Wire drawing processes

​Anyone who produces wire of a particularly high quality knows that the error tolerances are very small. The Optimizer4D helps to determine the optimum drawing speed. At the same time, the system detects when the loss of lubricant is imminent or has already occurred, and can stop the line if desired. Temporary mechanical damage, such as wire breaks, is reflected in the HFIM image. The Optimizer4D not only monitors production, but also documents the results. The software provides information on the extent to which the quality deviates from the deviates from the desired standards. QASS enables the following features: 

• An automated monitoring and documentation of all wire draws;
• Real-time visualizations of the running process, including in a 3D landscape;
• Deviations are immediately detected and documented;
• Error logging, even of small sections containing errors;
• Quality certificate with ring number and time stamp;​
• A graph shows the quality of each coil, each ring. If desired, the graph can be output as a document..

Optimizer4D - The measuring system for wire drawing

Condition monitoring of a drawing die sequence

Avoiding surface defects such as draw marks is more important than detecting surface defects because avoiding defects helps improve the quality of the end product and reduces the cost of repairs or scrap. When surface defects are avoided, the need for inspection and rework is reduced, saving time and resources. 
 
This is where QASS Condition Monitoring comes in. The Optimizer4D brings transparency by monitoring the condition of a drawing die sequence. In a dry drawing line, the cross-section reduction of a steel wire is monitored with piezoelectric sensors. After each drawing stage, the wire hardens and the friction behavior changes. The drawing tool and lubricant supply must be adjusted. In the ideal lubrication condition, mixed friction prevails, which is acoustically different from static or liquid friction. Changes in friction between the drawing die and the wire surface are continuously visualized to avoid critical friction. The drawing die transmits stronger signals as wear increases. The sum of critical friction powers causes frequency deviations. When tribological conditions change critically, the HFIM signal image also changes significantly. Optimizer4D detects this difference in system friction automatically and autonomously.

Determination of the optimum drawing speed

Different drawing speeds provide different HFIM signals. If the quality of the product deteriorates, easily detectable anomalies appear in the HFIM image. The QASS measurement system can optimize your processes and determine the most economical and optimal drawing speed.