Steel sucker rods and steel pony rods production line is based on SM11-450 horizontal forging press, including intermediate induction furnace with automatic loading and feeding mechanism, 6-axis industrial robot, SM11-450 horizontal forging press with horizontal die installation, whole piece induction quenching and tempering furnace and CNC lathe with automatic loading and feeding mechanism.
I. Production range
According to standard API 11B, dimensions and tolerances for steel sucker rods and steel pony rods are following:
II. Productivity
4 heads/min, 2 shifts/day, 260 working days/year.
Productivity per year 4×0.5×60×2×8×260=499,200 pcs
III. Production flow char
IV. Key equipment description
1. Intermediate frequency induction furnace
This production line adopts the intermediate frequency induction furnace with automatic loading and discharging device.
Steel bars are stored on the storage bench, turnover device turns the steel bar into feeding roller table, then variable frequency motor drives reducer, the reducer drives roller to rotate in order to make steel bar forward. After the end of steel bar is sent to inductor for a certain distance, the roller stops rotating.
The induction heating furnace is equipped with 2 sets of inductors, inductor GTR40 for sucker rod 5/8" to 3/4",inductor GTR50 for sucker rod 7/8”to 1 1/8”. The far-infrared thermometer is used to monitor and measure the heating temperature of the sucker rod in real time.
The induction furnace is equipped with closed type cooling tower filled with pure water, which is used to provide cooling water for both intermediate power and inductor. The circulating cooling medium is working in the closed circulations, without any foreign impurities, which not only ensures the purity of the cooling medium, but also eliminate the phenomenon of scaling inside pipeline.
2. Horizontal forging press
Our horizontal forging press is a kind of modern horizontal forging press with horizontal dies installation. It is idea equipment for steel sucker rod upsetting.
This horizontal forging press can realize multi-cavity forging, which is pretty convenient for sucker rod upsetting. Material gathering, wrench square forming, pin shoulder forming and flashing trimming can be achieve by only one set of horizontal forging press with one time heating, which is economic and efficient.
It is very easy to realize automatic sucker rod upsetting production with installation of industry robot.
It is simple to install dies and adjust dies.
This horizontal forging press has good rigidity, with excellent sucker rod upsetting precision.
The SPM is up to 45 times/min, bringing high productivity.
The clutch of horizontal upsetting press adopts single inertia floating block structure with small inertia, which has advantage of generating less heat, long working life and easy to replace after it is worn out.
Clamping force of our upsetting press is 1.11 times of upsetting force, which ensures the remain part of steel bar is securely clamped during upsetting process.
All solid steel sucker rods 7/8" to 1 1/8"can be upsetted by one set of horizontal forging press with different dies.
3. Heating treatment equipment
The production line adopts Intermediate frequency heat treatment equipment with automatic feeding and discharging device.
Sucker rods are stored on the storage bench, the turnover device turns the sucker rod into the feeding roller table. The feed conveying roller is composed of V-shaped roller which is placed at a certain angle so that makes the sucker rod move forward with rotate. The sucker rod is sent to the first inductor by the roller feeder device to heating until a certain temperature. The second inductor is tracking inductor that is special to compensate the temperature for the upsetting end of sucker rod. After the upsetting end of the sucker rod moves out of the first inductor, the tracking inductor moves along with the upsetting end of the sucker rod to heat the upsetting end of the sucker rod that makes the temperature of each part of the sucker rod consistent. The conveyor roller sent the sucker rod to the water jacket for quenching. The conveyor roller sent the sucker rod to the third inductor for tempering when the sucker rod finishes quenching. The third inductor is used to keep the temperature. Last, the sucker rod is transmitting by conveyor roller to the cooling bed.
The whole heat treatment process of sucker rod quenching and tempering (loading, conveying, heating, feeding, transmission, discharging, etc.) is automatically controlled by the Industrial Personal Computer.
The computer is in the core control position in the whole set of heat treatment equipment. The computer issues a corresponding command to the power supply after the calculation and comprehensive analysis of the collected temperature signal that makes the power supply output corresponding power. The production date, time and heating temperature are recorded and stored in real time and can be regularly delivered to the management level.
The heat treatment equipment adopts far-infrared thermometer. The temperature measurement accuracy is ±0.3%±1°C of the measured value.
4. CNC lathe
The sucker rod production line adopts CNC lathe complete with automatic feeding and discharging device.
The sucker rod are stored on the storage bench, turn over device turns the sucker rod into the feeding roller conveyor， then variable frequency motor drives reducer , the reducer drive the roller to rotate in order to make sucker rod forward. After the end of the sucker rod is sent to CNC lathe through the spindle bore for a certain distance, the roller stops rotating.
The CNC lathe is equipped with FANUC CNC system and servo motor.
