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HYDRON-UNIPRESS, Ltd.
Manufacturer of the equipment for the tin/lead industry
ul. Wólczańska 257, 93-035 Łódź, Poland fax:+4842-684 75 06, tel.: +4842-640 25 46
[email protected] www.hydrononline.com
REMARK : Hydron-Unipress, Ltd., of Lódz , Poland, is a corporation organized and existing under the laws of Poland. All information presented in this paper should be considered as an offer for further discussion and negotiation between all concerned parties on the principle of equality and mutual benefit. The technical data given in this offer may undergo modification as a result of technical improvements.
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
4
OFFER'S SCOPE
If your desire is to start your own manufacturing program in the field of solder making business the HYDRON-UNIPRESS Ltd. is happy to offer you : COMPLETE TECHNOLOGICAL LINE for manufacturing of FLUX CORED and
SOLID SOLDER BARS, ANODES and WIRES starting from the process of solder alloy preparation and with an annual output of 200ton, 400ton or more
HiTech, specialized, INDIVIDUAL EQUIPMENT for manufacturing of FLUX CORED and SOLID FINE and ULTRAFINE SOLDER WIRES from 0.118"/3.0mm down to 0.002"/0.05mm in diameter for electronic, microelectronic, electromechanic, automotive and lighting industries, non-toxic, LEAD-FREE SOLDERS for drink water piping soldering, LEAD PROFILES for stained-glass windows and Tiffany art, ANODES and BARS for galvanic bath and wave soldering, and many others applications
Participation in JOINT VENTURES for solder making business Any other form of COOPERATION desired being of the mutual interest. We GUARANTEE TECHNICAL AID throughout the implementation period.
APPLIED TECHNOLOGY HYDRON's manufacturing line developed to produce solders in form of a continuous wire with one, three, four or five cores filled with high quality flux, close to the circumference of the wire throughout its length, see Fig.1, is based on the drawing and extrusion technology, namely conventional and hydrostatic extrusion supported by wire drawing. Conventional and hydrostatic extrusion processes allows for production of the sub-millimeter gauge solders from the starting billet of tens of millimeters, see Fig.2. In the case of ultrafine flux cored solder wires, see Fig.3, the hydrostatic extrusion process has been introduced and proved to be superior to other methods, as for example wire drawing due to its distinguished features, i.e.: Gives very high reduction ratios in one single pass. Produces no tension forces acting on the product, therefore ultrafine gauges can be
manufactured. Assures high dimensional accuracy and surface finish. Gives more reliable products. Consumes less energy. Requires smaller floorspace. Allows for high production flexibility what makes simultaneous manufacturing of
variety of alloys and gauges possible.
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
5
Fig.1 FLUX CORED SOLDER RODS and WIRES made by HYDRON's MACHINERY
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
6
Fig. 2 HYDRON'S HOT (left), COLD (middle) and HYDROSTATIC (right) EXTRUSION CONCEPTS applied for SOLDER MAKING
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
7
Fig. 3 ULTRAFINE FLUX 5-CORED WIRES made with the HYDRON's HYDROSTATIC EXTRUDER (HTU-112); wire diameters : (top left) 0.049mm; (top right) 0.059mm; (middle left) 0.093mm; (middle right) 0.123mm; (bottom line) their cross-sections; (courtesy Nihon Handa Co.,Ltd.)
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
8
HYDRON'S BACKGROUND Extrusion technology has been creatively developed by the High Pressure Research Center of the Polish Academy of Sciences UNIPRESS in many areas. This technology has appeared as a result of research works done in UNIPRESS on plasticity of solids and metalforming under pressure. UNIPRESS' research equipment is known in many laboratories all over the world, as IBM Research Center, University of Tokyo, Bell Lab, MIT, Cambridge University and many others. UNIPRESS is also well known as a Center where the modern, highly efficient technology for solders making has been developed, tested and introduced as an industrial, highly effective process. Finally, UNIPRESS has founded two companies in Poland : the HYDRON-Unipress, Ltd. and the CYNEL-Unipress, Ltd. where the machinery for solders making is manufactured (HYDRON) and which uses these machines for mass solders production (CYNEL). CYNEL's solders made with HYDRON's machines are well known to almost 1500 industrial users, including : computer producers, electronic component manufacturers, TV an radio makers, instrument, meter and lamp producers, and others. HYDRON's units have been already installed and are succesfully operated in USA, Germany, France, Italy, England, Russia, Thailand, Malaysia, Singapore and Poland. Solders made with HYDRON's machinery meet world-wide standards and specifications.
MANUFACTURING STAGES HYDRON's solder making line involves the following four manufacturing stages, see Fig.4 : STAGE I Continuous Casting (round anodes or solid billets for further extrusion) STAGE II Hot Conventional Extrusion large gauges STAGE III Wire Drawing (mass production) or Cold Conventional Extrusion (small
batch production) medium gauges STAGE IV Wire Drawing or Hydrostatic Extrusion (Thinning) fine and ultrafine
gauges The HYDRON's System is driven and controlled electro-hydraulically, thus it is reliable, simple in operation and energy-saving.
PRODUCTION STRUCTURE The HYDRON's machines permit to produce both, the standard, pure tin-lead solders, as well as high- and low-melting, and special purpose solder alloys. Pure tin and pure lead can be also processed. All flux-cored and solid solders between 100mm(4"") and 0.1 mm(0.004") (or for some alloys even 0.03 mm( 0.0012") in diameter being in world-wide use can be manufactured. Production profile can be selected arbitrarily upon the Customer's demand, and can include both, round and complex cross sections of anodes, bars, rods, tapes, wires, etc., see Fig.4
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
9
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
10
flux-cored & solidwires
fine gauges
metal components
round anodes &solid billets
CONTINUOUS CASTING
HOT EXTRUSION
BAR SHEAR
COLD EXTRUSION
WIRE DRAWING I
WIRE DRAWING III
HYDROSTATIC EXTRUSION
MELTINING
flux
anodes, bars, rods,strips, wires
flux-cored & solid
solid bars(one, two,etc. pounds)
WIRE DRAWING II
large gauges
medium gauges
INSPECTION
SPOOLING & PACKING
ultrafine gauges
CUTTING
flux-cored & solidwires & cross-sections
flux-cored & solidwires
flux-cored & solidwires
flux-cored & solidwires
Fig.4 Solder Making Concept by Hydron
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
11
12 mm WIRE
for drawing
HEP 112
Melting Furnace 4000kg/shift
Hydron set - up for wire manufacturing
Metal Pumping
3 mm wire for spooling
Fine wire for spooling
SW-212/2
CCU-112
THICK WIRE DRAWING
400 kg/h
WIRE & BAR EXTRUSION up to 400kg/h solid 12 mm wire
THICK WIRE SPOOLING
400 kg/h
FINE WIRE SPOOLING
FINE WIRE DRAWING
MWD-112/3/12
MWD-112/3/12 SW-112
Ingots
Billets
BILLET CASTING Up to 1200 kg/h
12 mm WIRE
for drawing
3 mm WIRE for fine drawing
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
12
SOLDER GRADES The alloys which can be succesfully manufactured with HYDRON's equipment as flux-cored solder wires include full range of two component tin-lead grades and many multi-component one, as tin-lead alloys with antymony, copper, silver, etc.. The HYDRON's machines are also capable to run pure elements, i.e.: lead and tin. Other alloys can be manufactured on the particular Customer's request after throrough examination. Generally, the HYDRON's process permits a variety of the solder compositions and wire gauges to be produced simultaneously. All solder grades being use worldwide in the LIGHTING, AUTOMOTIVE, REFRIGERATING and FREEZING, CANS and PACKING industries, for ROOFING, WAVE SOLDERING, ELECTROPLATING, in ELECTRONICS and ELECTROTECHNICS, for COPPER DRINKING WATER PIPES SOLDERING (hot and cold), for RADIATORS, HYDRAULIC and ELECTRICAL SYSTEMS, for AUTOMATIC or HAND SOLDERING, by ELECTRICAL or GAS METHODS can be manufactured with use of the HYDRON's SYSTEMS (COMPLETE LINES) and/or INDIVIDUAL UNITS.
FLUXES In general, any high-quality, non-corrosive, non-hygroscopic and non-conductive protection flux can be introduced into the solder with use of the HYDRON's machinery. However, to obtain the high-quality, flux-cored solders and high productivity of the plant it is desirable to apply special grades, which can be supplied by CYNEL, manufactured on site at the Customer's plant or purchase on the market. An average amount between 2.0 and 3.0 wt% of flux in flux-cored solder is the world standard. It means that for the output of 200tons of solders the required quantity of flux is between 4tons and 6tons. However, HYDRON's machinery is very flexible as far as a flux content is considered. CYNEL's range varies between 0.5 wt% and 7.0 wt% of flux content, for commonly known FSW21, FSW24, FSW26, FSW31 and FSW32 fluxes (and their modifications) according to DIN 8511.
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
13
MANUFACTURING SYSTEM The HYDRON's process is realized by the following, individual units, see Figs.6: Hihg Pressure Continuous Casting Unit HP CCU-112 Horizontal Hot Extrusion Press HEP-112 Bar Marking and Shear BMS-112 (optional BMS-212 with packing system) Heavy Multiple Wire Drawing Machine MWD-112/3/12 Light Multiple Wire Drawing Machine MWD-112/3/12 Vertical Cold Extrusion Press CEP-112 Hydroextrusion Thinning Unit HTU-112 Spool Winders SW 212/2 or /and SW-112 (optional for commecial spooling) Central Hydraulic Supply System HSS-112 (optional, when a few HYDRON's Units
are set in a line) One Continuous Caster, one 200ton Hot Extrusion Press and three Wire Drawing
Units can approximately produce in a year (one shift per day) :
1,060,000lbs/480tons of solid solder wire 0.06"/1.5mm in dia. or
925,000lbs/420tons of solder flux-cored wire 0.061"/1.55mm in dia. + 353,000lbs/160tons of solder flux-cored wire 0.035"/0.9mm in dia.
or when supported with the one Bar Marking & Shearing Device it will give
2,650,000lbs/1,200tons of 1lb/0.5kg and 2lbs/1kgs solid bars alone
In case of mixed products this line will give annually approximately :
190,000lbs/85tons of solid solder wire 0.06"/1.5mm in dia. + 330,000lbs/150tons of solder flux-cored wire 0.061"/1.55mm in dia.,
or 130,000lbs/60tons of solder flux-cored wire 0.035"/0.9mm in dia. + 460,000lbs/210tons
of 1lb/0.5kg and 2lbs/1kgs solid bars
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
TEchnical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
14
HEP 112
Melting Furnace 4000kg/shift
Hydron set - up for wire manufacturing
Metal Pumping
3 mm wire for spooling
Fine wire for spooling
SW-212/2
CCU-112
THICK WIRE DRAWING
400 kg/h
BILLET CASTING Up to 1200 kg/h
WIRE & BAR EXTRUSION up to 400kg/h solid 12 mm wire
THICK WIRE SPOOLING
400 kg/h
FINE WIRE SPOOLING
FINE WIRE DRAWING
MWD-112/3/12
MWD-112/3/2 SW-112
Ingots
12 mm WIRE
for drawing
3 mm WIRE for fine drawing
Billets
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
15
HP CCU 112 HEP 112
Fig. 6 HYDRON's SOLDER MAKING
LINE
Our references : USA, RUSSIA, CHINA, GERMANY, FRANCE,
ITALY, MALAYSIA SINGAPORE, THAILAND
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
16
CCU-112 CONTINUOUS CASTING UNIT
APPLICATION
HYDRON's CCU-112 Continuous Casting Unit has been designed for continuous casting of a variety of soldering alloys, see Figs.7(1). The casting is continuously(2) pulled out by the double-sided pulling cylinder coupled with the clamping grip. The alloy feeding pump pumps the molten alloy into the Caster holding tank.
Beginning from pure tin and pure lead, through all standard 2-component Sn-Pb alloys and finally many special, multi-component soldering alloys as all alloys with copper, e.g.: Sn97Cu3; Sn60Pb38.5Cu1.5, and many others : Sn95Ag5; Sn59.6Pb38Bi2.4; with low content of Sb (0.2%); Sn50Pb32%Cd18, etc. can be easily cast with HYDRON's Continuous Caster.
The alloys have to be prepared separately and to be provided in a molten state. However, the melting pot is not a matter of supply, it can be delivered to the Customer on special request.
HYDRON's CCU-112 Continuous Caster is programmable controlled, and at present is the only one in the world which can cast continuously at 842oF/450oC.
If you have any specific alloy you want to try give us and we will test it.
TECHNICAL DATA Model 72mm/2.835" Model 140mm/4.5"
Billet size(3): 72mm;2.835" 140mm;5.5" Production capacity(4): 1000kgs/h;2200lbs/h 1500kgs/h;3300lbs/h Supply working pressure: 30MPa;450psi 30MPa;450psi
60MPa;900psi Supply voltage: 3x380V 50Hz 3x380V 50Hz Control system voltage: 24V (220V) 24V (220V) Heating power: 10kW 15kW Buzz saw power: 1.5kW;2H.P. 5.5kW;7.5H.P. Saw blade size: Hydraulic supply system power: 1.5kW;2H.P. 2.2kW;3H.P. Cooling water consumption: (pressure min. 2bar, free drain)
50liters/min 13.5U.S.gallons/min
100liters/min 26.5U.S.gallons/min
Overall dimensions (LxWxH): 4150x980x1420mm 13.6x3.2x4.7ft
4600x1050x1700mm 15.1x3.5x5.6ft
Total weight: 850kgs;1870lbs 1050kgs;2310lbs (1) unit does not include the melting furnace and the melting pot with the agitator (2) stroke length and the dwell between strokes of the pulling cylinder is set by the operator depending on the alloy grade and
other casting terms. They can be set as minimal as 5mm (stroke) and 0.5s (dwell), what practically makes the casting operation continuous.
(3) other sizes available (4) based on 60/40, 72mm dia, one hour output HYDRON's CCU-112 Continuous Caster produces cylindrical anodes or
semiproducts (round solid solder billets), see Fig.10, which can be further processed for solid or flux cored solder rods, bars, strips and wires by conventional hot extrusion at HYDRON's HEP-112 Automatic Hot Extrusion Press (see next Chapter) or at any other Press being of the Customer's possession.
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
17
Fig. 7 HYDRON CCU-112/72mm Continuous Casting Unit Fig. 8 HYDRON NEW HP CCU-112/72mm Continuous Casting Unit
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
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New: High Pressure Continuous Casting Unit. Adding high-pressure intensifier we had greatly improved our unit · Perfect contact with cooling sleeve after metals start to shrink · Less segregation (important for all lead frees · Higher metal density (increased by 1-3 %) · Higher outputs 30 – 50 % versus standard unit
Fig. 9 Best Quality Extrusion Billets cast with the HYDRON's HP CCU-112 Continuous Casting Unit versus Standard Continous Casting
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
19
* COMPARISON OF THE CCU-112 UNIT TO ITS COMPETITOR Comparison between the Continuous Caster made by HYDRON-Unipress, Ltd. and according Automatic Mould Caster of Competitor (output from both Units is this same, i.e. rod 72mm(2.84") in O.D. made of tin/lead soldering alloy)
COMPETITOR HYDRON
Casting (weigth/length) max.6.7kgs/190mm;14.7lbs/7.5" unlimited
Output 40kgs;88lbs per one casting 10-17kgs/min;22 - 38lbs/min
Billet ends cutting necessary (extra unit) eliminated
Billet for extrusion
(weigth/length)
6.2kgs/170mm;13.6lbs/6.9" 12.7kgs/360mm;28lbs/14.2"
Discards .5kg;1.1lbs ( 7.5% per casting) eliminated
Power consumptions approx. 24.6kW;33.5H.P. approx. 12kW;16H.P.
Alloy pump extra purchase included in the price
Type of unit stationary movable
Weigth - caster 1220kgs;2684lbs 850kgs;1,870lbs
- ends shear 680kgs;1500lbs -
- alloy pump 100kgs;220lbs -
Floor space
- caster 5.5m2;59ft2 4.1m2;44ft2
- ends shear 2m2;21.5ft2 -
Total floor space 2000kgs/7.5m2;4400lbs/80.5ft2 850kgs/4.1m2;1870lbs/44ft2
HIGH-PRESSURE INTENSIFIER
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
20
HEP-112 AUTOMATIC HOT EXTRUSION PRESS
APPLICATION HYDRON's HEP-112 Automatic Hot Extrusion Press, see Fig.11, is designed to
produce solid anodes, bars - Fig.13 and16, rods, strips - Fig.15 and wires or flux cored rods - Fig.14, for further extrusion, drawing or rolling.
Front, as well as side extrusion, can be apply for Hydron's HEP-112 Press.
TECHNICAL DATA Model
72mm/2.835"(1) Model
104mm/4.1"(1) Billet - diameter 72mm/2.835" 104mm/4.1" - length 380mm/15" 508mm/20" - volume approx.1.6dm3/95in3 approx.4.3dm3/264in3 - weight approx.12-15kgs/
26.5-33lbs approx.32-40kgs/ 70.5-88lbs
Working cycle: 1-5min 1.5-6min Production capacity(2): see Chapter "Output" see Chapter "Output" Multiplication factor 15 7.2 Maximal working parameters: - extrusion pressure 32MPa/5000psi 32MPa/5000psi - press load 200Ton/2,000kN
450,000lbf 200Ton/2,000kN/ 450,000lbf
- chamber temperature up to 145oC/293oF up to 145oC/293oF
- flux temperature up to 145oC/293oF up to 145oC/293oF - flux pressure up to 0.1MPa/15psi up to 0.1MPa/15psi Supply voltage: 3x380V 50Hz 3x380V 50Hz Control system voltage: 24V 24V Chamber heating power: 10kW 15kW Flux vessels heating power: 2kW 2kW Hydraulic supply system power: 22kW;30H.P. 22kW;30H.P. Water consumption: 10-30l/min
2.6-8.0U.S.gal./min
Overall dimensions (LxWxH): PRESS 3600x1210x1860mm
11.8x4x6.1ft 3800x1210x1860mm 12.5x4x6.1ft
COOLER 1600x700x1000mm 5.3x2.3x3.3ft
1600x700x1000mm 5.3x2.3x3.3ft
HYDRAULIC SUPPLY 1300x1100x1720mm 4.3x3.6x5.6ft
1300x1100x1720mm 4.3x3.6x5.6ft
BAR SHEAR 2360x830x1230mm 7.7x2.7x4ft
2360x830x1230mm 7.7x2.7x4ft (cutter for anodes: 2000x1000x1100mm 6.6x3.3x3.6ft)
Total weight: PRESS 1800kgs;3960lbs 1900kgs;4180lbs
COOLER 80kgs;176lbs 80kgs;176lbs HYDRAULIC SUPPLY 450kgs;990lbs 450kgs;990lbs
BAR SHEAR 450kgs;990lbs 450kgs;990lbs
(1) other sizes available (2) based on 60/40, 72mm dia, one hour output
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
21
HEP-112 Automatic Press can be coupled in-line with : HYDRON's MWD-112 Multiple Bull Block Drawing Machine (or any other being of the Customer's possession) to manufacture solid or flux cored fine wires, see Fig 18
HYDRON's BMS-112 Automatic Bar Marking and Shearing Unit to manufacture very effectively and fully automatically (up to 1100lbs/h;500kgs/h) solid bars of the Customer's designed geometry, see Fig.17.
HEP-112 Automatic Press operates in cycles. Each extrusion cycle allows
transformation of one 2.835"/72mm in dia. solid billet into a thinner solid product or the product with a few (1-5) flux filled cores.
Together with the HEP-112 Automatic Press HYDRON offers unique in the world
pressurized flux feeding system, Fig.12, allowing to monitor flux penetration into the product cores. Thus, the probability of the flux core discontinuity is significantly reduced.
HEP-112 Automatic Press is equipped with the programmable logic controller and
with the super economical, individual electro-hydraulic supply system with the frequency inverter.
Depend on the Customer's technology HYDRON's HEP-112 Automatic Press is
offered in a few versions that allow to produce one of the following or mixed assortment : oval, rectangular, star shape, etc. solid anodes, or rectangular and trapezoidal bar solders, see Fig.16, or one-, two- or three-strands of strips, Fig.15, or rods from 9mm up to 30mm in diameter, which may contain flux from 0.5 wt% up
to 7.0 wt%,
Fig. 11 HYDRON's HEP-112/72mm Automatic Hot Extrusion Press adapted to side extrusion with Hydraulic Supply Unit (far right),
Control Box (far left), and the Product Cooler (left)
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland_______________________________________________________________________April 2003
22
Fig. 13 Bar Solders (2 strands) extruded with HYDRON's HEP-112
Automatic Hot Extrusion Press (courtesy Asahi Solder)
Fig. 12 Pressurized flux feeding vessel (below) and flux melting vessel (above)
Fig 15 Bismuth Based Fusible Alloy Strips (3 strands) extruded with the HYDRON's HEP-112 Automatic Hot Extrusion Press
Fig. 14 Flux Cored Tin-Lead Based Rods extruded with the HYDRON's HEP-112
Fig. 16 Solders Anodes extruded with HYDRON's HEP-112
Automatic Hot Extrusion Press
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
23
Fig. 17 HYDRON AUTOMATIC LINE for BAR SOLDER MAKING HEP 112 Press link with BMS 212 (packing option)
Fig. 18 HYDRON LINE for SOLDER WIRE: HEP Press 112 link with MWD-112/3/12 Multiple Bull BlockHeavy Wire Drawing Machine (three drawing
cones model)
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland________________________________________________________________________April 2003
24
BMS-112 AUTOMATIC BAR MARKING and SHEARING UNIT
APPLICATION HYDRON's BMS-112 Automatic Bar Marking and Shearing Unit, see Fig.19, is
designed for shear and stamp (company's logo and alloy's grade) on the one or two strand flats (bars) which are extruded by the HYDRON's HEP-112 Automatic Hot Extrusion Press, see Fig.11 and Fig.17.
The cut surface is flat (no edges deformed) and burrfree. When coupled in-line with HYDRON's HEP-112 Automatic Hot Extrusion Press
makes manufacturing of solder bars fully automatic, reliable and very efficient(up to 1100lbs/h;500kgs/h) solid bars of the Customer's designed geometry .
TECHNICAL DATA
Shear force: 3Tonnes/6600lbs Shear time: 1s Shear length: 50-500mm(2-20inches) Shear cycle: 3-8s Feeding speed:
fast 10cm/s(4inch/s) slow 2cm/s(.8inch/s)
Motor power 0.75kW(1.0H.P.) Overall dimensions:(LxWxH): 2360x830x1500mm
7.7x2.7x4.9ft Total weight (with hydraulic supply): 450kgs/990lbs
Fig. 19 HYDRON BMS-112 and BMS 212 Automatic Bar Marking & Shearing Units
Hydron-Unipress, Ltd. (fax +4842-847-506, tel. +4842-402-546(7))_________________________________Production Program
Technical data may be modified as a result of technical improvements ul. Wólczańska 257, 93-035 Łódź, Poland_______________________________________________________________________April 2003
25
AS-112 AUTOMATIC ANODE SAW
Fig. 20 HYDRON LINE for ANODES: HEP Press 112 114 mm link
with AS 112 Anode Saw (flying)Fig. 20
APPLICATION HYDRON's AS-112 Automatic
Saw is designed for sawing of anodes which are extruded by the HYDRON's HEP-112
Automatic Hot Extrusion Press. Operation is fully automatic. Saw “fly” with extruded anode. Billets joints are automatically cut-out.
The cut surface is flat (no edges deformed) and burr free.
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MWD-112/3/12 MULTIPLE BULL-BLOCK HEAVY WIRE DRAWING MACHINES
APPLICATION HYDRON MWD-112 Multiple Bull-BlockHeavy Wire Drawing Machines, Fig.21
were designed to draw flux-cored and solid wire solder within the range starting from 0.5"/12.7mm down to approx. 0.125"/3mm,
All the worldwide known solder alloys, which can be drawn by the drawing machines made by the others producers can also be processed with the HYDRON's MWD-112 Drawing Machines.
According to Customer request the performance of the unit can be modified and adapted to other drawing diameters.
On Customer request the incoming wire diameter can be increased, up to 16mm . HYDRON's MWD-112 Drawing Machines are programmable controlled and
optionally equipped with automatic stop, stepless speed control (frequency inverter), die pre-pulling attachment and the exit wire counter.
HYDRON's MWD-112 Multiple Drawing Machines can work in-line with any Customer's extrusion presses and drawing units, as well as, be coupled in tandems or three between themself.
Fig. 18 HYDRON MWD-112/3/12 Multiple Bull Block Heave Wire Drawing Machine (three drawing cones model)
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TECHNICAL DATA
Model(1)(2) MWD-112/2/12
Number of shafts 3 Max. input dia. 16 9mm;0.63÷0.35" Min. output dia. 2.5 mm;0.010" Number of dies 21 Die dia. 38 mm;1.5" Die height 15mm;.6" Drawing speed -stepless (frequency inverter) 0.5 2 m/s;1.65÷6.5ft/s Supply voltage 380V, 3-phases Control system voltage 24V Motor power (inverter) 22kW;25H.P. Heating - heating elements 2kW Cooling system - heat exchanger spray on each die and drawing shaft
yes yes
Water consumption 10-20l/min;2.7÷5.4U.S.gal./min Cooling water pressure 2bar Cooling water inlet dia. ½" Production capacity(3) [kg/h;lbs/h]: dia.3mm(0.125") - 450kgs/h
990lbs/h Heating power 2 kW;2.7H.P. Take-up - freely to the container - wire spooler
yes no
Auxiliary tooling: - automatic stop - die pre-pulling attachment
standard standard
Total weight: UNIT + ELECTRIC CONTROL BOX 1600kgs;3520lbs
(1) notation: MWD - multiple wire drawing unit; 112 - model no.; /3(2)/ - no. of shafts ; 16, etc. - max. input wire dia. (approx.) (2) other sizes (models) available (3) based on 60/40, min. dia., one hour output Recommended die sequence 13% reduction
1 2 3 4 5 6 7 8 9 10 11 12 13 11.50mm 10.81mm 10.17mm 9.57mm 9.00mm 8.47mm 7.97mm 7.49mm 7.05mm 6.63mm 6.24mm 5.87mm 5.52mm
14 15 16 17 18 19 20 21 22 23 24 25 26 5.19mm 4.89mm 4.60mm 4.32mm 4.07mm 3.83mm 3.60mm 3.39mm 3.19mm 3.00mm 2.82mm 2.65mm 2.49mm
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MWD-112/2/3 MULTIPLE BULL-BLOCK LIGHT WIRE DRAWING MACHINES
APPLICATION
HYDRON MWD-112 Multiple Bull-Block Light Wire Drawing Machines, see Fig 22were designed to draw flux-cored and solid wire solder within the range starting from 3mm (0.125”)down to approx. 0.4 mm (0.015").
All the worldwide known solder alloys, which can be drawn by the drawing machines
made by the others producers can also be processed with the HYDRON's MWD-112 Drawing Machines.
According to Customer request the performance of the unit can be modified and
adapted to other drawing diameters. On Customer request the incoming wire diameter can be increased, up to 6mm
HYDRON's MWD-112 Drawing Machines are programmable controlled and
optionally equipped with automatic stop, stepless speed control (frequency inverter), die pre-pulling attachment and the exit wire counter.
HYDRON's MWD-112 Multiple Drawing Machines can work in-line with any
Customer's extrusion presses and drawing units, as well as, be coupled in tandems or three between themselfs, see the Chapter entitled "Outputs".
Fig. 22 HYDRON MWD-112/2/3 Multiple Bull Block Light Wire Drawing Machine (two drawing cones model)
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TECHNICAL DATA
Model(1)(2) MWD-112/2/3
Number of shafts 2 Max. input dia. 6 3mm;.24÷.12" Min. output dia. 1mm;.04" Number of dies 26 Die dia. 28mm;1.1" Die height 10mm;.4" Drawing speed -stepless (frequency inverter)
up to 6m/s;20ft/s
Supply voltage 380V, 3-phases Control system voltage 24V Motor power (inverter) 7.5 kW;10H.P. Heating - heating elements 2kW Cooling system - heat exchanger spray on each die and drawing shaft
yes yes
Water consumption 10-20l/min;2.7÷5.4U.S.gal./min Cooling water pressure 5bar Cooling water inlet dia. ½" Production capacity(3) [kg/h;lbs/h]: dia.1mm(.04") - 100kgs/h
220lbs/h Heating power 2 4kW;2.7÷5.4H.P. Take-up - freely to the container - wire spooler
yes optional
Auxiliary tooling: - automatic stop - die pre-pulling attachment
standard optional
Total weight: UNIT + ELECTRIC CONTROL BOX 1200kgs;2500lbs
(1) notation: MWD - multiple wire drawing unit; 112 - model no.; /3(2)/ - no. of shafts ; 3, etc. - nom. input wire dia. (approx.) (2) other sizes (models) available (3) based on 60/40, min. dia., one hour output Recommended die sequence 7%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3.087 2.984 2.885 2.789 2.696 2.606 2.520 2.436 2.355 2.276 2.201 2.128 2.057 1.988 1.922 1.858 1.796 1.737 1.679 1.623
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1.569 1.517 1.466 1.418 1.371 1.325 1.281 1.238 1.197 1.157 1.119 1.082 1.046 1.011 0.977 0.945 0.913 0.883 0.853 0.825
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 0.798 0.771 0.745 0.721 0.697 0.674 0.651 0.629 0.609 0.588 0.569 0.550 0.532 0.514 0.497 0.480 0.464 0.449 0.434 0.419
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CEU-112 SEMI-AUTOMATIC COLD EXTRUSION UNIT
APPLICATION
HYDRON CEU-112 Semi-Automatic Cold Extrusion Unit (build of several independently assambled individual, single presses), Fig.23 is designed to produce small lot sizes of fine cored- and solid soldering wires or shapes, made of special and hard-to-draw, non-ductile and brittle alloys, as bearing alloys SnSbCu- type (Sn83Sb11Cu6, etc.), Sn70Zn30 alloy, indium and bismuth based fusible alloys, e.g.: Bi49Pb18Sn12In21, Bi58Pb42, or others with cadmium,etc.
Wires and cross sections of diameter between 0.047"/1.2mm and a few millimeters in one single pass through one extrusion die from the billet diameter .78"- 1.18"/20mm-30mm can be manufactured,
Whereever the wire drawing meet difficulties you can try HYDRON CEU-112 Semi-Automatic Cold Extrusion Presses. Since product pulling is eliminated you are not limited by the tensile strength of the material being processed.
HYDRON's CEU-112 Press is self-loaded and operates in the semi-automatic mode. The optional take-up reel attachment reduces the need for operator supervision to a
minimum. Typically, HYDRON's CEU-112 Semi-Automatic Cold Extrusion Unit consists of four
identical presses fixed to one frame, see Fig23.
TECHNICAL DATA Working chamber diameter 0.78-1.18inch;20-30mm Tin-Lead Based Billet (solid or flux-cored) diameter length
0.78-1.18";20-30mm 7.9";200mm
Product (solid or flux-cored) diameter
0.05-0.24";1.2-6mm
Working cycle 8-18min Multiplication factor 64 Maximum working parameters extrusion pressure press load maximal chamber pressure maximal cylinder pressure
36,260psi;250MPa 80tons;785kN 160,000psi;1,100MPa 3,625psi;25MPa
Power consumption (one press) (four presses)
2.7H.P.;2.0kW 7.4H.P.;5.5kW
Overall dimensions PRESS (one) length width height HYDRAULIC SUPPLY (four presses) length width height
4.9ft;1,500mm 2.1ft;650mm 8.2ft;2500mm 2.3ft;700mm 1.3ft;400mm 2.6ft;800mm
Weight (one press) Weight (hydraulic supply) Total weight (4 presses+supply)
660lbs;300kgs 1100lbs;500kgs 3300lbs;1500kgs
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The extruded products in form of round flux-cored or solid wire solder may be wound
on commercial spools or undergo further diameter reducing by the hydrostatic extrusion process, see Fig.2. To do so HYDRON offers its unique machinery, i.e.: HYDRON's HTU-112 Hydroextrusion Thinning Unit, see Fig.24.
HYDRON's CEU-112 Semi-Automatic Cold Extrusion Unit is also very useful for manufacturing of profiled wires and rods as squares, rectangles, triangles, etc or lead cross sections for stained and leaded glass,
Fig. 21 HYDRON CEU-112 Semi-Automatic Cold Extrusion Presses
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HTU-112 HYDROEXTRUSION THINNING UNIT
APPLICATION
HYDRON HTU-112 Hydroextrusion Thinning Unit, see Fig.24, utilizes the hydrostatic extrusion technology, see Fig.2, for manufacturing of the flux-cored and solid wire solders, beginning from 0.035"/0.9mm in dia. down to 0.004"/0.1mm, and for some alloys even 0.0012"/0.03mm in dia.
The wire to be extruded (billet material) is coiled onto the working spool and the outgoing product (extruded fine and ultrafine wire), see Fig.3, can be optionally, freely collected into the container or wound onto the take-up spool (commercial, Fig.20, or working one).
TECHNICAL DATA Max. working pressure 36,000psi;250MPa Working chamber I.D. 3.94";100mm Starting wire O.D. below 0.06";1.5mm Final wire O.D. .035-.004";0.9-0.1mm
(exceptionally 0.0012";0.03mm) Billet weight max. 11-13.2lbs;5-6kgs Reduction ratio per pass max. 65% Extrusion speed 1.65-33ft/s;0.5-10m/s Extrusion speed control by flow control or by pulling
(when spooling at the exit hydrostatic extrusion augmented by drawing)
Hydraulic supply pressure 2,320psi;16MPa Working medium water with anticorrosive additives Working medium capacity 3U.S.gal.;12liters Power consumption 3.35H.P.;2.5kW Weight (thinning unit) Weight (hydraulic supply) Total weight
2645lbs;1200kgs 440lbs;200kgs 3085lbs;1400kgs
Many metals and alloys as pure Sn, pure Pb and wide range of pure Sn-Pb alloys
being in common worldwide use or with additions of antimony (Sn50PbSb1, Sn63PbSb1, Sn95Sb5), copper (Sn60PbCu2, Sn97Cu3), silver (Sn60PbAg4, Sn63PbAg1), and other elements can be extruded with the HTU-112 Thinning Unit.
Since the hydrostatic state of stresses within the extruded material very high reduction ratio in one pass through one die can be made (approx. 65% reduction). State of compressive, hydrostatic stresses increases alloys ductility, prohibiting cracks generation and propagation. Thus, for some alloys which resist to be drawn easily the HTU Thinning Unit is the reasonable alternative.
The maximal extrusion ratio is limited by the working pressure (up to 36,000psi/250MPa), therefore to obtain ultrafine gauges several successive extrusion passes are necessary. For example, to produce 0.01"/0.25mm wire from 0.047"/1.2mm wire the following passes should be made (4 extrusions) :
.047"/1.2mm .028"/0.7mm .022"/0.56mm .015"/0.38mm .01"/0.25mm
Automatic spooling of the exiting wire allows for extended operatorless runs (thinner
wire longer run).
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Fig. 24 HYDRON HTU-112 Hydroextrusion Thinning Unit
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SW-112 and SW- 212 SPOOL WINDERS HYDRON semiautomatic SW- 112 Spool Winders designed to spool solder wire ,
onto the commercial reels up to 5 kg. Spooler can be every time adapted to the specific Customer's needs for spooling
solder wires on the commercial, plastic reels, see Fig.4, or on the working spools necessary for HTU-112 Unit, see Fig.24. The plastic reels are in common, worldwide use.
HYDRON offers as well the semiautomatic Double Spool Winders for spooling the wires within the range of 2-4mm in O.D. onto the 5kgs;(11lbs) or 20kgs;(44l)bs spools.
TECHNICAL DATA UNIT SW 112 SW 212/2 Number of spools 1 2 Max. spool size 5 kg 250 mm 400 mm width 200 mm Spool fastening mechanical,
manual*(pneumatic option) mechanical,
manual*(pneumatic option) Wire lenght measurment electronic 100 mm
accuracy electronic 200 mm
accuracy Max input dia. 5 mm (0.200 “) 5 mm (0.200 “) Min input dia. 1.5 mm (0.062”) 1.5 mm (0.062”) Winding speed stepless stepless
fast winding 0.5 -10 m/s 0.5 -10 m/s slow 0.2- 1 m/s 0.2- 1 m/s
Supply voltage 3 x 380V 50 Hz 3 x 380V 50 Hz Motor power 0.5 kW 3.7 kW Production capacity 3 mm 0.5 kg spools 100
- 120 kg/h 3 mm 15 kg spools 400 -
600 kg/h Overall dimensions (LxWxH):
Unit 1300 x 600 x 1000 mm 1000 x 600 x 1510 mm Electric control box 600 x 300 x 1310 mm
Strightener 1000 x 600 x 1700 mm 4800 x 600 x 1700 mm
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Fig 25 Spool Winder SW 112 Semi-Automatic Spool Winder for spooling wires within the range of 2-5 mm in diamiter onto 1 to 2.5 kg spools.See table for details.
Fig 26 Spool Winder SW 212/2 Semi-Automatic Double Spool Winder for spooling wires within the range of 2-5 mm in OD onto 10 to 25 kg spools.See table and attached drawing for details.
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SALE CONDITIONS All purchased Units will be thoroughly tested in HYDRON's plant before shipment. The prices include packing, packaging and delivery Free Polish Border or FOB
Polish Harbour. Buyer shall be responsible for obtaining all permits, certifications and bonds as may
be required for installation and operation of the HYDRON's equipment at Buyer's plant.
Machines are fully assembled and actuated at the Buyer's site, according to mutual agreement and in the presence of the Manufacturer. Manufacturer will provide the specialized assembling team. Cooperation with the Buyer is here necessary. Period of installation depends on the order volume.
Buyer shall be responsible for installing necessary utilities including electrical, water, compressed air and connections required by the equipment as designated by Hydron.
However, operating of all Units is simple a short-term on-the-job training for the operators after installation period is necessary. Duration of the training will last as long as it is necessary for optimal machines operation.
Buyer shall be responsible for ensuring that the equipment, when assembled as a unit, as well as all parts, hydraulic accumulators, etc. complies with Buyer's country and local safety and health requirements.
Hydron will advise during the start-up period and will provide further assistance in the technical development of Buyer's production line. There is a possibility of HYDRON's assistance in manufacturing of short-life parts at the Buyer's plant.
Time of delivery
from three to six months from receipt of order and downpayment (depending on the configuration).
Terms of payment 30% - downpayment (at time of order) 60% - with delivery 10% - after start-up
Warranty twelve months for defective parts and workmanship, except parts subject to normal wear. HYDRON hopes the offered machines will meet your specific requirements. HYDRON will do its best to advise you the optimum installation, to complete your
order in the most effective way and be pleased to serve you at any time in the future.
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WHY to BUY HYDRON's MACHINERY ?
CONTINUOUS CASTING UNIT
continuous process greatly improves the casting quality
replaces two machines : ingot mould casting & double shear
no oxides and shrink holes no discards since movable can easily serve to
several melting pots
AUTOMATIC HOT EXTRUSION PRESS more than twice bigger billet in
comparison to presses of similiar capacity offered on a market
less floor space necessary (hinged piston makes the press body much shorter)
AUTOMATIC BAR MARKING & SHEARING UNIT
very efficient for solder bars production
burrless, flat cutting surface clear marking
SEMI-AUTOMATIC COLD EXTRUSION PRESS
replaces drawing for hard-to-draw alloys and small batch production
large reductions in single pass (good product uniformity)
does not require long and wasted start-up material (as drawing does)
high production flexibility (if set of presses installed each, single press can process different alloy through different die)
MULTIPLE BULL-BLOCK WIRE DRAWING MACHINE
high outputs easy to control and operate
very compact in comparison to drawing units offered on the market
HYDROEXTRUSION THINNING UNIT
complementary to drawing units for ultrafine wires
hard and brittle alloys (non-workable by drawing) can be processed
easiness to alter the product range (easy die replacement, prefabricated working spools)
very compact design (one square meter/ten square feet of floor space necessary)
ELECTRO-HYDRAULIC SUPPLY SYSTEM
reliable easy in operation
energy saving
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HYDRON OFFERS
INDIVIDUAL UNITS INDIVIDUAL EQUIPMENT for CONTINUOUS CASTING of SOFT SOLDER BARS and for their FURTHER PROCESSING to SOLID & FLUX-CORED ANODES, BARS, RODS, STRIPS, PROFILES and WIRES (for the list of units see Chapter entitled "Manufacturing System", and for the prices of single units, see the "Price List")
COMPLETE LINES COMPLETE TECHNOLOGICAL LINE for MANUFACTURING of SOLID & FLUX-CORED SOLDERS STARTING from an ALLOY PREPARATION down to the ULTRAFINE WIRES (the block diagram of the complete HYDRON's production line is shown on page 9. For the possible line arrangements, see Chapter "Manufacturing Systems" and "Outputs". For the prices of single units, see the "Price List". HYDRON is willing to provide current co-operation during the start-up period of production as well as further assistance in technical development of the line.
INTEGRATION with CUSTOMER's EQUIPMENT EXTENDING CUSTOMER'S EQUIPMENT CAPABILITIES by the ADAPTATION of CUSTOMER'S MACHINES to produce OTHER PRODUCT ASSORTMENT or INCLUDE SINGLE HYDRON'S UNITS into ALREADY EXISTING LINES (in particular, it may concern the adaptation of the Customer's Hot Extrusion Press for production of flux-cored rods, solid anodes or strips, bars by adding HYDRON's Bar Marking & Shearing Unit or coupling HYDRON's Drawing Machines with Customer's presses or other drawing units). More detailes on request.
MISCELLANEOUS SPECIALIZED TOOLING for SOLDER BUSINESS (including working chambers, pistons, plugs, seals, round and shaped dies, etc.) according to CUSTOMER's DEMAND.
CO-OPERATION JOINT VENTURES in NEW AREAS of SOLDERING BUSINESS or ANY OTHER FORMS of CO-OPERATION DESIRED
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REFERENCES(1) HYDRON's references include the following countries : USA GERMANY FRANCE ENGLAND
ITALY RUSSIA CHINA
THAILAND SINGAPORE MALAYSIA POLAND
(1) Suitable references will be provided upon request. ALL HYDRON's UNITS CAN OPERATE INDEPENDENTLY or
BE INTEGRATED WITH the CUSTOMER's EQUIPMENT WE GUARANTEE TECHNICAL AID THROUGHOUT THE
IMPLEMENTATION PERIOD WITH HYDRON's MACHINES YOUR MARKET OFFER CAN
BECOME MORE VERSATILE ALL UNITS are VERY COMPETITIVELY PRICED
To schedule meeting to review our design upgrades and performance data, to see a brief videotape to better demonstrate HYDRON's products' capabilities for you, and for any other information required please contact us :
Jan Laube, President Hydron-Unipress, Ltd., Poland
Fax:+4842-847-506 Tel.+4842-402-546(7) ul. Wólczańska 257, 93-035 Łódź, Poland