High Efficiency Coat Weight Control: The innovative QED AutoCoatTM system ensures premium quality, high efficiency, and significant Zinc and Galfan® savings.
Engineered as an upgrade to existing high-speed Zinc and Galfan® process lines, QED AutoCoatTM ensures consistent, precision Zinc or Galfan® coating and significant material savings; using independent measurement and fine-tune control, this elegant design allows for consistent and uniform coating weight application with an exactitude of ±10g/m2. With such high accuracy, the QED AutoCoatTM offers significant Zinc or Galfan® savings and results in a premium quality finished product. Data acquisition and networking with remote monitoring are provided using the latest generation Siemens PLC hardware and as always, our equipment is backed by QEDs renowned excellence in customer service. Feedback from our latest installations has been outstanding; come visit us to discuss how QED AutoCoatTM can benefit your production.
The QED Immersion Burner Galvanizing Furnace is built to coat continuous in-line steel wire strands with zinc. The wires dip into a longitudinal bath of molten metal, pass under a sinker and exit the furnace through a wiping system. The molten metal is contained in a ceramic lined bath designed for a long trouble-free life and supported by a rigid steel framework. The bath is heated by gas fired Immersion Burners using fourth generation recuperative technology to maintain a high thermal efficiency
Our latest development in ceramic lined furnaces is the Advanced Recuperative Technology Mark 4 Immersion Burner. This burner offers dramatically higher combustion efficiency from an extended double pass pre-heat design. Constructed of stainless and high nickel alloy steels, they have an extended operating lifespan and a much cooler skin temperature.
With a bed of fine aluminum oxide particles and precise air & gas control, QED Tempering fluidbed furnaces offer an environmentally friendly heat-treating solution in an energy efficient package. The fluidbeds rapid heat transfer results in significantly shorter furnace length and therefore more compact and easier to operate process lines. The QED Fluidbed Furnace is designed to heat-treat continuous in-line steel wire strands. The wires travel longitudinally through a bed of solid aluminum oxide particles that are fluidized by heated gases. Air and gaseous fuel is introduced into the bottom of the sand bed through sets of distributing burner and air piping assemblies. Combustion of the air and fuel mix occurs within the bed (submerged combustion) and transfers heat directly to the large surface area of the sand.
The QED Wire Lines Austenitizing furnace is solidly constructed of welded structural steel sections designed to support the refractory lining and withstand thermal stresses. These robust furnaces are constructed to sit on a level floor over a pit holding the combustion piping. The addition of pulse-firing technology improves the thermal efficiency and increases temperature uniformity; it also allows for a higher turn-down ratio, lower NOx emissions and more flexibility in burner and zone control .
Product category: Pickling and descaling lines for wires
A proven performer; our HighTurbulence™ Pickling System optimizes fluid flow to breakdown the static boundary layer surrounding the wires and rapidly remove scale. With multiple cascading stages, this efficient system lowers acid consumption and minimizes waste treatment requirements. The QED Pickling System is designed and built to clean the surface of continuous in-line steel wire strands in preparation for a subsequent coating operation. The wires run longitudinally through the system tanks in a straight path without dips or bends. The acid section is a totally enclosed space that prevents fumes from escaping to the plant atmosphere. The Entry (sealing) Section, Acid Sections and Rinse Sections are all incorporated into a common tank structure with internal divisions and structural supports. The tank is fabricated of special reinforced corrosion resistant plastics. The top cover is a bolted construction of multiple sections of reinforced plastic material. Quick lift-off hatches are provided at strategic intervals on the covers to allow easy access to the interior for maintenance.
Networked Panels with Remote Monitoring and Control
A powerful S7 Siemens PLC is at the heart of our furnace control systems. Programmed with user friendly software and advanced combustion algorithms, they deliver precision gas flow and accurate temperature control. One of the interesting new developments is web enabled systems for smartphone monitoring and remote troubleshooting of control panels.
The QED Vertical Wire Wiping System is designed and built to wipe multiple strands of steel wire as they exit the galvanizer or Galfan furnace. The wires exit the liquid metal zinc vertically through the wiping system and travel up through steadying rolls to the tower platform. Platform mounted large diameter rolls change the wire direction to horizontal before the secondary quench and waxing process. After being air wiped of excess drips, the wires descend from the tower towards the Take-ups. The tower is built of heavy structural steel beams and columns and designed for strength and to minimize vibration. The non-slip platform floor has a continuously welded edge plate to prevent water spillage onto the liquid zinc surface below.
QEDs vertical wiping system is capable of handling three different types of wiping modules:
QEDs Combo Wiping Module has the ability to mount any combination of the nitrogen and pad wipe units. Each mounting bracket has multiple positions; in each position the operator can mount any of the three previously mentioned wiping units. This provides the customer with the ability to interchange wiping units without stopping any other wires offering maximum production flexiblilty.
QED Quench quench tanks are designed and built to cool the wires to a manageable temperature after their initial surface cooling by the primary quench. The wires, maintaining a level path, are quenched in the water of the quench tank tray. The water is pumped from the lower reservoir tank to the tray by means cast iron centrifugal pump. Weir bars are located at each end of the tray to both guide the wires and to maintain sufficient water level.
The QED Wax System applies a light coating of water-soluble wax or Polymer to the galvanized wire surface to prevent corrosion and to act as a lubricant in subsequent wire forming processes. The solution is pumped from the reservoir tank below the tray to the process tray through a cast iron centrifugal pump. Special weir bars are located at each end of the tray to both guide the wires and to maintain the wax level. The wax is heated by a flange mounted electric immersion heater. A float valve on the water inlet line maintains the level in the tank.
As a part of our commitment to continued innovation, QED Wire Lines Inc. successfully lanuched the new industry standard in Coat Weight Control Systems.
The QED AutoCoatTM system, can easily be incorporated into an existing nitrogen wiping operation and offers our customers significant advantages including:
• Precision Coating for a Superior Product Finish • Significant Cost Savings in Zinc or Galfan® • True Closed Loop Control • High Speed Multiple Strand Analysis • Real Time Pad Wipe Coating Measurement • Ease of Integration • Latest Generation Siemens PLC Processing • Automatic and Manual Modes • Data Acquisition and Networking • Remote Monitoring
Feedback from the field has been outstanding….
An in-house development backed by 3 years of rigorous R&D as well as in field testing; the QED AutoCoatTM System is engineered to upgrade existing galvanizing and Galfan® process lines. It allows for reliable production of precisely coated wire via independent measurement and fine-tune control. QEDs AutoCoatTM is capable of true real time analysis and individual closed loop control of multiple wires when combined with our signature N2 Wiping System.
At the core of this 2nd generation coating weight control system are our new eddy-current sensors that deliver consistent and accurate coating measurements to ±10 g/m2. This innovative system insures premium quality, high efficiency, and significant material savings.
Visit us at stand 12B11 to discuss how QED AutoCoatTM can benefit your production.
QED Wire Lines Inc. is a custom furnace manufacturer and engineering company specializing in process equipment for the steel wire industry. Our leading-edge furnaces are custom built for multi-strand annealing, stress relieving, patenting and tempering processes. With over 30 years of industry experience and innovation, we proudly serve customers in over 20 countries. Our patented equipment is backed by QED's renowned excellence in service; with commissioning and installation supervision as well as spare parts support, QED provides a complete package for processing wire.
The Process Line Specialists and your supplier of Wire Industry Equipment: Energy Efficient Fluidbeds: with rapid heat transfer resulting in significantly shorter furnace length and more compact process lines. Pulse-Firing Muffle Tube Furnaces: Benefits include improved thermal efficiency, increased temperature uniformity and superior convective heat-transfer. Networked Panels with Remote Monitoring and Control: Programmed with user friendly software and advanced combustion algorithms, they deliver precise temperature control. Combustion Technology: Our patented system maintains a steady output with precise air-gas ratio on all our multiple burner furnaces. Industry leading Galvanizing & Galfan Coating: offering robust furnaces with new high efficiency recuperative immersion burners. Powerful Pre-Cleaning with Ultrasonics: incorporating new temperature and level control features with powerful ultrasonic transducers in combination with an innovative 4 stage suction wiping system. Patented Pickling: A proven performer, our HighTurbulence® Pickling System optimizes fluid flow turbulence to rapidly remove scale. Cost Saving Coat Weigh Control: The QED AutoCoat(TM) System acheivs consistent and uniform coating weight application with a precision of ±10g/m2. The results are significant Zinc or Galfan® savings and a premium quality finished product.