New type of aluminum vertical oxidation automatic line rectifier power supply system

　　Preface

　　In recent years, with the development of the national economy, the demand for door and window decorative profiles has been increasing at home and abroad. The traditional horizontal oxidation production line cannot substantially improve its production capacity due to its own tank form. More and more companies have begun to add vertical oxidation production lines with high automation, high output and high efficiency. Vertical oxidation production not only has the advantages of large volume and high output, but also overcomes the defect of wire marks at both ends of the product because it uses a single-end clamp instead of the original two-end clamp, creating conditions for high quality and high yield.

　　1. Rectification power supply system for distributed power supply

　　The vertical oxidation production line has a large tank volume, and the area of ​​profiles processed in each tank is equivalent to 3-4 times that of the traditional horizontal oxidation production line. A high-power rectifier power supply system is required to oxidize the aluminum profiles. In order to better control the uniformity of the oxide film thickness of each row of work materials, each oxidation tank is often equipped with 6 oxidation power supplies in a double-end distributed power supply form. The specific power supply method is shown in Figure 1 below.

　　This power supply mode requires that all oxidation power supplies supplied by the same tank have good consistency, including consistency in output characteristics and consistency in docking with the automation system. In order to achieve the requirements of this working mode, as mentioned above, three oxidation power supplies with the same rated capacity are placed on each beam on both sides of the oxidation tank, and the oxidation power supplies supplying each beam are synchronized through Modbus communication.

　　The distributed power supply rectifier power supply system makes the current distribution in the oxidation tank more uniform, and the qualified rate and quality of the produced aluminum profiles are higher. It also greatly reduces the use of cables and conductive bars, saves costs and reduces losses.

　　2. Intelligent connection with production line control system

　　Traditional oxidation production lines usually use manual or semi-automatic production control methods, which have the disadvantages of low automation, high labor costs, low production efficiency, and lax process control. The vertical oxidation production line can completely avoid the above disadvantages through a fully automatic method. The vertical oxidation production line adopts the most advanced surface treatment production technology and uses a fully computerized automatic control system to reduce human interference factors in the production process. The improvement of automation is conducive to product quality and stable process conditions.

　　The automated production line can achieve fully automated control of the entire production line, from crane control to temperature control, from rectifier power supply system to production management system. By adopting advanced industrial automation products, the labor cost of daily operation of the entire production line can be minimized.

　　Rectifier power supply systems usually use PLC as the core control component. As a standardized industrial automation product, PLC has the advantages of high processing speed, high reliability, and adaptability to a wide range of environmental conditions. It can also support the communication requirements of mainstream automated production line control systems and achieve real-time communication control between a single machine and the production line master control unit through various network communication interfaces.

　　As an important part of the fully automatic vertical oxidation production line, the rectifier power supply system can be designed to provide various network communication interfaces required by the production control system, including industrial Ethernet, fieldbus, serial communication, etc., to achieve "seamless" connection with the production line control system. All production management systems can also be connected with the ERP system in the factory, so that managers can fully understand the production situation of the entire production line without leaving home, and track and manage product quality in a timely and accurate manner.

　　3. New water-cooled fully enclosed oxidation power supply

　　With the increasing power level of oxidation power supplies and the higher requirements of the fully automatic aluminum profile surface treatment production line for oxidation power supplies, a new type of water-cooled fully enclosed thyristor rectifier power supply came into being.

　　The silicon components, transformers, busbars, etc. in the rectifier power supply equipment are all water-cooled, thus constructing a fully enclosed circulating water cooling system. Since the circulating water is not in direct contact with the atmosphere, its heat exchange is completed through an air-water or water-water heat exchange system, without the need for high-power air conditioning to absorb heat. This is the most energy-saving cooling method, and it also avoids the corrosion of the components in the equipment by the corrosive gases caused by air exchange. The following table 3 lists the performance indicators of the fully enclosed circulating water cooling system and other cooling methods.

　　The new water-cooled fully enclosed oxidation power supply adopts a water-cooled transformer, which significantly improves the heating problem of the transformer and the whole equipment, and improves and guarantees the efficiency and reliability of the whole machine. By using a water-cooled output aluminum busbar instead of a water-cooled output copper busbar, the weight is reduced by about 30%, and the cost is saved by more than 30%, making the whole machine superior in terms of installation, transportation, and cost. The fully enclosed cooling method not only brings good heat dissipation effect to the whole machine, but also greatly avoids the corrosion of the components in the equipment by the corrosive gas caused by air exchange, ensuring the long-term and good operation of the equipment.

　　4. Current situation and prospects

　　In the future, vertical oxidation production lines will develop in several directions: full automation of workshop production, high-power rectifier power supply, instrumentation of color matching inspection, paperless workshop management, and clean production and environmental protection. With the strong promotion of domestic enterprises, the rectifier power supply system for vertical oxidation production lines has been completely localized and has formed industrial batch applications. It has the characteristics of reliable operation, energy saving and environmental protection, high degree of automation, simple operation, and simple maintenance. Many facts have proved that stable, reliable, energy-saving and efficient, intelligently controlled, and innovatively designed rectifier power supply systems will become the most reliable guarantee for aluminum profile processing companies to gain an advantage in the increasingly fierce competition environment.

　　References

　　[1] Wu Xiaoyuan, Surface Treatment Technology of Aluminum Alloy Profiles, Metallurgical Industry Press, 2009

　　[2] Zhu Zufang, Aluminum Alloy Anodizing and Surface Treatment Technology, Chemical Industry Press, 2004

　　[3] Wang Jinkuan, Ma Shuhua, Wu Yuchuan, Industrial Network Technology, Beijing University of Posts and Telecommunications Press, 2007

　　[5] Di Qianqian et al. The development of transformer cooling methods[J]. Journal of Tianjin University of Commerce, 2000

　　[6] Zhou Bensheng. Corrosion and protection of metals in industrial cooling water systems. Chemical Industry Press, 1993