Wuxi Wondery Industry Equipment Co., Ltd

I. Industry Insight: Strict Demands for Atmosphere Control and Temperature Uniformity in Precision Cold-Drawn Tubes In the manufacturing supply chains of automotive fuel pipes, hydraulic cylinders, and high-pressure boiler lines composed of precision cold-drawn steel tubes (such as SAE 1008/1010 grades), work hardening stands out as a critical roadblock affecting subsequent bending, flaring, and machining operations. To eliminate residual micro-stresses and reconstitute raw material ductility, the steel pipes must undergo a precise bright annealing or normalizing treatment at high temperatures up to $950^{circ}text{C}$. However, conventional open-atmosphere furnaces prompt extreme superficial oxidation and decarburization at such thermal levels, compromising dimensional tolerances and increasing surface roughness far beyond premium industrial delivery grades. WONDERY’s Support Roller Type Mesh Belt Bright Annealing Production Line represents the definitive engineering response to these thermal processing challenges. The system creates an air-tight, hermetically isolated thermal processing envelope filled with a cracked ammonia atmosphere ($text{H}_2text{ 75}% + text{N}_2text{ 25}%$) acting as a highly reducing protective barrier. By sustaining a structured 60-minute in-furnace transit time, the line guides the tube profiles through a strict "Heating-Holding-Dual Cooling" sequence under an oxygen-free envelope, ensuring the output tubes arrive at the unloading table completely clean, bright, and scales-free. Following the successful commissioning of heavy-duty vertical Vacuum Pressure Impregnation systems for industrial motor insulation (referenced in the document named "260602VPI1500-3000 Semi-auto Vacuum Impregnation Equipment System.docx"), WONDERY has once again asserted its core competency in industrial fluid heating and metallurgy by delivering this continuous line stretching a total length of 36,825 mm (Model: WDL260608BR). II. Technical Solutions and Full-Line Process Architecture 1. Continuous Modular Long-Axis Framework & Low-Stress Synchronous Drive Engineering To orchestrate the continuous feeding profile of long-axis seamless steel pipes ($L = 6000text{ mm}$, diameter $Phi14 sim 38.1text{ mm}$), WONDERY divided the 36.8-meter line into five structurally interdependent modules engineered for low tensile deformation: Front Loading Roller Conveyor: Features a heavy structural steel welded entry bed measuring $6000 times 900 times 1020text{ mm}$ driven by a $0.55text{ kW}$ variable frequency gear motor setup. This section leads to an integrated $2000text{ mm}$ stainless steel preheating connector containing a ceramic fiber curtain air-lock door and an automatic gas ignition system to isolate the internal reduction atmosphere from atmospheric air. Low-Tension Support Roller Drive (Proprietary Technology): Standard mesh belt lines running continuously at $950^{circ}text{C}$ subject the conveyor belt to high mechanical tension, leading to thermal creep and frequent tearing. WONDERY eliminates this vulnerability via a synchronous idler support design. High-temperature SUS310 alloy rollers support the mesh belt across the heating chamber, while the lower return rollers use a core-type design paired with high-temperature KF bearing assemblies and aluminum alloy heat sinks. The mesh belt ($SUS314, 400 times 49000 times 2.0/3.0text{ mm}$) serves primarily as a material carrier rather than a tension element, as sprockets and chains drive every idler roller in unison. This minimizes the operating tension on the belt, heavily extending its operational lifespan. 2. Four-Zone Independent Low-Voltage Radiant Heating & Anti-Decarburization Refractory Insulation Squirrel Cage Radiant Tube Configuration: The main heating chamber spans a longitudinal distance of $6000text{ mm}$ with an allocated heating capacity of $130text{ kW}$ divided into 4 independent temperature control zones. The furnace contains 36 horizontal radiant tube shells ($Phi124 times 1050text{ mm}$ made of seamless SUS310) enclosing heavy 0Cr25Al5 heating elements supported by corundum insulators. Low-Voltage Power Supply Safety Distribution: The radiant tubes are powered by safe, low secondary voltage ($42text{ V}$) via 4 dry-type step-down transformers (380V/42V) mounted directly to the furnace exterior. This parallel low-voltage configuration reduces electrical fatigue on the resistance wires and allows operators to isolate and service a single radiant tube assembly without halting the continuous operation of the line. Anti-Carburization Brickwork & Forced Atmosphere Convection: The internal refractory lining incorporates LBK26 anti-carburization bricks bonded with high-purity silica sol, backed by structural insulation board, calcium silicate sheeting, and multi-layer Luyang cera blankets for a total insulation profile thickness of $400text{ mm}$. The roof houses 4 forced-convection atmosphere mixing blowers ($0.75text{ kW}$ motors with SUS310 blades and NSK bearings), ensuring a longitudinal temperature uniformity of $pm6^{circ}text{C}$ and a cross-sectional accuracy of $pm3^{circ}text{C}$. 3. Cascade Open-Jacket Liquid Chilling & Fail-Safe Digital Control Integration Dual-Stage Cooling Chambers: Directly following the heating zone, a $700text{ mm}$ slow-cooling chamber brings temperatures down progressively to prevent unexpected phase transformations in sensitive steel alloys. The pipe then travels through a $9000text{ mm}$ water-cooled section split into multiple zones using an open, self-pressurizing reflux jacket (Zone 1 uses a SUS310 liner, Zone 2 uses a SUS321 liner). Supported by a $15,000text{ L/h}$ industrial recirculating water setup, the cooling sector drops the pipe unloading temperature to $le120^{circ}text{C}$ before it reaches the final $7000text{ mm}$ discharge roller conveyor. Top-Tier Industrial Digital Control Center: Automated logic throughout the line is orchestrated by a Mitsubishi PLC paired with a 14-inch MCGS digital touchscreen interface. Precise thermal monitoring is managed by 5 Honeywell DC1040 PID controllers coupled with Shimax solid-state relays for thyristor voltage regulation, achieving a control resolution of $pm1^{circ}text{C}$. Fail-Safe Safety Interlocks & Gas Purging: The entire low-voltage distribution architecture relies on integrated Siemens air switches, contactors, and circuit breakers. The control cabinet features an automated emergency safety interlock: if factory power is suddenly cut, the system isolates the cracked ammonia gas line and injects a $6text{ m}^3$ reserve of high-pressure nitrogen to purge the furnace chambers, preventing flame flashback or explosive mixtures. Production logs (including temperature curves, speeds, and faults) are exported to Excel and retained on a dedicated PC for 6 months.

Industry Insight: Stringent Demands for Temperature Uniformity and Melt Purity in Industrial Tinning Processes In the precision manufacture of mechanical bearings, processing of high-end electrical Babbitt alloy bushings, and surface anti-corrosion treatment of electronic components, hot-dip tinning is a critical process for establishing inter-facial bond strength. Although the melting point of tin is relatively low (approx. 232°C), in actual production, the working temperature of the molten tin must be stably maintained within a higher medium-temperature process window to obtain optimal leveling performance and an excellent wetting diffusion layer. At elevated temperatures, molten tin reacts aggressively with iron elements in conventional steel, generating hard, brittle Fe-Sn inter-metallic compounds (such as $FeSn_2$ dross). This not only accelerates localized corrosion and thinning of the pot wall but also introduces hard particulates into the molten pool, undermining coating density and surface gloss. Concurrently, if the heat flux density surrounding the pot is uneven, localized overheating will induce intense thermal convection, exacerbating surface oxidation. Through a targeted low-surface-load plate heating matrix and extra-thick low-carbon pure iron pot technology, WONDERY successfully resolved the temperature control and material corrosion pain points in molten metal processing for a prominent UAE engineering company (Osborne Engineering LLC). Technical Solutions and Parameterized Evidence 1. 1.1m Customized Pure Iron Pot: Eradicating "Iron Contamination" at the Source To satisfy the strict requirements of hot-dip tinning for melt purity, WONDERY deeply customized both the metallurgy and geometry of the reactor: Structural Dimensions: The effective internal working dimensions of the tin pot are 1.1 L × 1.1 W × 1.0 H meters, providing a standard vertical steady-state structure capable of accommodating large batches of heavy-duty precision bearing pads or bushing components for entire immersion dipping. 30mm Extra-Thick Plate Technology: The pot walls are fabricated entirely from 30mm high-purity low-carbon pure iron plates (Pure Iron Pot) by specialized welding. Compared with general stainless steel or carbon steel, high-purity pure iron contains negligible levels of carbon, silicon, and other impurities. This significantly passivates the grain boundary penetration rate of high-temperature tin liquid, minimizes iron dissolution, multiplies the operational lifespan of the pot body, and ensures long-term melt purity. 2. Four-Sided Plate-Type Heating Matrix and Balanced Y-Type Wiring To eliminate "dead zones" or localized tin boiling caused by excessive local thermal density and non-uniform radiation from traditional tubular heating pins, WONDERY deployed an all-enveloping thermal field configuration: Large-Area Plate Heating Elements: The perimeter of the tin pot is closely surrounded by 4 pieces of heavy-duty plate-type heating wires, with individual plate dimensions reaching 1200 mm (Width) × 850 mm (Height) and a rated output of 12.5 kW per piece. Low Surface-Load Heat Transfer: A total output of 50 kW (configured as a 7×7 kW balanced load design) is distributed evenly over a vertical heating area of nearly 4 square meters. This large-area, low-surface-load mechanism ensures that thermal energy flows into the pure iron pot wall via gentle conduction and radiation, mitigating material thermal fatigue caused by steep temperature gradients. National Standard Y-Type Configuration: The heating arrays are connected using a Y-type (Star) configuration to a 380VAC 3-phase industrial power supply. The neutral-balanced design minimizes single-phase voltage stress and is paired with 25 $mm^2$ national standard (GB standard) pure copper cables in the primary circuit to guarantee safe conductor temperature rise under full continuous load. 3. Closed-Loop Visual Power Regulation Securing an Exact ±1°C Control Accuracy The thickness and adhesion of hot-dip coatings are exceptionally sensitive to thermal fluctuations (typically, a variance of just 5°C alters the viscosity of molten tin and the thickness of the diffusion layer significantly). WONDERY therefore engineered a smart closed-loop electronic control architecture: Dual-End Collaborative Temperature Measurement: Precision thermocouple nodes are integrated symmetrically at both ends of the 1.1m tin pot. When the system detects a drop in local melt temperature below the setpoint, dynamic signals are fed back instantly to the central processing core. Thyristor Power Modulation: The core control incorporates 1 set of modularized SCR Power Controllers rather than traditional on-off contactors. Utilizing advanced algorithms, the system performs microsecond-level linear phase-angle or cycle微调 (fine-tuning) on the primary circuit current. 10-Inch Visual HMI Console: The front panel of the centralized control cabinet (dimensions: approx. 1500 × 600 × 500 mm) integrates a 10-inch Weinview high-resolution industrial touchscreen. The fully graphical interface displays real-time thermal trajectory logs, locking the temperature accuracy of the entire molten tin pool to a strict ±1°C boundary. Standard Export Delivery and Turnkey Execution WONDERY strictly adheres to industrial-grade turnkey supply protocols, explicitly demarcating boundaries to ensure seamless project integration overseas: Comprehensive Supply Scope: The delivery includes the high-purity pure iron pot core, insulated containment furnace casing, 4 full-scale plate heating units, an independent intelligent control cabinet (housing the Weinview HMI, SCR regulator, and Chint low-voltage switchgear), a complete array of compensation wires and sensing components, alongside comprehensive technical prints including general assembly drawings, electrical schematics, and full-lifecycle maintenance handbooks. Standardized Performance Assurance: All internal piping, wiring, and electrical pressure tests are completed at the Wuxi production base. The fully integrated skid design allows the UAE buyer to bring the system online immediately after connecting the main power supply, satisfying all industrial demands for continuous, premium hot-dip tinning production.

1. Project Background A steel structure manufacturer planned to build a natural gas heated linear hot dip galvanizing line for processing steel components up to 8.6 meters in length, including transmission towers, highway guardrails, and building embedments. Customer requirements: Zinc pot size: 8.6m × 1.0m × 1.6m Zinc capacity: 75 tons Hourly output: 3 tons Must meet emission standards for acid mist and zinc fumes WUXI WONDERY INDUSTRY EQUIPMENT CO., LTD. was responsible for process design and equipment integration. 2. Technical Challenges and Solutions H2: Acid Mist Treatment – Sealed Negative Pressure + Two-Stage Spray Neutralization Operating conditions: Three pickling tanks, each 8.6m × 1.0m × 1.6m Immersion time: 6 minutes per tank (adjustable) High acid mist generation requiring complete containment Design solution: Fully enclosed acid mist chamber: 11m × 10.6m × 4.0m, flame-retardant fiberglass panels Negative pressure maintenance: 11kW variable frequency fan Two-stage scrubber tower: Tower size: φ1800mm × 6500mm, PP material (10mm thickness) Filler: PP wreath (3.5 inches diameter), two layers Defogging layer: PP spheres (2.0 inches diameter), one layer Spray layer: PP-1/2 spiral nozzles, two layers Circulating pump: 5.5kW vertical acid/alkali resistant pump Automatic pH control: Dual pH probes (inlet/outlet) with automatic dosing Technical conclusion: The combination of enclosed structure + negative pressure exhaust + two-stage spray neutralization effectively controls acid mist escape. Online pH monitoring ensures accurate chemical dosing, suitable for continuous pickling of 8.6-meter long tanks. H2: Zinc Fume Treatment – Double-Sided Suction + Bag Filter + Water Curtain Deodorization Operating conditions: Zinc pot size: 8.6m × 1.0m × 1.6m Zinc bath temperature: 438–450℃ (PLC controlled) High volume of zinc particulate fume during immersion Design solution: Double-sided suction ducts: Side ducts: 8600mm × 2500mm × 250mm, two sets End duct: 6000mm × 3000mm × 250mm, one set With deflectors, flanges, and sealing strips Bag filter system: Main unit size: 5540mm × 3000mm × 6500mm Filtration area: 640m² Filter bags: φ133mm × L3500mm, 426 sets Filter material: waxed nylon needle-punched (service life ≥2 years) Fan: 55kW double-sided suction variable frequency fan Water curtain deodorization tower: Tower size: φ2800mm × 6500mm, PP material (12mm thickness) Circulating pump: 7.5kW vertical acid/alkali resistant pump Operation strategy: Variable frequency fan runs only 2–3 minutes per zinc pot loading Bag filter collects zinc particles; water curtain removes odors Technical conclusion: For an 8.6-meter long zinc pot, double-sided suction covers the entire fume generation area. The 640m² filtration area meets the 3 tons/hour production requirement. The VFD control strategy reduces continuous power consumption. 3. Waste Heat Recovery Options (Selected by Customer) Module Technical Parameters Function Combustion air preheating Alloy tube heat exchanger, 50–150℃ air preheat Reduces natural gas consumption Sludge drying box 304 stainless steel, 5500×750×375mm Reduces filter cake moisture from 80% to 10% Pot edge heat recovery Double-layer stainless steel coil, pot edge temp ~200℃ Heats water for acid preheating or workshop heating 4. Engineering Interface Responsibilities in this case: Supplier: Equipment supply, internal piping, control cabinet & internal cables, installation guidance, commissioning guidance, training materials Buyer: Civil work, plant building, external utilities (water/electricity/gas), compressed air, hoisting equipment, scaffolding, meals/accommodation for technicians, fire protection, lightning protection 5. Case Summary For this 8.6m hot dip galvanizing line, the following fume treatment solutions were implemented: Acid mist: Sealed negative pressure chamber + two-stage spray neutralization Zinc fume: Double-sided suction + bag filter + water curtain deodorization All equipment parameters match the 8.6m × 1.0m × 1.6m tank dimensions and 3 tons/hour capacity. The waste heat recovery modules further reduce operating energy costs.