Breakthrough in 800mm large taper wire cutting process for electrostatic precipitator electrode plate

The performance of industrial waste gas purification equipment often depends on the precision of core components. When the electrode plates of electrostatic precipitators need to withstand high temperature, high pressure and high corrosion environment, traditional processing methods are difficult to balance complex tapers and micron-level precision. How to use 800 large taper medium wire cutting technology to cut high-precision airflow guide grooves on ultra-thin metal plates? This not only affects the life of the equipment, but also directly affects the efficiency of waste gas purification.

Electrostatic precipitator electrode plate: structure and processing difficulties  

As the core component of industrial waste gas purification equipment, the electrode plate of the electrostatic precipitator needs to meet the three requirements of high conductivity, corrosion resistance and complex airflow guide structure. The processing difficulties are mainly concentrated in the following aspects:

1. High-precision cutting of ultra-thin sheets

Electrode plates are usually made of 1-3mm stainless steel or titanium alloy. The thin-walled structure is easy to deform, and traditional laser cutting is prone to produce heat-affected zones, resulting in edge warping.

The airflow guide groove must maintain a straightness of ≤±0.00 3 mm, otherwise it will affect the uniformity of the electric field and reduce the dust removal efficiency.

2. Processing challenges of 800 large taper structures

The edge of the electrode plate needs to be processed with a gradual taper of 15°-45° to ensure smooth airflow and reduce turbulence.

When cutting a large taper, the electrode wire is prone to deflection and tension fluctuations, resulting in excessive taper surface roughness (traditional process Ra ≤ 0.7-1.4 μm).

3. Substrate treatment for corrosion-resistant coating

The surface needs to be sprayed with PTFE or ceramic coating, and the surface roughness of the processed substrate needs to be ≤Ra 0.8μm, otherwise the coating will easily peel off.

Case analysis: Practical application of 800 large taper medium wire technology

An industrial waste gas purification equipment manufacturer adopted ZK-800G large-taper medium-speed wire-cutting machine tool produced by Zhikai CNC and successfully broke through the bottleneck of electrode plate processing:

1. High stability taper cutting

Zhikai's dual servo taper control system can adjust the UV axis and XY axis linkage in real time to ensure that the electrode wire deflection is less than 0.005mm during 800 large taper cutting. Actual processing data shows:

The cone surface roughness is stable at Ra ≤ 0.7-1.4 μm, which is better than the industry standard (Ra 1.2μm);

The taper angle error is ≤0.02°, meeting the requirements of airflow dynamics design.

2. Ultra-thin plate anti-deformation technology

Through pulse power optimization and adaptive tension control, the processing heat input is reduced by 40%, and the flatness of the electrode plate is controlled within 0.05mm/m², which is 3 times higher than laser cutting.

3. Efficient processing of complex grooves

By using an intelligent path planning algorithm, the guide grooves, mounting holes and tapered edges of the electrode plate can be processed in one go, increasing efficiency by 50% and reducing unit costs by 22% compared to traditional segmented processes.

Data highlights:

The processing qualification rate increased from 88% to 99.3%;

The service life of the electrode plate is extended by 30%, corresponding to a 15% increase in exhaust gas purification efficiency.

Zhikai CNC: Deepening technology and providing superior services  

Re-development:

Exclusively developed "taper cutting expert system", with 17 built-in electrode plate processing technology packages, supporting customers to call with one click;

The ZK-800G machine tool adopts a granite bed with a thermal deformation coefficient of <0.5μm/℃, ensuring long-term processing stability.

Improve service  

Provide "process hosting" service, where Zhikai engineers remotely monitor equipment status and optimize parameters in real time;

An eight-hour emergency response circle has been established nationwide, the spare parts pool covers 90% of wearing parts, and downtime due to failures has been shortened by 80%.

Industry expansion: What else can Zhikai Technology process?

In addition to the electrostatic precipitator electrode plate, the 800 large taper medium wire technology has been successfully applied to:

1. SCR denitration catalyst metal carrier: honeycomb hole group processing, hole diameter tolerance ≤ ± 0.00 3 mm;

2. VOCs waste gas treatment equipment vortex disk: spiral taper airway is formed in one step;

3. Titanium alloy fins for flue gas heat exchanger: 0.3mm ultra-thin fins are cut without deformation.

Summarize

"In the field of industrial purification, precision is the cornerstone of environmental protection, and innovation is the engine of efficiency. Zhikai CNC cuts out a key line of defense in the battle to protect the blue sky with its 800-degree 'tightrope dance'."

Choosing Zhikai is not only choosing a machine tool, but also choosing the commitment of "zero defect processing" - we use our technical strength and service soft power to help every environmental protection enterprise achieve the dual standards of emissions and benefits.

Zhikai has always adhered to the concept of customer first. For 20 years, it has worked silently and developed the wire-cutting machine tools in the slow wire-cutting system. Through continuous technological innovation and lean manufacturing, it has created high-performance 7740 gear wire-cutting EDM, F-type rotary medium wire-cutting machine tools, 500 new EDM wire-cutting machines, T-type 7735 EDM wire-cutting machines, 800 new wire-cutting machines, 400 high-performance wire-cutting EDM, large dk7732 EDM wire-cutting machines, 400 CNC wire-cutting machines, and small linear rail wire-cutting machines. Precision processing, low failure rate and high stability make production more efficient; the perfect after-sales system and technical training escort customers in Shayang County, Jingshan City, Duodao District, Zhongxiang City, Dongbao District and other places. Choosing Zhikai means choosing the all-round guarantee of trust, quality and service to create a brilliant future together.

If you have any needs, please contact Zhikai : 18013131588