Flat flexible energy-saving cable special-shaped copper core overmolding device and method

Abstract

The present invention relates to the field of cable production technology, specifically to a device and method for sheathing and molding special-shaped copper cores of flat flexible energy-saving cables, comprising a copper core extrusion molding device, a first sheathing machine, and a second sheathing machine, which are sequentially arranged along the conveying direction of a thin copper busbar; the prepared special-shaped copper core is a conductor with an arc-shaped special-shaped structure, and utilizes the skin effect. Compared with a traditional busbar of the same specification, the current carrying capacity is improved by about 10%, and compared with a cable with the same cross-sectional area, the current carrying capacity is increased by more than 15%, and an ultra-large current carrying capacity product with a current carrying capacity of up to 8000A can be produced, which significantly improves the power transmission efficiency and meets the needs of high-load power transmission; under the conditions of the same cross-sectional area and the same current carrying capacity, the conductor consumes about 8% less copper material than traditional busbars and cables during the production process, thereby reducing production costs and improving resource utilization efficiency; the bending radius is small during installation, and the conductor is easy to bend, which reduces the difficulty of installation.

Description

Technical Field

[0001] The present invention relates to the technical field of cable production, and in particular to a device and method for overmolding a special-shaped copper core of a flat flexible energy-saving cable. Background Art

[0002] In power transmission and distribution systems, busbars are important components used to carry and distribute large currents and large cross-sections. Traditional busbars are usually made of thicker copper bars with no insulation or sheathing on the conductor surface, resulting in high material costs, high energy consumption, and low safety. At the same time, since traditional busbars have fixed shapes and sizes, their installation flexibility and efficiency in specific environments are limited. Therefore, a flat flexible energy-saving cable special-shaped copper core overmolding device and method are proposed to improve current carrying capacity and safety of use, reduce energy loss, and be suitable for different installation and use environments. Summary of the Invention

[0003] In response to the problems in the prior art, the present invention provides a device and method for overmolding the special-shaped copper core of a flat flexible energy-saving cable, which improves the current carrying capacity and safety of use, reduces energy loss, and is suitable for different installation and use environments.

[0004] The technical solution adopted by the present invention to solve its technical problems is a flat flexible energy-saving cable special-shaped copper core sheathing molding device, which includes a copper core extrusion molding device, a first sheathing machine, and a second sheathing machine which are arranged in sequence along the conveying direction of the thin copper busbar; the copper core extrusion molding device includes a shell with a feed port and a discharge port on both sides respectively, and the upper and lower parts of the inner side of the shell are movably connected with several groups of rotating rods distributed along the conveying direction of the thin copper busbar, and the spacing between the upper and lower adjacent rotating rods gradually decreases along the conveying direction of the thin copper busbar. A roller knife assembly is slidably connected to the rotating rod, and a driving mechanism is provided on the side of the shell for driving the rotating rod to rotate after the rotating rod moves toward the thin copper busbar. A conveying assembly for conveying the copper core is provided on the side of the shell close to the feed port.

[0005] Specifically, the roller cutter assembly includes a sleeve slidably connected to the rotating rod, and a first squeezing roller and a second squeezing roller mounted on the sleeve. A vertical slide groove corresponding to the two ends of the rotating rod is provided on the side of the housing. The end of the rotating rod close to the driving mechanism passes through the slide groove and is slidably connected to the slide groove. The ends of the rotating rod and the sleeve away from each other are connected to the housing through a telescopic mechanism.

[0006] The first extrusion roller is provided with a plurality of groups of circular arc-shaped annular grooves, and the second extrusion roller is provided with a plurality of groups of trapezoidal annular grooves.

[0007] Specifically, the driving structure includes a turbine connected to one end of a rotating rod, and a worm arranged horizontally and meshing with the turbine for transmission. Both ends of the worm are rotatably connected to a support plate fixed to the outside of the shell. One end of the worm is connected to the output end of the drive motor, and the drive motor is mounted on the support plate.

[0008] Specifically, an eddy current heating ring is provided between adjacent sleeves, and a thin copper bar passes through the eddy current heating ring; the top of the shell body away from the feed port is connected to an inert gas inlet connector.

[0009] Specifically, the adjustment structure includes a vertically arranged movable plate, one end of the sleeve is slidably connected to one side of the movable plate, the side of the movable plate away from the sleeve is fixedly connected to an electric hydraulic telescopic rod, and the fixed end of the electric hydraulic telescopic rod is fixedly connected to a vertically arranged support leg;

[0010] One end of the rotating rod is fixedly connected to the first sealing plate, and one end of the sleeve is slidably connected to the second sealing plate. The second sealing plate is slidably connected to the outer side of the shell, and the first sealing plate and the second sealing plate respectively correspond to the sliding grooves on both sides of the shell.

[0011] Specifically, several groups of horizontally distributed conveying rollers are provided on the upper and lower sides of the shell near the feed port. The two ends of the conveying rollers are rotatably connected to vertically arranged moving rods. A horizontally arranged mounting plate is fixedly connected to the outside of the shell. A movable groove is provided on the mounting plate. One end of the moving rod passes through the movable groove and is fixedly connected to an extrusion plate. An extrusion spring is provided on the side of the mounting plate close to the extrusion plate. A pressing control device for controlling the telescopic mechanism is provided between the mounting plate and the extrusion plate.

[0012] Specifically, the telescopic mechanism includes a movable cylinder vertically fixed on both sides of the shell, two groups of horizontally arranged electromagnets are slidably connected in the movable cylinder, and the two groups of electromagnets are magnetically attracted in the initial state. A vertically arranged movable rod is provided on the side away from the electromagnets, and a return spring is fixedly connected between the side of the electromagnet close to the movable rod and the inner wall of the piston cylinder. A first sliding ring fixedly connected to the end of the movable rod is slidably connected to the rotating rod, and a second sliding ring fixedly connected to the end of the movable rod is slidably connected to the sleeve;

[0013] The pressing control device comprises a plurality of pressing switches arranged on the upper surface of the mounting plate. The lower surface of the extrusion plate is in pressing contact with the pressing switches, and the pressing switches are used to control the electromagnets.

[0014] Specifically, two groups of symmetrically arranged conical air outlet shells are provided on the upper and lower sides of the shell near the feed inlet. The contraction sections of the conical air outlet shells are provided with air outlets for blowing air toward the thin copper busbar, and the conical air outlet shells are connected to the interior of the shell.

[0015] Specifically, an auxiliary roller symmetrically arranged up and down is connected to one side of the shell near the discharge port; a vertically arranged positioning roller is provided between the left and right adjacent sleeves, and the positioning roller is in rolling contact with both sides of the thin copper busbar. The two ends of the positioning roller are rotatably connected to a connecting rod, and the end of the connecting rod away from the positioning roller is fixedly connected to the inner wall of the shell.

[0016] A method for overmolding a flat flexible energy-saving cable with a special-shaped copper core adopts the above-mentioned device for overmolding a flat flexible energy-saving cable with a special-shaped copper core, and specifically comprises the following steps:

[0017] Step 1: Place the thin copper busbar near the feed port of the copper core extrusion molding device, start the conveying component of the copper core extrusion molding device, and convey the thin copper busbar from the feed port into the shell through the conveying component;

[0018] Step 2: The driving mechanism drives the rotating rod to rotate, driving the roller cutter assembly to extrude the thin copper busbar, so that the thin copper busbar gradually forms a special-shaped copper core during the conveying process, and the processed special-shaped copper core is sent out from the discharge port;

[0019] Step 3: The special-shaped copper core sent out from the discharge port of the copper core extrusion molding device is transported to the first coating machine, and the first coating machine performs a coating operation on the special-shaped copper core to complete the coating of the inner heat dissipation layer on the surface of the special-shaped copper core;

[0020] Step 4: The shaped copper core that has been coated for the first time is transported to a second coating machine. The second coating machine coats the shaped copper core that has been coated for the first time again, and completes the coating of the insulation layer on the basis of the first coating.

[0021] Beneficial effects of the present invention:

[0022] (1) The device and method for overmolding the special-shaped copper core of a flat flexible energy-saving cable described in the present invention are as follows: the special-shaped copper core prepared is a conductor with an arc-shaped special-shaped structure, and the skin effect is utilized. Compared with the traditional busbar of the same specification, the current carrying capacity is increased by about 10%, and compared with the cable with the same cross-sectional area, the current carrying capacity is increased by more than 15%. It can produce ultra-large current-carrying products with a current carrying capacity of up to 8000A, significantly improving the power transmission efficiency and meeting the high-load power transmission requirements; under the conditions of the same cross-sectional area and the same current carrying capacity, the conductor consumes about 8% less copper than the traditional busbar and cable during the production process, reducing the production cost and improving the resource utilization efficiency; the bending radius is small during installation, and it is easy to bend, reducing the difficulty of installation.

[0023] (2) The device and method for overmolding the special-shaped copper core of a flat flexible energy-saving cable described in the present invention can automatically adjust the distance between the roller-knife assembly and the copper busbar according to the thickness of the copper busbar through the linkage of the conveying roller, the extrusion plate, the pressing control device and the telescopic mechanism, thereby realizing adaptive processing of copper busbars of different thicknesses. This automated adjustment mechanism improves production efficiency, reduces manual intervention, and ensures product quality.

[0024] (3) The device and method for overmolding the special-shaped copper core of a flat flexible energy-saving cable described in the present invention have multiple functions of protection, heat dissipation and cleaning formed by the inert gas in the shell. On the one hand, it isolates oxygen to prevent oxidation of the copper busbar; on the other hand, the gas discharged from the discharge port dissipates heat and preheats the copper busbar, which is convenient for subsequent overmolding. The gas discharged from the conical air outlet shell can also blow off impurities, thereby optimizing the production process.

[0025] (4) The flat flexible energy-saving cable special-shaped copper core sheathing molding device and method described in the present invention, the first extrusion roller and the second extrusion roller in the roller knife assembly can be slidably switched, and the adjustment structure can quickly meet the diverse production needs and improve the flexibility of production; the electric hydraulic telescopic rod, the movable plate and the first sealing plate and the second sealing plate in the adjustment structure can not only adjust the position of the roller knife assembly, but also maintain the sealing inside the shell, ensure the environment for the copper core extrusion molding, and ensure the molding quality of the copper core. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present invention will be further described below with reference to the accompanying drawings and examples.

[0027] Figure 1 is an axonometric drawing of the present invention;

[0028] Figure 2 It is another perspective axonometric drawing of the present invention;

[0029] Figure 3 is a side view of the present invention;

[0030] Figure 4 for Figure 2 A magnified view of area A;

[0031] Figure 5 for Figure 2 A magnified view of area B;

[0032] Figure 6 Schematic diagram of the internal structure of the housing of the present invention;

[0033] Figure 7 It is a schematic top view of the internal structure of the housing of the present invention;

[0034] Figure 8 for Figure 6 Magnified view of area C;

[0035] Figure 9 for Figure 6 Magnified view of area D;

[0036] Figure 10 It is a schematic diagram of the rotating rod structure of the present invention;

[0037] Figure 11This is a side view of the arc-shaped special-shaped copper core of the present invention;

[0038] Figure 12 It is a side view of the trapezoidal shaped copper core of the present invention;

[0039] Figure 13 This is a cross-sectional view of the arc-shaped special-shaped copper core cable of the present invention;

[0040] Figure: 1, first coating machine; 2, second coating machine; 3, feed port; 4, discharge port; 5, housing; 6, rotating rod; 7, sleeve; 8, first extrusion roller; 9, second extrusion roller; 10, chute; 11, connecting rod; 12, moving plate; 13, electric hydraulic telescopic rod; 14, support leg; 15, first closing plate; 16, second closing plate; 17, turbine; 18, worm; 19, support plate; 20, drive motor; 2 1. Eddy current heating ring; 22. Air inlet connector; 23. Conveyor roller; 24. Moving rod; 25. Mounting plate; 26. Movable groove; 27. Extrusion plate; 28. Extrusion spring; 29. ​​Movable cylinder; 30. Electromagnet; 31. Movable rod; 32. Return spring; 33. First sliding ring; 34. Second sliding ring; 35. Press switch; 36. Conical air outlet housing; 37. Air outlet; 38. Auxiliary roller; 39. Positioning roller. DETAILED DESCRIPTION

[0041] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0042] In order to improve the current carrying capacity and the safety of use, reduce the energy loss, and be applicable to different installation and use environments, as an embodiment of the present invention, Figure 1 、 Figure 2 、 Figure 3 、 Figure 4 、 Figure 6 As shown, the flat flexible energy-saving cable special-shaped copper core sheathing molding device and method described in the present invention include a copper core extrusion molding device, a first sheathing machine 1, and a second sheathing machine 2 arranged in sequence along the conveying direction of the thin copper busbar; the copper core extrusion molding device includes a shell 5 with a feed port 3 and a discharge port 4 on both sides respectively, and the upper and lower parts of the inner side of the shell 5 are movably connected with several groups of rotating rods 6 distributed along the conveying direction of the thin copper busbar. The spacing between the upper and lower adjacent rotating rods 6 gradually decreases along the conveying direction of the thin copper busbar. A roller knife assembly is slidably connected to the rotating rod 6. A driving mechanism is provided on the side of the shell 5 for driving the rotating rod 6 to rotate after the rotating rod 6 moves toward the thin copper busbar. A conveying assembly for conveying the copper core is provided on the side of the shell 5 close to the feed port 3.

[0043] When in use, during the cable production process, the thin copper bar is first placed on the conveying assembly, and then the conveying assembly is started. At this time, the conveying assembly smoothly feeds the thin copper bar from the feed port 3 into the interior of the housing 5. After the thin copper bar enters the housing 5, the driving mechanism is started to drive the rotating rod 6 to rotate. During the rotation process, the roller knife assembly applies a uniform extrusion force to the thin copper bar, causing the thin copper bar to gradually deform and finally form into the required arc-shaped special-shaped structure;

[0044] When the thickness of the thin copper busbar is thicker, if the rotating rod 6 is still kept in the initial position, the part of the roller cutter assembly located on the side away from the feed port 3 will generate too much squeezing force on the copper busbar during operation, which will easily cause the copper busbar to deform excessively, seriously affecting the forming quality of the copper core, causing deviations in shape and dimensional accuracy of the copper core, reducing product quality and making it difficult to ensure product consistency. Therefore, when the thickness of the thin copper busbar is thicker, the position of the rotating rod 6 must be adjusted in time to keep a suitable distance between the roller cutter assembly and the copper busbar, ensuring that the extrusion force applied by the roller cutter assembly to the copper busbar is moderate during the processing, ensuring that the copper busbar is formed according to the predetermined shape and size, thereby improving product quality and consistency.

[0045] The copper core after extrusion forming will enter the subsequent processing equipment in sequence. First, the copper core enters the first coating machine 1. The first coating machine 1 is responsible for performing the first coating operation on the copper core. During this process, the inner heat dissipation layer is coated to ensure that the copper core has good heat dissipation performance. The copper core that completes the first coating then enters the second coating machine 2. The second coating machine 2 performs the second coating operation. This is mainly to complete the coating of the insulation layer to provide reliable insulation protection for the cable. After the insulation layer is coated, the armor layer can be selected according to the specific needs of the product to enhance the mechanical strength and protective performance of the cable. After the armor layer is coated, the outer sheath layer is installed on the cable to complete the entire cable processing flow.

[0046] In order to meet the diverse production needs, for example, Figure 6 、 Figure 7 、 Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 、 Figure 13As shown, the present invention also includes a roller cutter assembly including a sleeve 7 slidably connected to a rotating rod 6, and a first squeezing roller 8 and a second squeezing roller 9 mounted on the sleeve 7. A side of the housing 5 is provided with a vertically arranged slide 10 corresponding to the two ends of the rotating rod 6. The end of the rotating rod 6 close to the driving mechanism passes through the slide 10 and is slidably connected to the slide 10. The ends of the rotating rod 6 and the sleeve 7 away from each other are both connected to the housing 5 via a telescopic mechanism.

[0047] The first squeezing roller 8 is provided with a plurality of groups of circular arc-shaped annular grooves, and the second squeezing roller 9 is provided with a plurality of groups of trapezoidal annular grooves.

[0048] During use, the desired forming shape is determined according to product design requirements, and the sleeve 7 is driven to slide along the rotating rod 6, and the first squeezing roller 8 with an arc-shaped annular groove installed on the sleeve 7 is moved to a suitable processing position; if a trapezoidal squeezing effect is required, the second squeezing roller 9 is moved to the corresponding working position. In this process, the movement of the sleeve 7 realizes the selection of the appropriate roller body, meeting diverse production needs;

[0049] At the same time, the conveying assembly smoothly feeds the thin copper bar from the feed port 3 into the housing 5. During the copper bar conveying process, the telescopic mechanism drives the rotating rod 6 at the corresponding position to move, thereby adjusting the position of the rotating rod 6 to ensure that the appropriate distance between the roller knife assembly and the thin copper bar is maintained;

[0050] The driving mechanism drives the rotating rod 6 to rotate, and then the first squeezing roller 8 or the second squeezing roller 9 installed on the sleeve 7 starts to rotate. If the first squeezing roller 8 is involved in the processing, the arc-shaped annular groove will extrude a precise arc shape on the thin copper busbar; if the second squeezing roller 9 is put into work, the trapezoidal annular groove will extrude a trapezoid that meets the requirements on the thin copper busbar, effectively ensuring the smooth progress of the production process, while ensuring the high quality and high consistency of the products.

[0051] In order to facilitate the operation of the drive roller cutter assembly, for example, Figure 3 、 Figure 6 As shown, the present invention also includes a driving structure including a turbine 17 connected to one end of the rotating rod 6, and a worm 18 arranged horizontally and meshing with the turbine 17 for transmission, both ends of the worm 18 are rotatably connected to a support plate 19 fixed to the outside of the shell 5, one end of the worm 18 is connected to the output end of the drive motor 20, and the drive motor 20 is mounted on the support plate 19.

[0052] When in use, the driving motor 20 drives the worm 18 to rotate, and the worm 18 drives the turbine 17 to rotate synchronously, and the turbine 17 drives the rotating rod 6 and the sleeve 7 mounted on the rotating rod 6 to rotate together, and the roller cutter assembly installed on the sleeve 7 enters the working state to extrude the thin copper bar;

[0053] During the extrusion process, the roller-cutter assembly applies uniform extrusion pressure to the thin copper busbar. The extrusion pressure causes the thin copper busbar to gradually undergo plastic deformation according to the predetermined design requirements, and finally form it into the required arc-shaped special-shaped structure or trapezoid.

[0054] In order to improve the overall performance and service life of the cable, for example, Figure 2 、 Figure 6 、 Figure 7 、 Figure 8 As shown, the present invention also includes an eddy current heating ring 21 provided between adjacent sleeves 7, through which the thin copper busbar passes; and the top of the side of the shell 5 away from the feed port 3 is connected to an inert gas inlet connector 22.

[0055] During use, before the thin copper bar starts to be conveyed, the eddy current heating ring 21 is first turned on. The thin copper bar is conveyed by the conveying assembly and passes through the eddy current heating ring 21. At the same time, the inert gas valve connected to the air inlet connector 22 is opened to allow the inert gas to enter the interior of the housing 5 through the air inlet connector 22. The eddy current heating ring 21 heats the thin copper bar, thereby increasing the temperature of the thin copper bar and enhancing the plasticity of the material. When the roller cutter assembly extrude the thin copper bar, the thin copper bar is more likely to deform, thereby reducing the extrusion force required and reducing the wear of the equipment.

[0056] The inert gas introduced from the air inlet connector 22 fills the interior of the housing 5, forming an inert gas shield around the thin copper busbar. This layer of protective gas can effectively isolate oxygen in the air, preventing the thin copper busbar from being oxidized during the heating and extrusion process, ensuring that the conductivity and other physical and chemical properties of the thin copper busbar are not affected, thereby improving the overall performance and service life of the cable.

[0057] When the gas enters the shell 5 through the air inlet connector 22, part of the gas will naturally be discharged from the outlet 4 because the air inlet connector 22 is located close to the outlet 4. The discharged gas forms an airflow at the outlet 4, which plays a role in dissipating air and dissipating heat for the thin copper busbar that has been shaped. On the one hand, it can promptly take away the excess heat generated by the thin copper busbar during the shaping process, and prevent the internal structure of the thin copper busbar from changing or affecting the subsequent processing quality due to excessive temperature; on the other hand, this airflow does not reduce the temperature of the thin copper busbar indefinitely, but keeps the thin copper busbar within a certain suitable temperature range, so that the thin copper busbar enters the first coating machine 1 for preheating. The appropriate preheating temperature helps to improve the fit between the coating material and the thin copper busbar, so that the inner heat dissipation layer can be more tightly and evenly attached to the surface of the thin copper busbar during the coating process, thereby enhancing the heat dissipation effect while improving the performance and quality of the entire cable, ensuring the continuity and efficiency of the cable production process.

[0058] In order to ensure the sealing of the housing 5, for example, Figure 2 、 Figure 5 、 Figure 6 、 Figure 9 、 Figure 10 As shown, the present invention further includes an adjustment structure including a vertically arranged movable plate 12, one end of the sleeve 7 is slidably connected to one side of the movable plate 12, a side of the movable plate 12 away from the sleeve 7 is fixedly connected to an electric hydraulic telescopic rod 13, and a fixed end of the electric hydraulic telescopic rod 13 is fixedly connected to a vertically arranged support leg 14;

[0059] One end of the rotating rod 6 is fixedly connected to the first sealing plate 15, and one end of the sleeve 7 is slidably connected to the second sealing plate 16. The second sealing plate 16 is slidably connected to the outer side of the shell 5. The first sealing plate 15 and the second sealing plate 16 respectively correspond to the sliding grooves 10 on both sides of the shell 5.

[0060] During use, in order to meet different processing requirements, the position of the sleeve 7 in the roller cutter assembly needs to be adjusted. At this time, the electric hydraulic telescopic rod 13 can be started to drive the movable plate 12 to move. Driven by the movable plate 12, the sleeve 7 will slide smoothly along the rotating rod 6, thereby accurately moving the first squeezing roller 8 or the second squeezing roller 9 installed on the sleeve 7 to the appropriate processing position;

[0061] During the movement of the sleeve 7, the sleeve 7 maintains a sliding connection with the second sealing plate 16. During this period, the first sealing plate 15 and the second sealing plate 16 respectively cooperate with the slide grooves 10 on both sides of the shell 5 to maintain the sealing of the inner wall of the shell 5, preventing external dust, impurities and other pollutants from entering the shell 5, ensuring the environment for the extrusion molding of the copper core and ensuring the molding quality of the copper core;

[0062] In addition, when the telescopic mechanism drives the rotating rod 6 to adjust its position in the vertical direction, the corresponding relationship between the first sealing plate 15 and the second sealing plate 16 and the slide groove 10 can continuously ensure the sealing of the inner wall of the shell 5, and avoid the closed environment inside the shell 5 from being destroyed due to the movement of the rotating rod 6. At the same time, when the rotating rod 6 moves, one end of the sleeve 7 is slidably connected to one side of the movable plate 12, so as to facilitate the adjustment of the position of the rotating rod 6.

[0063] In order to ensure the molding quality of the copper core, for example, Figure 2 、 Figure 3 、 Figure 4 As shown in the figure, the present invention also includes several groups of horizontally distributed conveying rollers 23 provided on the upper and lower sides of the shell 5 near the feed port 3, and the two ends of the conveying rollers 23 are rotatably connected to vertically arranged moving rods 24. A horizontally arranged mounting plate 25 is fixedly connected to the outer side of the shell 5, and a movable groove 26 is provided on the mounting plate 25. One end of the moving rod 24 passes through the movable groove 26 and is fixedly connected to an extrusion plate 27. An extrusion spring 28 is provided on the side of the mounting plate 25 close to the extrusion plate 27, and a pressing control device for controlling the telescopic mechanism is provided between the mounting plate 25 and the extrusion plate 27.

[0064] When in use, the thin copper busbar is transported by the conveying roller 23, and the thin copper busbar to be processed is transported into the housing 5 for shaping processing;

[0065] If the thickness of the thin copper busbar is thin, the telescopic mechanism does not adjust the position of the rotating rod 6, and the roller-cutting assembly can apply extrusion force to the thin copper busbar to meet the forming requirements of the copper core; however, if the thickness of the thin copper busbar is thick, the surface of the thin copper busbar squeezes the conveying roller 23 and drives the conveying roller 23 to move. When the conveying roller 23 moves, it relies on the moving rod 24 to drive the extrusion plate 27 to move upward synchronously. At the same time, when the extrusion plate 27 moves upward, it drives the extrusion spring 28 to store force. When the extrusion plate 27 moves to different heights, the pressing control device drives the corresponding telescopic mechanism to work, and relies on the corresponding telescopic mechanism to drive the corresponding rotating rod 6 to move, so that the rotating rods 6 with a smaller upper and lower spacing are separated from each other, so that the corresponding roller-cutting assembly does not contact the thin copper busbar, avoiding the thin copper busbar from being damaged by excessive extrusion, ensuring that the thicker thin copper busbar is gradually shaped according to the preset shape and size, and ensuring the forming quality of the copper core.

[0066] In order to ensure that the thin copper bar can be processed and formed under the appropriate number of roller cutter assemblies, for example, Figure 2 、 Figure 3 、 Figure 5 、 Figure 10 As shown, the present invention also includes a telescopic mechanism including a movable cylinder 29 vertically fixed on both sides of the housing 5, two groups of horizontally arranged electromagnets 30 are slidably connected in the movable cylinder 29, and the two groups of electromagnets 30 are magnetically attracted in the initial state. A vertically arranged movable rod 31 is provided on the side away from the electromagnet 30, and a return spring 32 is fixedly connected between the side of the electromagnet 30 close to the movable rod 31 and the inner wall of the piston cylinder, a first sliding ring 33 fixedly connected to the end of the movable rod 31 is slidably connected to the rotating rod 6, and a second sliding ring 34 fixedly connected to the end of the movable rod 31 is slidably connected to the sleeve 7;

[0067] The pressing control device includes a plurality of pressing switches 35 arranged on the upper surface of the mounting plate 25 . The lower surface of the extrusion plate 27 is in pressing contact with the pressing switches 35 . The pressing switches 35 are used to control the electromagnet 30 .

[0068] During use, when the thin copper busbar is conveyed into the housing 5 by the conveying roller 23 for processing, if the thin copper busbar is thin, the extrusion plate 27 will not exert sufficient pressure on the press switch 35, the electromagnet 30 is in the initial state, the first sliding ring 33 and the second sliding ring 34 on the rotating rod 6 and the sleeve 7 remain in the same position, and the roller-cutter assembly normally applies extrusion force to the copper busbar to perform shaping processing;

[0069] When the pressing plate 27 moves to a certain position, it no longer presses the corresponding pressing switch 35, and the pressing switch 35 is triggered to turn off the electromagnet 30 in the corresponding movable cylinder 29. After the magnetic attraction of the electromagnet 30 is turned off, the two sets of electromagnets 30 are no longer magnetically attracted. At the same time, under the elastic force of the return spring 32, the electromagnet 30 drives the movable rod 31 connected thereto to move. The movement of the movable rod 31 will cause the first sliding ring 33 on the rotating rod 6 and the second sliding ring 34 on the sleeve 7 to be displaced, thereby driving the rotating rod 6 and the sleeve 7 to adjust their positions, thereby increasing the distance between the roller cutter assembly and the thick copper bar, avoiding the roller cutter assembly with a smaller spacing from generating an extrusion force on the thin copper bar, and ensuring that the thin copper bar can be processed and formed under the appropriate number of roller cutter assemblies;

[0070] When the processed thin copper busbar is separated from the conveying roller 23, the squeezing force of the copper busbar on the conveying roller 23 is eliminated. At this time, the elastic potential energy of the squeezing spring 28 is released, and after driving the squeezing plate 27 to return to its initial state, the lower surface of the squeezing plate 27 is squeezed against the press switch 35 again, triggering the press switch 35, and then starting the electromagnet 30 in the corresponding movable cylinder 29. After the electromagnet 30 is energized, magnetism is generated, and the two groups of electromagnets 30 are attracted to each other. The adsorption force causes the movable rod 31 to move. The movement of the movable rod 31 drives the first sliding ring 33 on the rotating rod 6 and the second sliding ring 34 on the sleeve 7 to move synchronously, thereby restoring the rotating rod 6 and the sleeve 7 to their initial relative positions, and finally realizing the reset of the roller pressing assembly to the initial working state, preparing for a subsequent round of thin copper busbar processing.

[0071] For example, Figure 2 、 Figure 4 As shown, the present invention also includes two groups of conical air outlet shells 36 symmetrically arranged above and below the shell 5 near the feed port 3, and the contraction sections of the conical air outlet shells 36 are provided with air outlets 37 for blowing air to the thin copper busbar, and the conical air outlet shells 36 are connected to the interior of the shell 5.

[0072] During use, after the inert gas enters the housing 5 through the air inlet connector 22, part of the inert gas is discharged from the discharge port 4. In the process of escaping from the housing 5, the surface of the thin copper busbar that has been shaped is subjected to a heat dissipation effect, which can promptly remove the heat accumulated in the thin copper busbar during the shaping process, effectively controlling the temperature of the thin copper busbar and avoiding changes in the material properties of the thin copper busbar due to excessive temperature.

[0073] Another part of the inert gas is discharged from the conical air outlet shell 36. Since the air outlet 37 of the conical air outlet shell 36 is facing the thin copper busbar, the gas will directly act on the surface of the thin copper busbar when it is discharged. The flowing inert gas generates sufficient impact force to effectively blow off various impurities adsorbed by the thin copper busbar during the feeding stage, such as dust and debris, effectively preventing impurities from entering subsequent processing links, avoiding impurities from interfering with the extrusion molding, coating and other processes of the thin copper busbar, optimizing the entire cable production process, and improving the reliability and stability of the product.

[0074] For example, Figure 3 、 Figure 6 、 Figure 7 、 Figure 8 As shown, the present invention also includes that an auxiliary roller 38 symmetrically arranged up and down is connected to one side of the shell 5 near the discharge port 4; a vertically arranged positioning roller 39 is provided between the left and right adjacent sleeves 7, and the positioning roller 39 is in rolling contact with both sides of the thin copper busbar, and the two ends of the positioning roller 39 are rotatably connected to the connecting rod 11, and the end of the connecting rod 11 away from the positioning roller 39 is fixedly connected to the inner wall of the shell 5.

[0075] When in use, the positioning roller 39 plays a positioning role on the thin copper bar by rolling contact with both sides of the thin copper bar, preventing the thin copper bar from being offset or misaligned during the extrusion process, thereby improving the accuracy of the thin copper bar extrusion molding;

[0076] The auxiliary roller 38 is located near the discharge port 4 and plays an auxiliary output role for the thin copper busbar that is about to be processed. It can share part of the friction force of the thin copper busbar during the discharge process, so that the thin copper busbar can be sent out from the discharge port 4 more smoothly, avoiding surface scratches or deformation of the thin copper busbar due to excessive resistance during discharge, thereby improving the surface quality and production efficiency of the product.

[0077] The present invention also provides a method for overmolding a flat flexible energy-saving cable with a special-shaped copper core, which uses the above-mentioned flat flexible energy-saving cable with a special-shaped copper core overmolding device, and specifically includes the following steps:

[0078] Step 1: Place the thin copper busbar near the feed port 3 of the copper core extrusion molding device, start the conveying component of the copper core extrusion molding device, and convey the thin copper busbar from the feed port 3 to the housing 5 through the conveying component;

[0079] Step 2: The driving mechanism drives the rotating rod 6 to rotate, driving the roller cutter assembly to extrude the thin copper busbar, so that the thin copper busbar gradually forms a special-shaped copper core during the conveying process, and the processed special-shaped copper core is sent out from the discharge port 4;

[0080] Step 3: The special-shaped copper core sent out from the discharge port 4 of the copper core extrusion molding device is transported to the first coating machine 1. The first coating machine 1 performs a coating operation on the special-shaped copper core to complete the coating of the inner heat dissipation layer on the surface of the special-shaped copper core;

[0081] Step 4: The shaped copper core that has been coated for the first time is transported to the second coating machine 2. The second coating machine 2 performs a coating operation on the shaped copper core that has been coated for the first time again, and completes the coating of the insulation layer on the basis of the first coating.

[0082] When the present invention is in use, the eddy current heating ring 21 is turned on, and the inert gas valve connected to the air inlet connector 22 is opened, so that the inert gas fills the interior of the housing 5 to form a protective atmosphere, and at the same time preheats the subsequent thin copper busbar to enhance the plasticity of the material;

[0083] According to product design requirements, if an arc-shaped extrusion effect is required, the electric hydraulic telescopic rod 13 is activated to drive the movable plate 12 to move, so that the sleeve 7 slides along the rotating rod 6, and the first extrusion roller 8 is moved to the appropriate processing position; if a trapezoidal extrusion effect is required, the second extrusion roller 9 is moved to the working position; during the adjustment process, the first sealing plate 15 and the second sealing plate 16 cooperate with the slide grooves 10 on both sides of the shell 5 to maintain the sealing of the shell 5;

[0084] The thin copper busbar is placed on the conveying roller 23 and smoothly conveyed into the housing 5 by the rotation of the conveying roller 23. During the conveying process, if the thickness of the thin copper busbar is relatively thin, the telescopic mechanism does not adjust the position of the rotating rod 6, and the roller-knife assembly can apply extrusion force to the thin copper busbar to meet the forming requirements of the copper core.

[0085] When the pressing plate 27 moves to a certain position, it no longer presses the corresponding pressing switch 35, and the pressing switch 35 is triggered to turn off the electromagnet 30 in the corresponding movable cylinder 29. After the magnetic attraction of the electromagnet 30 is turned off, the two sets of electromagnets 30 are no longer magnetically attracted. At the same time, under the elastic force of the return spring 32, the electromagnet 30 drives the movable rod 31 connected thereto to move. The movement of the movable rod 31 will cause the first sliding ring 33 on the rotating rod 6 and the second sliding ring 34 on the sleeve 7 to be displaced, thereby driving the rotating rod 6 and the sleeve 7 to adjust their positions, thereby increasing the distance between the roller cutter assembly and the thick copper bar, avoiding the roller cutter assembly with a smaller spacing from generating an extrusion force on the thin copper bar, and ensuring that the thin copper bar can be processed and formed under the appropriate number of roller cutter assemblies;

[0086] The drive motor 20 is started, and the drive motor 20 drives the worm 18 to rotate, and the worm 18 drives the turbine 17 to rotate synchronously, thereby driving the rotating rod 6 and the sleeve 7 sleeved on the rotating rod 6 to rotate together, so that the roller cutter assembly performs an extrusion operation on the thin copper bar;

[0087] The inert gas introduced from the air inlet connector 22 fills the interior of the housing 5, forming an inert gas shield around the thin copper busbar. This layer of protective gas can effectively isolate oxygen in the air, preventing the thin copper busbar from being oxidized during the heating and extrusion process, ensuring that the conductivity and other physical and chemical properties of the thin copper busbar are not affected, thereby improving the overall performance and service life of the cable.

[0088] When the gas enters the shell 5 through the air inlet connector 22, part of the gas will naturally be discharged from the discharge port 4 because the air inlet connector 22 is located close to the discharge port 4. The discharged gas forms an airflow at the discharge port 4, which plays a role in dissipating air and dissipating heat for the thin copper busbar that has been shaped. On the one hand, it can promptly take away the excess heat generated by the thin copper busbar during the shaping process, and prevent the internal structure of the thin copper busbar from changing or affecting the subsequent processing quality due to excessive temperature; on the other hand, this airflow does not reduce the temperature of the thin copper busbar indefinitely, but keeps the thin copper busbar within a certain suitable temperature range, so that the thin copper busbar enters the first coating machine 1 for preheating. The appropriate preheating temperature helps to improve the fit between the coating material and the thin copper busbar, so that the inner heat dissipation layer can be more tightly and evenly attached to the surface of the thin copper busbar during the coating process, thereby enhancing the heat dissipation effect while improving the performance and quality of the entire cable, and ensuring the consistency and efficiency of the cable production process;

[0089] At the same time, another portion of the inert gas is discharged from the conical air outlet housing 36. Since the air outlet 37 of the conical air outlet housing 36 faces the thin copper busbar, the gas will directly act on the surface of the thin copper busbar when it is discharged. The flowing inert gas generates sufficient impact force to effectively blow off various impurities adsorbed by the thin copper busbar during the feeding stage, such as dust and debris, effectively preventing the impurities from entering the subsequent processing links and avoiding interference with the thin copper busbar extrusion molding, coating and other processes.

[0090] The copper core after extrusion forming will enter the subsequent processing equipment in sequence. First, the copper core enters the first coating machine 1. The first coating machine 1 is responsible for performing the first coating operation on the copper core. During this process, the inner heat dissipation layer is coated to ensure that the copper core has good heat dissipation performance. The copper core that completes the first coating then enters the second coating machine 2. The second coating machine 2 performs the second coating operation. This is mainly to complete the coating of the insulation layer to provide reliable insulation protection for the cable. After the insulation layer is coated, the armor layer can be selected according to the specific needs of the product to enhance the mechanical strength and protective performance of the cable. After the armor layer is coated, the outer sheath layer is installed on the cable to complete the entire cable processing flow.

[0091] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above-described embodiments. The above-described embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A flat flexible energy-saving cable special-shaped copper core overmolding device, characterized in that: The invention comprises a copper core extrusion molding device, a first coating machine (1), and a second coating machine (2) which are sequentially arranged along the conveying direction of the thin copper bar; the copper core extrusion molding device comprises a shell (5) with a feed port (3) and a discharge port (4) respectively provided on both sides; the upper and lower parts of the inner side of the shell (5) are movably connected with a plurality of rotating rods (6) distributed along the conveying direction of the thin copper bar; the spacing between the upper and lower adjacent rotating rods (6) gradually decreases along the conveying direction of the thin copper bar; a roller knife assembly is slidably connected to the rotating rod (6); a driving mechanism is provided on the side of the shell (5) for driving the rotating rod (6) to rotate after the rotating rod (6) moves toward the thin copper bar; a conveying assembly for conveying the copper core is provided on the side of the shell (5) close to the feed port (3); The roller cutter assembly comprises a sleeve (7) slidably connected to a rotating rod (6), and a first squeezing roller (8) and a second squeezing roller (9) mounted on the sleeve (7); a side of the housing (5) is provided with a vertically arranged slide groove (10) corresponding to the two ends of the rotating rod (6); an end of the rotating rod (6) close to the driving mechanism passes through the slide groove (10) and is slidably connected to the slide groove (10); and the ends of the rotating rod (6) and the sleeve (7) away from each other are both connected to the housing (5) via a telescopic mechanism; The first squeezing roller (8) is provided with a plurality of groups of circular arc-shaped annular slots, and the second squeezing roller (9) is provided with a plurality of groups of trapezoidal annular slots.

2. A flat flexible energy-saving cable special-shaped copper core overmolding device according to claim 1, characterized in that: The driving structure includes a worm wheel (17) connected to one end of the rotating rod (6), and a worm (18) arranged horizontally and meshing with the worm wheel (17) for transmission. Both ends of the worm (18) are rotatably connected to a support plate (19) fixed to the outside of the housing (5). One end of the worm (18) is connected to the output end of the driving motor (20), and the driving motor (20) is mounted on the support plate (19).

3. A flat flexible energy-saving cable special-shaped copper core overmolding device according to claim 2, characterized in that: An eddy current heating ring (21) is provided between adjacent sleeves (7), and a thin copper bar passes through the eddy current heating ring (21); and the top of the side of the shell (5) away from the feed port (3) is connected to an inert gas inlet connector (22).

4. A flat flexible energy-saving cable special-shaped copper core overmolding device according to claim 3, characterized in that: The adjustment structure includes a vertically arranged movable plate (12), one end of the sleeve (7) is slidably connected to one side of the movable plate (12), a side of the movable plate (12) away from the sleeve (7) is fixedly connected to an electric hydraulic telescopic rod (13), and a fixed end of the electric hydraulic telescopic rod (13) is fixedly connected to a vertically arranged support leg (14); One end of the rotating rod (6) is fixedly connected to a first sealing plate (15), one end of the sleeve (7) is slidably connected to a second sealing plate (16), the second sealing plate (16) is slidably connected to the outer side of the shell (5), and the first sealing plate (15) and the second sealing plate (16) respectively correspond to the sliding grooves (10) on both sides of the shell (5).

5. A flat flexible energy-saving cable special-shaped copper core overmolding device according to claim 4, characterized in that: A plurality of groups of horizontally distributed conveying rollers (23) are provided on the upper and lower sides of the housing (5) near the feed port (3), and the two ends of the conveying rollers (23) are rotatably connected to vertically arranged moving rods (24). A horizontally arranged mounting plate (25) is fixedly connected to the outer side of the housing (5), and a movable groove (26) is provided on the mounting plate (25). One end of the moving rod (24) passes through the movable groove (26) and is fixedly connected to an extrusion plate (27). An extrusion spring (28) is provided on the side of the mounting plate (25) close to the extrusion plate (27), and a pressing control device for controlling the telescopic mechanism is provided between the mounting plate (25) and the extrusion plate (27).

6. A flat flexible energy-saving cable special-shaped copper core overmolding device according to claim 5, characterized in that: The telescopic mechanism includes a movable cylinder (29) vertically fixed on both sides of the housing (5), two groups of horizontally arranged electromagnets (30) are slidably connected in the movable cylinder (29), the two groups of electromagnets (30) are magnetically adsorbed in the initial state, and a vertically arranged movable rod (31) is provided on the side away from the electromagnet (30), a return spring (32) is fixedly connected between the side of the electromagnet (30) close to the movable rod (31) and the inner wall of the piston cylinder, a first sliding ring (33) fixedly connected to the end of the movable rod (31) is slidably connected to the rotating rod (6), and a second sliding ring (34) fixedly connected to the end of the movable rod (31) is slidably connected to the sleeve (7); The pressing control device includes a plurality of pressing switches (35) arranged on the upper surface of the mounting plate (25), the lower surface of the extrusion plate (27) is in pressing contact with the pressing switches (35), and the pressing switches (35) are used to control the electromagnet (30).

7. A flat flexible energy-saving cable special-shaped copper core overmolding device according to claim 6, characterized in that: Two groups of tapered air outlet shells (36) are symmetrically arranged on the upper and lower sides of the shell (5) near the feed port (3). The contraction sections of the tapered air outlet shells (36) are each provided with an air outlet (37) for blowing air toward the thin copper bar. The tapered air outlet shells (36) are connected to the interior of the shell (5).

8. A flat flexible energy-saving cable special-shaped copper core overmolding device according to claim 7, characterized in that: An auxiliary roller (38) symmetrically arranged in an upper and lower direction is connected to one side of the housing (5) near the discharge port (4); a vertically arranged positioning roller (39) is provided between the left and right adjacent sleeves (7), the positioning roller (39) is in rolling contact with both sides of the thin copper bar, and both ends of the positioning roller (39) are rotatably connected to a connecting rod (11), and the end of the connecting rod (11) away from the positioning roller (39) is fixedly connected to the inner wall of the housing (5).

9. A method for overmolding a flat, flexible, energy-saving cable with a special-shaped copper core, using the apparatus for overmolding a flat, flexible, energy-saving cable with a special-shaped copper core according to any one of claims 1 to 8, comprising the following steps: Step 1: Place the thin copper busbar near the feed port (3) of the copper core extrusion molding device, start the conveying component of the copper core extrusion molding device, and convey the thin copper busbar from the feed port (3) to the housing (5) through the conveying component; Step 2: The driving mechanism drives the rotating rod (6) to rotate, driving the roller cutter assembly to extrude the thin copper bar, so that the thin copper bar gradually forms a special-shaped copper core during the conveying process, and the processed special-shaped copper core is sent out from the discharge port (4); Step 3: The special-shaped copper core sent out from the discharge port (4) of the copper core extrusion molding device is transported to the first coating machine (1), and the first coating machine (1) performs a coating operation on the special-shaped copper core to complete the coating of the inner heat dissipation layer on the surface of the special-shaped copper core; Step 4: transport the shaped copper core that has been coated for the first time to the second coating machine (2). The second coating machine (2) performs a coating operation on the shaped copper core that has been coated for the first time again, and completes the coating of the insulation layer on the basis of the first coating.

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