In the bar processing industry, driven by the dual demands of large-scale mass production and multi-specification flexible production, traditional cooling bed systems face growing pain points: low efficiency for small-sized bars, uneven cooling for large-sized bars, poor adaptability to multiple scenarios, and high energy consumption. To address these challenges, an integrated skirt plate cooling bed solution tailored for split bar production has emerged. Designed with core logic of full-process precision control, multi-specification compatibility, and low-consumption efficiency, it connects the entire chain from post-rolling cutting, high-speed conveying, uniform cooling to smooth discharge. Covering 10–40mm full-specification bars, it adapts to high-speed rolling up to 12m/s, flexibly handles small-batch, multi-specification orders, and reduces energy and operation costs through optimized design—providing a practical and cost-effective upgrade path for the industry.
I. Core Positioning: A Dual-Driven Solution for Flexible Production & Cost Reduction
Bar processing enterprises currently face three major pain points:
- For small-sized bars (10–12mm) in double-split rolling, traditional cooling beds are prone to stacking and uneven cooling, leading to inconsistent product performance.
- For medium-to-large bars (14–40mm) in single-line rolling, long equipment changeover time and low efficiency make it difficult to accept multi-specification orders.
- Under high-speed production, energy consumption rises, equipment wear accelerates, and operation and maintenance costs remain high.
This solution precisely targets these pain points, achieving flexible adaptation across multiple scenarios with one machine and full-process low-consumption operation optimization:
- Double-split rolling scenario: Optimized for 10–12mm small-sized bars, it enables parallel cooling of multiple bar groups via synchronous transmission and wide-width cooling bed layout, increasing single-batch cooling capacity by 40% compared to traditional cooling beds, eliminating efficiency loss and energy waste caused by “small single-group capacity and frequent start-stop”.
- Single-line rolling scenario: Compatible with 14–40mm medium-to-large bars, it allows quick adaptation without replacing core components—only through electrical parameter adjustment and minor mechanical structure tweaks, reducing equipment changeover time from 30 minutes to less than 5 minutes, significantly improving efficiency for multi-specification orders.
- Rhythm matching & energy balance: Withstands rolling speeds up to 12m/s, seamlessly connecting with mainstream bar mills to avoid efficiency gaps caused by “mill waiting for cooling bed”. Optimized transmission system and cooling path design reduce unit product energy consumption by 15%–20% compared to traditional solutions, aligning with the industry’s green and low-carbon development trend.
II. Technical Highlights: Detail Innovation + System Collaboration for Full-Process Precision Control
1. High-Temperature Stable Cutting System: Millimeter-Level Precision & Long-Term Durability at 850°C
As the first critical post-rolling process, the crank-type flying shear achieves three breakthroughs in precision, stability, and durability:
- Adopts high-temperature-resistant alloy blades and hydraulic buffer mechanism, enabling stable cutting of 850°C hot bars, avoiding blade deformation and excessive burrs in traditional equipment at high temperatures.
- Crop length is strictly controlled to ≤200mm, with a perpendicularity deviation of ≤0.5mm/m, significantly reducing labor and material losses in subsequent grinding processes.
- Supports dual modes of “normal cutting + emergency cutting”, cutting off workpieces within 0.5 seconds in case of failure. Equipped with infrared temperature measurement and foreign object detection sensors for real-time monitoring and automatic alarm.
- Driven by a high-power DC motor and precision planetary gearbox, transmission efficiency exceeds 95%. Blades are surface-hardened (HRC ≥55), doubling their service life compared to traditional blades.
2. High-Speed Synchronous Pinch Roll: Differential-Free Transmission & Flexible Clamping at 13m/s
As the “speed synchronizer” connecting rolling and cutting, it features a symmetrical structure of fixed lower roll + lifting upper roll:
- Dual-cylinder linkage drive automatically adjusts clamping force (0.5–2.5MPa adjustable) according to bar specifications (φ10–φ40mm).
- Rubber-coated roll surface ensures stable clamping for plain round bars and adapts to the uneven surface of deformed steel bars, avoiding slipping and surface scratches, and improving product surface qualification rate by over 10%.
- Equipped with high-precision encoders and speed sensors, it collects workpiece running speed (full range 4–13m/s) in real time, achieving differential-free matching between “pinch speed and cutting speed”, solving the problem of cutting deviation caused by tail stall in traditional pinch rolls, and controlling cutting length error within ±3mm.
- Modular roll design allows quick roll surface replacement without full disassembly, reducing maintenance time to within 1 hour. The transmission system is equipped with an automatic lubrication system to reduce manual maintenance and mechanical wear.
3. High-Efficiency Uniform Cooling System: Temperature Balancing & Smooth Transmission Chain with 54m Width
Adopting a step rack-type cooling bed, it achieves uniform cooling, lossless transmission, and efficient adaptation through multi-module collaboration (input, cooling, alignment, discharge):
- Input roller table: Features a “0°–12° gradual inclination for the first 7 rollers” to avoid stacking and collision of bars during entry, and realizes automatic alignment via gravity. Roller speed is frequency-adjustable (1–18m/s), with single-roller independent motor drive—single-roller failure does not affect overall operation, and equipment availability exceeds 98%. Made of 45# steel with precision machining and surface chrome plating, it is wear-resistant and corrosion-resistant, with a service life of over 3 years.
- Cooling bed body: 54m wide and 9500mm long, with electrically adjustable spacing (600–1200mm) between fixed and moving racks, adapting to dense cooling of small-sized bars and heat dissipation of large-sized bars. Q345 alloy steel racks are tempered at high temperature, capable of withstanding direct contact with hot bars up to 950°C. Tooth pitch is 75mm, step time is 3s, ensuring consistent flipping angle of bars during cooling, with a cooling uniformity deviation of ≤15°C. Multi-point infrared thermometers monitor inlet, middle, and outlet temperatures in real time, automatically adjusting step speed and cooling air volume to ensure the outlet temperature of small-to-medium bars is stably ≤200°C.
- Alignment & discharge system: Low-speed alignment roller table (≈1.1m/s) with side positioning baffles, alignment error ≤5mm. 24A heavy-duty chain with electrically adjustable step pitch (8–70mm) to avoid bar collision. Discharge trolley is equipped with hydraulic lifting cylinders and flexible rubber pads, with a reciprocating speed of ≈0.5m/s and positioning accuracy ≤3mm, realizing lossless and precise transmission.
- Lubrication & environmental protection: Adopts manual glycerin lubrication with an oil tank recovery device for cyclic utilization of lubricating oil, reducing costs and avoiding pollution.
4. Auxiliary System: Intelligent Monitoring + Convenient Operation & Maintenance
- Equipped with a PLC control system and touch-screen HMI, it displays real-time equipment status, fault alarm information, and production statistics, supporting remote monitoring and parameter adjustment.
- Built-in vibration and temperature sensors monitor key components (motors, bearings, hydraulic systems) in real time, automatically alarming and providing fault location and troubleshooting solutions when abnormalities occur.
- Standardized design of key wearing parts, accompanied by a spare parts list and quick replacement guide, reducing the difficulty of spare parts procurement and maintenance.
III. Core Value: Multi-Dimensional Empowerment for Cost Reduction & Efficiency Improvement
- Compatibility upgrade: Covers 10–40mm full-specification bars, enabling quick scenario switching without replacing core components. Equipment utilization rate increases to over 90%, adapting to the needs of small and medium-sized enterprises with frequent multi-specification order switching.
- Precision improvement: Full-process precision control from cutting, transmission, cooling to alignment reduces scrap rate by 15%–20% compared to traditional equipment, reducing raw material waste and manual correction costs, and enhancing product market competitiveness.
- Efficiency optimization: Adapts to 12m/s rolling speed, 18m/s roller table transmission capacity, and 54m wide parallel cooling, seamlessly connecting upstream and downstream processes. Reduced equipment changeover and downtime increase overall production efficiency by 30% compared to traditional solutions.
- Cost reduction: Unit product energy consumption reduced by 15%–20%; durability of key components improved, with mean time between failures (MTBF) exceeding 8000 hours, reducing operation and maintenance costs by approximately 25%; intelligent control reduces manual intervention, saving 1–2 operators per shift.
- Green & environmental protection: Cyclic utilization of lubricating oil, no additional water spraying during cooling (no wastewater generation), and equipment operating noise controlled below 85dB, complying with industrial environmental standards.
IV. Application Scenarios & Industry Value
This solution is widely applicable, adapting to large-scale bar production workshops of major steel enterprises and meeting the needs of small and medium-sized processing enterprises for multi-specification orders. It is particularly suitable for:
- Production of 10–40mm round steel, deformed steel bars, and split bars;
- High-speed, large-batch rolling scenarios;
- Flexible production scenarios with frequent multi-specification order switching;
- High-end bar processing with strict requirements for product precision and surface quality.
Pilot enterprise application data shows that the solution can increase product qualification rate to over 98%, shorten production cycle by 30%, and reduce comprehensive cost by approximately 20%, effectively solving the traditional production pain points of “low efficiency, poor precision, and high cost”. Against the backdrop of the bar processing industry’s transformation toward refinement, high efficiency, and greenization, this solution achieves core advantages of “flexible compatibility, precision control, and low-consumption efficiency” through full-process optimized design, providing a feasible upgrade path for the industry and helping enterprises of all sizes enhance their core competitiveness.
