy grade and
other casting terms. They can be set as minimal as 5mm (stroke) and 0.5s (dwell), what practically makes the casting
operation continuous.
(3)
(4)
other sizes available
based on 60/40, 72mm dia, one hour output
HYDRON's CCU-112 Continuous Caster produces cylindrical anodes or
semiproducts (round solid solder billets), see Fig.10, which can be further processed
for solid or flux cored solder rods, bars, strips and wires by conventional hot
extrusion at HYDRON's HEP-112 Automatic Hot Extrusion Press (see next Chapter)
or at any other Press being of the Customer's possession.
16
Fig. 7
Fig. 8
HYDRON CCU-112/72mm Continuous Casting Unit
HYDRON NEW HP CCU-112/72mm Continuous Casting Unit
17
New: High Pressure Continuous Casting Unit.
Adding high-pressure intensifier we had greatly improved our unit
· Perfect contact with cooling sleeve after metals start to shrink
· Less segregation (important for all lead frees
· Higher metal density (increased by 1-3 %)
· Higher outputs 30 – 50 % versus standard unit
Fig. 9
Best Quality Extrusion Billets cast with the HYDRON's
HP CCU-112 Continuous Casting Unit versus Standard Continous Casting
18
HIGH-PRESSURE INTENSIFIER
* COMPARISON OF THE CCU-112 UNIT TO ITS COMPETITOR
Comparison between the Continuous Caster made by HYDRON-Unipress, Ltd. and according Automatic
Mould Caster of Competitor (output from both Units is this same, i.e. rod 72mm(2.84") in O.D. made of
tin/lead soldering alloy)
COMPETITOR
Casting (weigth/length)
max.6.7kgs/190mm;14.7lbs/7.5"
HYDRON
unlimited
Output
40kgs;88lbs per one casting
10-17kgs/min;22 - 38lbs/min
Billet ends cutting
necessary (extra unit)
eliminated
Billet for extrusion
6.2kgs/170mm;13.6lbs/6.9"
12.7kgs/360mm;28lbs/14.2"
.5kg;1.1lbs ( 7.5% per casting)
eliminated
(weigth/length)
Discards
Power consumptions
approx. 24.6kW;33.5H.P.
approx. 12kW;16H.P.
Alloy pump
extra purchase
included in the price
Type of unit
stationary
movable
Weigth - caster
1220kgs;2684lbs
850kgs;1,870lbs
- ends shear
680kgs;1500lbs
-
- alloy pump
100kgs;220lbs
-
- caster
5.5m2;59ft2
4.1m2;44ft2
- ends shear
2m2;21.5ft2
-
2000kgs/7.5m2;4400lbs/80.5ft2
850kgs/4.1m2;1870lbs/44ft2
Floor space
Total floor space
19
HEP-112 AUTOMATIC HOT EXTRUSION PRESS
APPLICATION
HYDRON's HEP-112 Automatic Hot Extrusion Press, see Fig.11, is designed to
produce solid anodes, bars - Fig.13 and16, rods, strips - Fig.15 and wires or flux cored rods
- Fig.14, for further extrusion, drawing or rolling.
Front, as well as side extrusion, can be apply for Hydron's HEP-112 Press.
TECHNICAL DATA
Billet - diameter
- length
- volume
- weight
Working cycle:
Production capacity(2):
Multiplication factor
Maximal working parameters:
- extrusion pressure
- press load
- chamber temperature
- flux temperature
- flux pressure
Supply voltage:
Control system voltage:
Chamber heating power:
Flux vessels heating power:
Hydraulic supply system power:
Water consumption:
Model
72mm/2.835"(1)
72mm/2.835"
380mm/15"
approx.1.6dm3/95in3
approx.12-15kgs/
26.5-33lbs
1-5min
see Chapter "Output"
15
Model
104mm/4.1"(1)
104mm/4.1"
508mm/20"
approx.4.3dm3/264in3
approx.32-40kgs/
70.5-88lbs
1.5-6min
see Chapter "Output"
7.2
32MPa/5000psi
200Ton/2,000kN
450,000lbf
up to 145oC/293oF
32MPa/5000psi
200Ton/2,000kN/
450,000lbf
up to 145oC/293oF
up to 145oC/293oF
up to 0.1MPa/15psi
3x380V 50Hz
24V
10kW
2kW
22kW;30H.P.
10-30l/min
2.6-8.0U.S.gal./min
up to 145oC/293oF
up to 0.1MPa/15psi
3x380V 50Hz
24V
15kW
2kW
22kW;30H.P.
3600x1210x1860mm
11.8x4x6.1ft
1600x700x1000mm
5.3x2.3x3.3ft
1300x1100x1720mm
4.3x3.6x5.6ft
2360x830x1230mm
7.7x2.7x4ft
3800x1210x1860mm
12.5x4x6.1ft
1600x700x1000mm
5.3x2.3x3.3ft
1300x1100x1720mm
4.3x3.6x5.6ft
2360x830x1230mm
7.7x2.7x4ft
(cutter for anodes:
2000x1000x1100mm
6.6x3.3x3.6ft)
1800kgs;3960lbs
80kgs;176lbs
450kgs;990lbs
450kgs;990lbs
1900kgs;4180lbs
80kgs;176lbs
450kgs;990lbs
450kgs;990lbs
Overall dimensions (LxWxH):
PRESS
COOLER
HYDRAULIC SUPPLY
BAR SHEAR
Total weight:
PRESS
COOLER
HYDRAULIC SUPPLY
BAR SHEAR
(1)
(2)
other sizes available
based on 60/40, 72mm dia, one hour output
20
HEP-112 Automatic Press can be coupled in-line with :
HYDRON's MWD-112 Multiple Bull Block Drawing Machine (or any other being of
the Customer's possession) to manufacture solid or flux cored fine wires, see Fig 18
HYDRON's BMS-112 Automatic Bar Marking and Shearing Unit to manufacture
very effectively and fully automatically (up to 1100lbs/h;500kgs/h) solid bars of the
Customer's designed geometry, see Fig.17.
HEP-112 Automatic Press operates in cycles. Each extrusion cycle allows
transformation of one 2.835"/72mm in dia. solid billet into a thinner solid product or
the product with a few (1-5) flux filled cores.
Together with the HEP-112 Automatic Press HYDRON offers unique in the world
pressurized flux feeding system, Fig.12, allowing to monitor flux penetration into the
product cores. Thus, the probability of the flux core discontinuity is significantly
reduced.
HEP-112 Automatic Press is equipped with the programmable logic controller and
with the super economical, individual electro-hydraulic supply system with the
frequency inverter.
Depend on the Customer's technology HYDRON's HEP-112 Automatic Press is
offered in a few versions that allow to produce one of the following or mixed
assortment :
oval, rectangular, star shape, etc. solid anodes, or
rectangular and trapezoidal bar solders, see Fig.16, or
one-, two- or three-strands of strips, Fig.15, or
rods from 9mm up to 30mm in diameter, which may contain flux from 0.5 wt% up
to 7.0 wt%,
Fig. 11
HYDRON's HEP-112/72mm Automatic Hot Extrusion Press
adapted to side extrusion with Hydraulic Supply Unit (far right),
Control Box (far left), and the Product Cooler (left)
21
Fig. 13
Bar Solders (2 strands) extruded
with HYDRON's HEP-112
Automatic Hot Extrusion Press
(courtesy Asahi Solder)
Fig. 12
Pressurized flux feeding
vessel (below) and flux
melting vessel (above)
Fig. 14
Flux Cored Tin-Lead
Based Rods extruded with the
HYDRON's HEP-112
Fig 15 Bismuth Based Fusible Alloy
Strips (3 strands) extruded
with the HYDRON's HEP-112
Fig. 16
Solders Anodes extruded
with HYDRON's HEP-112
ul. Wólczańska 257, 93-035 Łódź, Poland_______________________________________________________________________April 2003
22
Fig. 17
HYDRON AUTOMATIC LINE for BAR SOLDER MAKING HEP 112
Press link with BMS 212 (packing option)
Fig. 18
HYDRON LINE for SOLDER WIRE: HEP Press 112 link with MWD112/3/12 Multiple Bull BlockHeavy Wire Drawing Machine (three drawing
cones model)
23
BMS-112 AUTOMATIC BAR MARKING and SHEARING UNIT
APPLICATION
HYDRON's BMS-112 Automatic Bar Marking and Shearing Unit, see Fig.19, is
designed for shear and stamp (company's logo and alloy's grade) on the one or two
strand flats (bars) which are extruded by the HYDRON's HEP-112 Automatic Hot
Extrusion Press, see Fig.11 and Fig.17.
The cut surface is flat (no edges deformed) and burrfree.
When coupled in-line with HYDRON's HEP-112 Automatic Hot Extrusion Press
makes manufacturing of solder bars fully automatic, reliable and very efficient
(up to 1100lbs/h;500kgs/h) solid bars of the Customer's designed geometry
.
TECHNICAL DATA
Shear force:
Shear time:
Shear length:
Shear cycle:
Feeding speed:
3Tonnes/6600lbs
1s
50-500mm(2-20inches)
3-8s
fast
slow
Motor power
Overall dimensions:(LxWxH):
Total weight (with hydraulic supply):
Fig. 19
10cm/s(4inch/s)
2cm/s(.8inch/s)
0.75kW(1.0H.P.)
2360x830x1500mm
7.7x2.7x4.9ft
450kgs/990lbs
HYDRON BMS-112 and BMS 212 Automatic Bar Marking & Shearing Units
24
AS-112 AUTOMATIC ANODE SAW
APPLICATION
HYDRON's AS-112 Automatic
Saw is designed for sawing of
anodes which are extruded by the
HYDRON's HEP-112
Automatic Hot Extrusion Press.
Operation is fully automatic. Saw
“fly” with extruded anode. Billets
joints are automatically cut-out.
The cut surface is flat (no edges
deformed) and burr free.
Fig. 20Fig. 20.HYDRON
LINE
forLINE
ANODES:
HEP
HYDRON
for ANODES:
Press
112
114
link
HEP
112
/114
mmmm
press
with AS
112
Anode
Saw
link with
(flying)Fig. 20
AS 112 Anode Saw (flying)
25
MWD-112/3/12 MULTIPLE BULL-BLOCK HEAVY WIRE
DRAWING MACHINES
APPLICATION
HYDRON MWD-112 Multiple Bull-BlockHeavy Wire Drawing Machines, Fig.21
were designed to draw flux-cored and solid wire solder within the range starting
from 0.5"/12.7mm down to approx. 0.125"/3mm,
All the worldwide known solder alloys, which can be drawn by the drawing machines
made by the others producers can also be processed with the HYDRON's MWD-112
Drawing Machines.
According to Customer request the performance of the unit can be modified and
adapted to other drawing diameters.
On Customer request the incoming wire diameter can be increased, up to 16mm .
HYDRON's MWD-112 Drawing Machines are programmable controlled and
optionally equipped with automatic stop, stepless speed control (frequency inverter),
die pre-pulling attachment and the exit wire counter.
HYDRON's MWD-112 Multiple Drawing Machines can work in-line with any
Customer's extrusion presses and drawing units, as well as, be coupled in tandems
or three between themself.
Fig. 18
HYDRON MWD-112/3/12 Multiple Bull Block
Heave Wire Drawing Machine (three drawing cones model)
26
TECHNICAL DATA
Model(1)(2)
MWD-112/2/12
Number of shafts
Max. input dia.
Min. output dia.
Number of dies
Die dia.
Die height
Drawing speed -stepless (frequency inverter)
Supply voltage
Control system voltage
Motor power (inverter)
Heating - heating elements
Cooling system
- heat exchanger
spray on each die and drawing shaft
Water consumption
Cooling water pressure
Cooling water inlet dia.
Production capacity(3) [kg/h;lbs/h]:
3
16 9mm;0.63÷0.35"
2.5 mm;0.010"
21
38 mm;1.5"
15mm;.6"
0.5 2 m/s;1.65÷6.5ft/s
380V, 3-phases
24V
22kW;25H.P.
2kW
yes
yes
10-20l/min;2.7÷5.4U.S.gal./min
2bar
½"
dia.3mm(0.125") - 450kgs/h
990lbs/h
2 kW;2.7H.P.
yes
no
Heating power
Take-up - freely to the container
- wire spooler
Auxiliary tooling:
standard
- automatic stop
standard
- die pre-pulling attachment
Total weight:
UNIT + ELECTRIC CONTROL BOX 1600kgs;3520lbs
(1) notation: MWD - multiple wire drawing unit; 112 - model no.; /3(2)/ - no. of shafts ; 16, etc. - max. input wire dia. (approx.)
(2) other sizes (models) available
(3) based on 60/40, min. dia., one hour output
Recommended die sequence 13% reduction
1
11.50mm
14
5.19mm
2
3
10.81mm 10.17mm
15
16
4.89mm 4.60mm
4
9.57mm
17
4.32mm
5
9.00mm
18
4.07mm
6
8.47mm
19
3.83mm
7
7.97mm
20
3.60mm
8
7.49mm
21
3.39mm
9
7.05mm
22
3.19mm
10
6.63mm
23
3.00mm
11
6.24mm
24
2.82mm
12
5.87mm
25
2.65mm
13
5.52mm
26
2.49mm
27
MWD-112/2/3 MULTIPLE BULL-BLOCK LIGHT WIRE
DRAWING MACHINES
APPLICATION
HYDRON MWD-112 Multiple Bull-Block Light Wire Drawing Machines, see Fig 22
were designed to draw flux-cored and solid wire solder within the range starting
from 3mm (0.125”)down to approx. 0.4 mm (0.015").
All the worldwide known solder alloys, which can be drawn by the drawing machines
made by the others producers can also be processed with the HYDRON's MWD-112
Drawing Machines.
According to Customer request the performance of the unit can be modified and
adapted to other drawing diameters. On Customer request the incoming wire
diameter can be increased, up to 6mm
HYDRON's MWD-112 Drawing Machines are programmable controlled and
optionally equipped with automatic stop, stepless speed control (frequency inverter),
die pre-pulling attachment and the exit wire counter.
HYDRON's MWD-112 Multiple Drawing Machines can work in-line with any
Customer's extrusion presses and drawing units, as well as, be coupled in tandems
or three between themselfs, see the Chapter entitled "Outputs".
Fig. 22
HYDRON MWD-112/2/3 Multiple Bull Block
Light Wire Drawing Machine (two drawing cones model)
28
TECHNICAL DATA
Model(1)(2)
MWD-112/2/3
Number of shafts
Max. input dia.
Min. output dia.
Number of dies
Die dia.
Die height
Drawing speed -stepless (frequency
inverter)
Supply voltage
Control system voltage
Motor power (inverter)
Heating - heating elements
Cooling system
- heat exchanger
spray on each die and drawing shaft
Water consumption
Cooling water pressure
Cooling water inlet dia.
Production capacity(3) [kg/h;lbs/h]:
2
6 3mm;.24÷.12"
1mm;.04"
26
28mm;1.1"
10mm;.4"
up to 6m/s;20ft/s
380V, 3-phases
24V
7.5 kW;10H.P.
2kW
yes
yes
10-20l/min;2.7÷5.4U.S.gal./min
5bar
½"
dia.1mm(.04") - 100kgs/h
220lbs/h
2 4kW;2.7÷5.4H.P.
yes
optional
Heating power
Take-up - freely to the container
- wire spooler
Auxiliary tooling:
standard
- automatic stop
optional
- die pre-pulling attachment
Total weight:
UNIT + ELECTRIC CONTROL BOX 1200kgs;2500lbs
(1) notation: MWD - multiple wire drawing unit; 112 - model no.; /3(2)/ - no. of shafts ; 3, etc. - nom. input wire dia. (approx.)
(2) other sizes (models) available
(3) based on 60/40, min. dia., one hour output
Recommended die sequence 7%
1
2
3
3.087 2.984 2.885
21
22
23
1.569 1.517 1.466
41
42
43
0.798 0.771 0.745
4
5
6
7
8
9
2.789 2.696 2.606 2.520 2.436 2.355
24
25
26
27
28
29
1.418 1.371 1.325 1.281 1.238 1.197
44
45
46
47
48
49
0.721 0.697 0.674 0.651 0.629 0.609
10
11
12
13
14
15
2.276 2.201 2.128 2.057 1.988 1.922
30
31
32
33
34
35
1.157 1.119 1.082 1.046 1.011 0.977
50
51
52
53
54
55
0.588 0.569 0.550 0.532 0.514 0.497
16
17
18
19
20
1.858 1.796 1.737 1.679 1.623
36
37
38
39
40
0.945 0.913 0.883 0.853 0.825
56
57
58
59
60
0.480 0.464 0.449 0.434 0.419
29
CEU-112 SEMI-AUTOMATIC COLD EXTRUSION UNIT
APPLICATION
HYDRON CEU-112 Semi-Automatic Cold Extrusion Unit (build of several
independently assambled individual, single presses), Fig.23 is designed to produce
small lot sizes of fine cored- and solid soldering wires or shapes, made of special
and hard-to-draw, non-ductile and brittle alloys, as bearing alloys SnSbCu- type
(Sn83Sb11Cu6, etc.), Sn70Zn30 alloy, indium and bismuth based fusible
alloys, e.g.: Bi49Pb18Sn12In21, Bi58Pb42, or others with cadmium,etc.
Wires and cross sections of diameter between 0.047"/1.2mm and a few millimeters
in one single pass through one extrusion die from the billet diameter .78"1.18"/20mm-30mm can be manufactured,
Whereever the wire drawing meet difficulties you can try HYDRON CEU-112 SemiAutomatic Cold Extrusion Presses. Since product pulling is eliminated you are not
limited by the tensile strength of the material being processed.
HYDRON's CEU-112 Press is self-loaded and operates in the semi-automatic mode.
The optional take-up reel attachment reduces the need for operator supervision to a
minimum.
Typically, HYDRON's CEU-112 Semi-Automatic Cold Extrusion Unit consists of four
identical presses fixed to one frame, see Fig23.
TECHNICAL DATA
Working chamber diameter
Tin-Lead Based Billet (solid or flux-cored)
diameter
length
Product (solid or flux-cored)
diameter
Working cycle
Multiplication factor
Maximum working parameters
extrusion pressure
press load
maximal chamber pressure
maximal cylinder pressure
Power consumption
(one press)
(four presses)
Overall dimensions
PRESS (one)
length
width
height
HYDRAULIC SUPPLY (four presses)
length
width
height
Weight
(one press)
Weight
(hydraulic supply)
Total weight (4 presses+supply)
0.78-1.18inch;20-30mm
0.78-1.18";20-30mm
7.9";200mm
0.05-0.24";1.2-6mm
8-18min
64
36,260psi;250MPa
80tons;785kN
160,000psi;1,100MPa
3,625psi;25MPa
2.7H.P.;2.0kW
7.4H.P.;5.5kW
4.9ft;1,500mm
2.1ft;650mm
8.2ft;2500mm
2.3ft;700mm
1.3ft;400mm
2.6ft;800mm
660lbs;300kgs
1100lbs;500kgs
3300lbs;1500kgs
30
The extruded products in form of round flux-cored or solid wire solder may be wound
on commercial spools or undergo further diameter reducing by the hydrostatic
extrusion process, see Fig.2. To do so HYDRON offers its unique machinery, i.e.:
HYDRON's HTU-112 Hydroextrusion Thinning Unit, see Fig.24.
HYDRON's CEU-112 Semi-Automatic Cold Extrusion Unit is also very useful for
manufacturing of profiled wires and rods as squares, rectangles, triangles, etc or
lead cross sections for stained and leaded glass,
Fig. 21
HYDRON CEU-112 Semi-Automatic Cold Extrusion Presses
31
HTU-112 HYDROEXTRUSION THINNING UNIT
APPLICATION
HYDRON HTU-112 Hydroextrusion Thinning Unit, see Fig.24, utilizes the hydrostatic
extrusion technology, see Fig.2, for manufacturing of the flux-cored and solid wire
solders, beginning from 0.035"/0.9mm in dia. down to 0.004"/0.1mm, and for some
alloys even 0.0012"/0.03mm in dia.
The wire to be extruded (billet material) is coiled onto the working spool and the
outgoing product (extruded fine and ultrafine wire), see Fig.3, can be optionally,
freely collected into the container or wound onto the take-up spool (commercial,
Fig.20, or working one).
TECHNICAL DATA
Max. working pressure
36,000psi;250MPa
Working chamber I.D.
3.94";100mm
Starting wire O.D.
below 0.06";1.5mm
Final wire O.D.
.035-.004";0.9-0.1mm
(exceptionally 0.0012";0.03mm)
Billet weight
max. 11-13.2lbs;5-6kgs
Reduction ratio per pass
max. 65%
Extrusion speed
1.65-33ft/s;0.5-10m/s
Extrusion speed control
by flow control or by pulling
(when spooling at the exit hydrostatic
extrusion augmented by drawing)
Hydraulic supply pressure
2,320psi;16MPa
Working medium
water with anticorrosive additives
Working medium capacity
3U.S.gal.;12liters
Power consumption
3.35H.P.;2.5kW
Weight (thinning unit)
2645lbs;1200kgs
Weight (hydraulic supply)
440lbs;200kgs
Total weight
3085lbs;1400kgs
Many metals and alloys as pure Sn, pure Pb and wide range of pure Sn-Pb alloys
being in common worldwide use or with additions of antimony (Sn50PbSb1,
Sn63PbSb1, Sn95Sb5), copper (Sn60PbCu2, Sn97Cu3), silver (Sn60PbAg4,
Sn63PbAg1), and other elements can be extruded with the HTU-112 Thinning Unit.
Since the hydrostatic state of stresses within the extruded material very high
reduction ratio in one pass through one die can be made (approx. 65% reduction).
State of compressive, hydrostatic stresses increases alloys ductility, prohibiting
cracks generation and propagation. Thus, for some alloys which resist to be drawn
easily the HTU Thinning Unit is the reasonable alternative.
The maximal extrusion ratio is limited by the working pressure (up to
36,000psi/250MPa), therefore to obtain ultrafine gauges several successive
extrusion passes are necessary. For example, to produce 0.01"/0.25mm wire from
0.047"/1.2mm wire the following passes should be made (4 extrusions) :
.047"/1.2mm
.028"/0.7mm
.022"/0.56mm
.015"/0.38mm
.01"/0.25mm
Automatic spooling of the exiting wire allows for extended operatorless runs (thinner
wire longer run).
32
Fig. 24
HYDRON HTU-112 Hydroextrusion Thinning Unit
33
SW-112 and SW- 212 SPOOL WINDERS
HYDRON semiautomatic SW- 112 Spool Winders designed to spool solder wire ,
onto the commercial reels up to 5 kg.
Spooler can be every time adapted to the specific Customer's needs for spooling
solder wires on the commercial, plastic reels, see Fig.4, or on the working spools
necessary for HTU-112 Unit, see Fig.24. The plastic reels are in common, worldwide
use.
HYDRON offers as well the semiautomatic Double Spool Winders for spooling the
wires within the range of 2-4mm in O.D. onto the 5kgs;(11lbs) or 20kgs;(44l)bs
spools.
TECHNICAL DATA
UNIT
Number of spools
Max. spool size
Spool fastening
Wire lenght measurment
Max input dia.
Min input dia.
Winding speed
fast winding
slow
Supply voltage
Motor power
Production capacity
SW 112
1
5 kg
250 mm
mechanical,
manual*(pneumatic option)
electronic 100 mm
accuracy
5 mm (0.200 “)
1.5 mm (0.062”)
stepless
0.5 -10 m/s
0.2- 1 m/s
3 x 380V 50 Hz
0.5 kW
3 mm 0.5 kg spools 100
- 120 kg/h
SW 212/2
2
400 mm width 200 mm
mechanical,
manual*(pneumatic option)
electronic 200 mm
accuracy
5 mm (0.200 “)
1.5 mm (0.062”)
stepless
0.5 -10 m/s
0.2- 1 m/s
3 x 380V 50 Hz
3.7 kW
3 mm 15 kg spools 400 600 kg/h
1300 x 600 x 1000 mm
1000 x 600 x 1510 mm
600 x 300 x 1310 mm
4800 x 600 x 1700 mm
Overall dimensions
(LxWxH):
Unit
Electric control box
Strightener
1000 x 600 x 1700 mm
34
Fig 25 Spool Winder SW 112
Semi-Automatic Spool Winder for spooling wires within the range of 2-5 mm in
diamiter onto 1 to 2.5 kg spools.See table for details.
Fig 26 Spool Winder SW 212/2
Semi-Automatic Double Spool Winder for spooling wires within the range of 2-5
mm in OD onto 10 to 25 kg spools.See table and attached drawing for details.
35
SALE CONDITIONS
All purchased Units will be thoroughly tested in HYDRON's plant before shipment.
The prices include packing, packaging and delivery Free Polish Border or FOB
Polish Harbour.
Buyer shall be responsible for obtaining all permits, certifications and bonds as may
be required for installation and operation of the HYDRON's equipment at Buyer's
plant.
Machines are fully assembled and actuated at the Buyer's site, according to mutual
agreement and in the presence of the Manufacturer. Manufacturer will provide the
specialized assembling team. Cooperation with the Buyer is here necessary. Period
of installation depends on the order volume.
Buyer shall be responsible for installing necessary utilities including electrical, water,
compressed air and connections required by the equipment as designated by
Hydron.
However, operating of all Units is simple a short-term on-the-job training for the
operators after installation period is necessary. Duration of the training will last as
long as it is necessary for optimal machines operation.
Buyer shall be responsible for ensuring that the equipment, when assembled as a
unit, as well as all parts, hydraulic accumulators, etc. complies with Buyer's country
and local safety and health requirements.
Hydron will advise during the start-up period and will provide further assistance in
the technical development of Buyer's production line. There is a possibility of
HYDRON's assistance in manufacturing of short-life parts at the Buyer's plant.
Time of delivery
from three to six months from receipt of order and downpayment (depending on
the configuration).
Terms of payment
30% - downpayment (at time of order)
60% - with delivery
10% - after start-up
Warranty
twelve months for defective parts and workmanship, except parts subject to
normal wear.
HYDRON hopes the offered machines will meet your specific requirements.
HYDRON will do its best to advise you the optimum installation, to complete your
order in the most effective way and be pleased to serve you at any time in the future.
36
WHY to BUY HYDRON's MACHINERY ?
CONTINUOUS CASTING UNIT
continuous process greatly improves
the casting quality
replaces two machines : ingot mould
casting & double shear
no oxides and shrink holes
no discards
since movable can easily serve to
several melting pots
AUTOMATIC HOT EXTRUSION PRESS
more than twice bigger billet in
comparison to presses of similiar
capacity offered on a market
less floor space necessary (hinged
piston makes the press body much
shorter)
AUTOMATIC BAR MARKING & SHEARING UNIT
very efficient
production
for
solder
bars
burrless, flat cutting surface
clear marking
SEMI-AUTOMATIC COLD EXTRUSION PRESS
replaces drawing for hard-to-draw
alloys and small batch production
large reductions in single pass (good
product uniformity)
does not require long and wasted
start-up material (as drawing does)
high production flexibility (if set of
presses installed each, single press
can process different alloy through
different die)
MULTIPLE BULL-BLOCK WIRE DRAWING MACHINE
high outputs
easy to control and operate
very compact in comparison to
drawing units offered on the market
HYDROEXTRUSION THINNING UNIT
complementary to drawing units for
ultrafine wires
hard and brittle alloys (non-workable
by drawing) can be processed
easiness to alter the product range
(easy die replacement, prefabricated
working spools)
very compact design (one square
meter/ten square feet of floor space
necessary)
ELECTRO-HYDRAULIC SUPPLY SYSTEM
reliable
easy in operation
energy saving
37
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))________________________________________Production Program
HYDRON OFFERS
INDIVIDUAL UNITS
INDIVIDUAL EQUIPMENT for CONTINUOUS CASTING of SOFT SOLDER BARS and
for their FURTHER PROCESSING to SOLID & FLUX-CORED ANODES, BARS, RODS,
STRIPS, PROFILES and WIRES (for the list of units see Chapter entitled
"Manufacturing System", and for the prices of single units, see the "Price List")
COMPLETE LINES
COMPLETE TECHNOLOGICAL LINE for MANUFACTURING of SOLID & FLUXCORED SOLDERS STARTING from an ALLOY PREPARATION down to the
ULTRAFINE WIRES (the block diagram of the complete HYDRON's production line is
shown on page 9. For the possible line arrangements, see Chapter "Manufacturing
Systems" and "Outputs". For the prices of single units, see the "Price List".
HYDRON is willing to provide current co-operation during the start-up period of
production as well as further assistance in technical development of the line.
INTEGRATION with CUSTOMER's EQUIPMENT
EXTENDING CUSTOMER'S EQUIPMENT CAPABILITIES by the ADAPTATION of
CUSTOMER'S MACHINES to produce OTHER PRODUCT ASSORTMENT or
INCLUDE SINGLE HYDRON'S UNITS into ALREADY EXISTING LINES (in particular, it
may concern the adaptation of the Customer's Hot Extrusion Press for production of
flux-cored rods, solid anodes or strips, bars by adding HYDRON's Bar Marking &
Shearing Unit or coupling HYDRON's Drawing Machines with Customer's presses or
other drawing units). More detailes on request.
MISCELLANEOUS
SPECIALIZED TOOLING for SOLDER BUSINESS (including working chambers,
pistons, plugs, seals, round and shaped dies, etc.) according to CUSTOMER's
DEMAND.
CO-OPERATION
JOINT VENTURES in NEW AREAS of SOLDERING BUSINESS or ANY OTHER
FORMS of CO-OPERATION DESIRED
ul. Wólczańska 257, 93-035 Łódź, Poland___________________________________________________________April 2003
38
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))________________________________________Production Program
REFERENCES(1)
HYDRON's references include the following countries :
USA
GERMANY
FRANCE
ENGLAND
ITALY
RUSSIA
CHINA
THAILAND
SINGAPORE
MALAYSIA
POLAND
(1) Suitable references will be provided upon request.
ALL HYDRON's UNITS CAN OPERATE INDEPENDENTLY or
BE INTEGRATED WITH the CUSTOMER's EQUIPMENT
WE GUARANTEE TECHNICAL AID THROUGHOUT THE
IMPLEMENTATION PERIOD
WITH HYDRON's MACHINES YOUR MARKET OFFER CAN
BECOME MORE VERSATILE
ALL UNITS are VERY COMPETITIVELY PRICED
To schedule meeting to review our design upgrades and performance data, to see a
brief videotape to better demonstrate HYDRON's products' capabilities for you, and for
any other information required please contact us :
Jan Laube, President
Hydron-Unipress, Ltd., Poland
Fax:+4842-847-506 Tel.+4842-402-546(7)
ul. Wólczańska 257, 93-035 Łódź, Poland
ul. Wólczańska 257, 93-035 Łódź, Poland___________________________________________________________April 2003
39

HYDRON-UNIPRESS, Ltd.

Transcription

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