Continuous production process for wrapping preforming and squaring integrated film-covered wire

Abstract

The invention relates to a continuous production process of a wrapping preforming and squaring integrated film-covered wire, and belongs to the technical field of composite material forming. Comprising a pay-off machine, a coating machine, a squaring machine, a first lead assembly, a first pressing assembly and a curing assembly, and the production process comprises the following steps that S10, raw materials are paid off; step S20, coating with an adhesive tape; step S30, carrying out pre-pressing treatment; and S40, winding output and wire rod squaring treatment are carried out. The technical problems that in the prior art, wire rods need to be wound and output through a wire winding machine between the wire rod coating process and the die pressing process, multiple times of wire arrangement are needed, production is not continuous enough, and consequently the production efficiency is reduced are solved.

Description

Technical Field

[0001] The invention belongs to the technical field of composite material forming, and in particular relates to a continuous production process for a film-wrapped wire integrating wrapping preforming and squaring. Background Art

[0002] The film-wrapped wire is covered with an insulating layer through multiple coating processes, and the outer layer structure is plastically extruded through a square pressing die. The square wire can effectively reduce the skin effect and the loss of high-frequency current, and can further increase the slot fill rate and space volume ratio of the coil.

[0003] Patent publication number CN215342100U discloses a novel film-covered wire, comprising a conductor and an insulating film covering the outer periphery thereof, wherein the conductor is formed by twisting a plurality of enameled wires; and the cross section of the film-covered wire is square.

[0004] Patent publication number CN217290202U discloses a wire flattening tool, relating to the field of processing technology. The tool comprises an upper die base, within which an upper die core is disposed; and a lower die base, within which a lower die core is disposed. When the upper and lower die bases are in contact, a gap is formed between the upper and lower die cores to accommodate the wire. The upper and lower die bases are connected by guide posts, and the upper die base can move along the guide posts toward or away from the lower die base.

[0005] The existing technology has at least the following problems during use:

[0006] During the processing of square wires, a winding machine is required to reel and output the wires between the processes of coating the wires and pressing the molds. This requires multiple wire sorting processes, resulting in discontinuous production and reduced production efficiency. Summary of the Invention

[0007] The present invention provides a continuous production process for film-wrapped wire that integrates wrapping, preforming and square pressing, which is used to solve the technical problems in the prior art that a winding machine is required to wind and output the wire between the processes of coating the wire and pressing the mold, multiple wire sorting is required, production is not continuous, and production efficiency is reduced.

[0008] In order to achieve the above object, the present invention is implemented by the following technical solutions:

[0009] The following steps are involved:

[0010] Step S10: untwisting and unwinding the raw material using a pay-off machine, and outputting the raw material from a first output port of the pay-off machine through a first lead assembly;

[0011] Step S20: tape wrapping, inputting the wire material processed in step S10 from the second input port of the wrapping machine and performing a wrapping process on the wire material;

[0012] Step S30: pre-pressing treatment, using a first pressing component to press the wrapped wire for the first time, and then using a curing component to cure the preformed wire;

[0013] Step S40 , forming, winding and outputting, using a square press to perform a second square forming process on the solidified wire material, and finally outputting the finished wire material through the third output port of the square press.

[0014] Furthermore, the equipment used includes: a wire take-up machine having multiple winding sections and auxiliary sections, the wire take-up machine is rotatably arranged outside the third output port, the winding section winds the wire, and the auxiliary section is used to guide the switching between the multiple winding sections; a diameter gauge is arranged on the square press, for detecting the wire processed by the square press; a meter machine is arranged on the square press, for measuring the wire output by the square press; a spark machine is arranged on the square press, for online detection of the wire output by the square press.

[0015] Furthermore, the step S30 further includes the following steps:

[0016] Step S31: the first pressing assembly performs preliminary pressing on the wrapped wire to perform preliminary plasticization on the wrapped wire;

[0017] Step S32: the curing assembly heats and cures the plasticized wire material to preliminarily fix the shape of the wire material;

[0018] Step S33: transferring the preformed wire material in step S32 from the second output port to the third input port.

[0019] Furthermore, the step S40 includes the following steps:

[0020] Step S41: The square pressing machine is provided with a second pressing assembly, and the second pressing assembly further solidifies the solidified wire material;

[0021] Step S42: monitoring and controlling the final pressed size of the wire rod by the caliper;

[0022] Step S43: Using the spark machine, perform defect detection on the wire after measuring the outer diameter;

[0023] Step S44: Using the meter counter, the length of the wire after being inspected by the spark machine is detected and controlled.

[0024] Furthermore, the step S40 further includes the following steps:

[0025] Step S45: the winding unit winds up the processed wire;

[0026] Step S46: Control the total winding length D0 of each winding section by setting the meter counter, set a transition threshold N, and perform real-time comparison of the length D of the wire passing through the meter counter;

[0027] Step S47: When the length D reaches the transition threshold N, the wire take-up machine is rotated to drive the auxiliary part to contact the wire, and the auxiliary part guides the wire to the other idle winding part;

[0028] Step S48: When the length D reaches the total winding length D0, the auxiliary part is started for slitting, the fully loaded winding part is taken off the line, and the unloaded winding part is started for the next round of winding.

[0029] Furthermore, a guide is provided at the second output port of the coating machine for guiding the wire from the second output port into the third input port.

[0030] The present invention provides a continuous production process for film-wrapped wires that integrates wrapping, preforming, and squaring, and has the following beneficial effects:

[0031] By setting up a wire-unwinding machine, a coating machine and a square pressing machine, and configuring a first lead assembly, a first pressing assembly and a curing assembly, continuous production of film-wrapped wire with integrated wrapping preforming and square pressing is achieved, which reduces the process connection time and improves production efficiency; by setting up a diameter gauge, a meter counter and a spark machine on the square pressing machine, the size detection, length measurement and defect detection of the wire after square pressing are achieved, thereby ensuring the quality of the wire; by setting up multiple winding sections and auxiliary sections on the wire-rewinding machine, combined with the real-time comparison and control of the winding length by the meter counter, automatic switching of the winding section, wire guidance and slitting are achieved, thereby improving the degree of winding automation and production continuity; by setting up a take-up machine at the second output port of the coating machine to guide the wire transmission, and the first pressing assembly to perform preliminary pressing and heat curing in steps, the pre-forming and curing of the wire is achieved, which provides a good foundation for subsequent square pressing and ensures the accuracy of the wire shape. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0033] Figure 1A schematic structural diagram of a film-wrapped wire device integrating wrapping, preforming, and squaring provided in an embodiment of the present invention;

[0034] Figure 2 A schematic structural diagram of a film-wrapped wire take-up machine with integrated wrapping, preforming, and squaring capabilities provided by an embodiment of the present invention;

[0035] Figure 3 A schematic flow chart of a continuous production process for integrated wrapping preforming and squaring provided in an embodiment of the present invention.

[0036] In the figure: 10-wire pay-off machine; 20-coating machine; 30-square pressing machine; 11-first lead assembly; 21-first pressing assembly; 31-curing assembly; 32-wire take-up machine; 321-winding section; 322-auxiliary section; 33-diameter gauge; 34-meter counter; 35-spark machine; 36-second pressing assembly. DETAILED DESCRIPTION

[0037] The embodiments of the present application are described in detail below with reference to the accompanying drawings.

[0038] In the description of this application, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.

[0039] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature specified as "first" or "second" may explicitly or implicitly include one or more of such features. Throughout this application, unless otherwise specified, "plurality" means two or more.

[0040] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "installation," "connection," and "connection" should be understood in a broad sense. For example, they can refer to welding, bolting, or riveting; fixed connection, detachable connection, or integral connection; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; or internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0041] Example:

[0042] like Figure 1 and Figure 2 As shown, the following steps are included:

[0043] Step S10: untwisting and unwinding the raw material using a pay-off machine 10, and outputting the raw material from a first output port of the pay-off machine 10 via a first lead assembly 11;

[0044] Step S20, tape wrapping, inputting the wire material processed in step S10 from the second input port of the wrapping machine 20, and performing a wrapping process on the wire material;

[0045] Step S30: pre-pressing treatment, using the first pressing assembly 21 to press the wrapped wire for the first time, and then using the curing assembly 31 to cure the preformed wire;

[0046] Step S40 , forming, winding and outputting, using the square pressing machine 30 to perform a second square pressing and forming process on the solidified wire material, and finally outputting the finished wire material through the third output port of the square pressing machine 30 .

[0047] In this embodiment, at the start of production, the control system parameters of the pay-off machine 10 are set, including the back-twisting device, which is set to 10 rpm-15 rpm. Those skilled in the art can make specific selections based on the production process of different types of wires to eliminate the internal stress of the raw materials during the pay-off process. At the same time, the pay-off tension is monitored in real time by a tension sensor to ensure that the wire is evenly paid out from the pay-off machine. The first lead assembly 11 consists of a guide wheel and a tension adjustment wheel. The guide wheel guides the direction of the wire, and the tension adjustment wheel further fine-tunes the wire tension to ensure that the wire is output in a stable state.

[0048] During the operation of the coating machine 20, after adding the coating tape, the wrapping angle and the wrapping speed are set. The specific parameters are a wrapping angle of 45°-60°. Those skilled in the art can make specific selections based on the production process of different types of wires. The wrapping speed is 20 rev / min-30 rev / min. Those skilled in the art can make specific selections based on the production process of different types of wires. The wire processed in step S10 is introduced from the second input port of the coating machine 20, and the coating machine 20 is started. The wire passes through the coating machine 20 driven by the traction device, and the wrapping mechanism of the coating machine 20 drives the tape to rotate around the wire to achieve wrapping processing of the wire.

[0049] Furthermore, as shown in the figure, the equipment also includes: a wire take-up machine 32, having multiple winding sections 321 and an auxiliary section 322, the wire take-up machine 32 is rotatably arranged outside the third output port, the winding section 321 winds the wire, and the auxiliary section 322 is used to guide the switching between the multiple winding sections 321; a diameter gauge 33, arranged on the square press 30, for detecting the wire processed by the square press 30; a meter machine 34, arranged on the square press 30, for measuring the wire output by the square press 30; a spark machine 35, arranged on the square press 30, for online detection of the wire output by the square press 30.

[0050] In this embodiment, the wire take-up machine 32 is located at the end of the production line, integrating multiple winding sections 321 and auxiliary guide sections, including floating guide rollers and tension compensators. The winding section 321 is equipped with a pneumatic clamping device, and the auxiliary section 322 is equipped with an infrared centering sensor to ensure the accuracy of wire guidance during winding and switching. The diameter gauge 33 is a laser non-contact diameter gauge 33, installed 100 mm in front of the third output port of the square press 30. It scans the cross-sectional dimensions of the wire in real time and can detect the side length and diagonal tolerance of square / rectangular sections. The meter counter 34 is a contact roller meter counter equipped with an encoder and PLC system for control. It simultaneously records the production line speed and cumulative length and has a meter pulse output function. The spark tester 35 is a power frequency AC spark tester with a detection electrode spacing of 50 mm. It can detect insulation layer defects online, with a leakage current threshold set to 10 mA and a response time of less than 0.1 second.

[0051] Furthermore, step S30 further includes the following steps:

[0052] Step S31: The first pressing assembly 21 performs preliminary pressing on the wrapped wire to perform preliminary plasticization on the wrapped wire;

[0053] Step S32: the curing component 31 heats and cures the plasticized wire material to preliminarily fix the shape of the wire material;

[0054] Step S33: transferring the wire material preformed in step S32 from the second output port to the third input port.

[0055] In this embodiment, in step S31, the wire is preliminarily pressed and shaped. When selecting the mold, an appropriate pre-pressing mold is selected according to the wire specifications, specifically including a circular to elliptical transition mold and a square chamfered pre-forming mold. The mold material is made of cemented carbide; during the gap calibration, the mold adjustment mechanism is driven by a servo motor to set the gap between the upper and lower molds to 85%-90% of the wire diameter; the hydraulic system pressure is adjusted according to the wire material and the number of coating layers. In the specific setting, the copper wire is set to 0.6MPa-0.8MPa, the aluminum wire is set to 0.4MPa-0.6MPa, and the pressure fluctuation is controlled within ±0.05 MPa, those skilled in the art can select specific parameters based on the production process of different types of wires; during the pressing operation, the PLC control system is first used to synchronize the linear speed of the pressing assembly with the outlet speed of the coating machine 20 to ensure that the wire enters the pressing area smoothly; during the shaping process, when the wire passes through the pre-pressing die, the upper and lower dies apply progressive pressure to gradually deform the circular cross-section into a square-like shape, while compacting the coating layer and eliminating interlayer bubbles; during the processing process, a laser displacement sensor is used to monitor the mold gap in real time. When the gap change is detected to be greater than 0.02mm, the pressure compensation mechanism is automatically triggered;

[0056] In step S32, it is first necessary to heat and cure to finalize the shape. During the parameter setting process of the curing component 31, the curing component 31 is divided into three heating zones, with the temperature of zone 1 being 180°C-200°C, zone 2 being 160°C-180°C, and zone 3 being 140°C-160°C, forming a gradient cooling structure to avoid stress concentration caused by sudden cooling. The heating method specifically adopts a far-infrared ceramic heating plate, and the residence time of the wire in the curing zone is controlled by adjusting the conveyor chain speed, which is specifically set to 20-40 seconds. Those skilled in the art can select specific parameters according to the production process of different types of wires; preheating start: preheat the curing component 31 for 30 minutes before starting the machine, so that each temperature zone reaches the set value and stabilizes before introducing the wire; when the wire passes through the heating zone, the adhesive in the coating layer undergoes a cross-linking reaction, and the curing shrinkage rate is controlled at 0.3%-0.5%, forming a stable preformed structure. After curing, the wire is quickly cooled to below 60°C through the air cooling channel to ensure that the shape is stable before entering the next process;

[0057] In step S33, the transmission is transitioned, and 5 groups of V-shaped guide wheels are set between the second output port and the third input port. The wheel groove radius is 0.2-0.3mm larger than the wire radius to reduce the risk of scratches during transmission; the magnetic powder brake is then used to control the transmission tension, and the tension value is set to 5N-8N. Those skilled in the art can select specific parameters based on the production process of different types of wires; the linear speed of the pressing assembly and the square press 30 is monitored in real time by the encoder. When the speed deviation is greater than 0.3%, the transmission motor speed is automatically adjusted to ensure that the wire is not stretched or relaxed; a buffer section with adjustable length is set in the middle of the transmission path. When the equipment starts and stops or the speed fluctuates, the buffer section automatically compensates to avoid sudden changes in the force on the wire; a dust suction device is set in the middle of the transmission path, and a negative pressure fan is used to remove metal debris and dust on the surface of the wire; a group of ion wind rods are installed before and after the guide wheel to eliminate static electricity on the surface of the wire and prevent adsorbed dust from affecting subsequent processing.

[0058] Furthermore, step S40 includes the following steps:

[0059] Step S41: The square pressing machine 30 includes a second pressing assembly 36, which further solidifies the solidified wire material.

[0060] Step S42: Monitor and control the final pressed size of the wire rod by using the caliper 33;

[0061] Step S43: Using the spark machine 35, the wire rod after the outer diameter is measured is subjected to defect detection;

[0062] Step S44 , the length of the wire after being inspected by the spark machine 35 is inspected and controlled by the meter counter 34 .

[0063] In this embodiment, the second pressing component 36 is deeply cured and formed, and the mold is divided into an actively driven upper mold and a floating supported lower mold. The gap adjustment is achieved by a servo electric cylinder, and the electro-hydraulic servo system is used to dynamically adjust according to the cross-sectional size of the preformed wire. The secondary pressing pressure is 1.5-2 times that of the initial pressing, and the holding time is 3-8 seconds. Those skilled in the art can select specific parameters according to the production process of different types of wires; a non-contact laser diameter gauge 33 is selected, and the specific model can be LDM-200, which is installed at the outlet of the square press 30. The detection light beam is perpendicular to the axis of the wire, and the detection data is transmitted to the PLC control system through the bus. A spark machine 35 is used to detect defects in the insulation layer; a high-precision contact meter wheel is used in combination with an incremental encoder for measurement, and the corresponding compensation parameters are set according to the surface roughness corresponding to the encapsulation process and the wire process.

[0064] Furthermore, step S40 further includes the following steps:

[0065] Step S45: The winding unit 321 winds the processed wire;

[0066] Step S46: The total winding length D0 of each winding section 321 is controlled by setting a meter counter 34, and a transition threshold N is set to perform a real-time comparison of the length D of the wire passing through the meter counter 34;

[0067] Step S47: When the length D reaches the transition threshold N, the wire take-up machine 32 is rotated to drive the auxiliary part 322 to contact the wire, and the auxiliary part 322 guides the wire to the other idle winding part 321;

[0068] Step S48: When the length D reaches the total winding length D0, the auxiliary part 322 is started for slitting, the fully loaded winding part 321 is taken off the line, and the unloaded winding part 321 is started for the next round of winding.

[0069] In this embodiment, the winding section 321 is specifically a winding roller that is rotatably arranged. The transition threshold value N is 95% of the total winding length D0. When the total winding length D0 of the winding roller is 600 meters, the length of the transition threshold value N is 570 meters. When the length D measured by the meter counter 34 is 570 meters, the wire take-up machine 32 is provided with a winding station and an output station. There are at least two groups of winding rollers, each of which is provided with an auxiliary part 322. The winding roller that performs winding work at the winding station is connected to the servo drive motor. When the winding section 321 on the winding station reaches 570 meters, the frame of the wire take-up machine 32 is started to rotate, thereby switching between the stations of the winding section 321, and switching the winding section 321 that has reached the threshold to the output station. The subsequent 5% of the wire is collected at the output station, and the position of the auxiliary part 322 is adjusted and moved, and the wire cutter is deployed at the cutting point in advance. When the meter counter 34 reaches 600 meters of the total winding length D0, the wire cutter in the auxiliary part 322 cuts the wire, and the guide wheel and pressure roller on the auxiliary part 322 guide the wire from the winding part 321 on the output station to the unloaded new winding part 321 on the winding station. After the full winding part 321 is at the output station, the pneumatic chuck on one side of the shaft is loosened, so that the entire winding part 321 rotates around the rotating column set on the other side of the winding roller shaft, and the wire on the winding roller is unloaded in conjunction with the clamping structure in the prior art.

[0070] Furthermore, a guide is provided at the second output port of the coating machine 20 for guiding the wire from the second output port into the third input port.

[0071] To sum up, by setting up a wire-unwinding machine 10, a coating machine 20 and a square pressing machine 30, and configuring a first lead assembly 11, a first pressing assembly 21 and a curing assembly 31, continuous production of film-wrapped wire with integrated wrapping preforming and square pressing is achieved, process connection time is reduced, and production efficiency is improved; by setting a diameter gauge 33, a metering machine 34 and a spark machine 35 on the square pressing machine 30, size detection, length measurement and defect detection of the wire after square pressing are achieved, and the quality of the wire is guaranteed; by setting multiple winding sections 321 and auxiliary sections 322 on the wire-rewinding machine 32, combined with the real-time comparison and control of the winding length by the metering machine 34, automatic switching, wire guiding and slitting of the winding section 321 are achieved, and the degree of winding automation and production continuity are improved; by setting a take-up machine at the second output port of the coating machine 20 to guide the wire transmission, and the first pressing assembly 21 performs preliminary pressing and heating curing in steps, the pre-forming curing of the wire is achieved, providing a good foundation for subsequent square pressing processing and ensuring the accuracy of the wire shape.

[0072] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications or substitutions that can be easily conceived by a person skilled in the art within the technical scope of the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be based on the scope of protection of the claims.

Claims

1. The continuous production process of film wrapping line integrating wrapping preforming and square pressing is characterized by: The following steps are involved: Step S10, unwinding the raw material using a wire unwinding machine (10), and outputting the raw material from a first output port of the wire unwinding machine (10) via a first lead assembly (11); Step S20, tape wrapping, inputting the wire material processed in step S10 from the second input port of the wrapping machine (20) and performing a wrapping process on the wire material; Step S30, pre-pressing treatment, using a first pressing component (21) to press the wrapped wire for the first time, and then using a curing component (31) to perform pre-forming curing; Step S40, forming, winding and outputting, using a square pressing machine (30) to perform a second square pressing and forming process on the solidified wire material, and finally outputting the finished wire material through the third output port of the square pressing machine (30).

2. The continuous production process of film-wrapped wire with integrated wrapping, preforming and squaring according to claim 1 is characterized in that: Equipment also used includes: A wire take-up machine (32) having a plurality of winding sections (321) and an auxiliary section (322), wherein the wire take-up machine (32) is rotatably arranged outside the third output port, the winding section (321) winds the wire, and the auxiliary section (322) is used to guide the switching between the plurality of winding sections (321); a diameter gauge (33), arranged on the square press (30), for testing the wire material processed by the square press (30); a meter counter (34), arranged on the square pressing machine (30), for measuring the wire rod output by the square pressing machine (30); The spark machine (35) is arranged on the square press (30) and is used for online detection of the wire rod output by the square press (30).

3. The continuous production process of film-wrapped wire with integrated wrapping, preforming and squaring according to claim 2 is characterized in that: The step S30 further includes the following steps: Step S31, the first pressing component (21) performs preliminary pressing on the wrapped wire material, and performs preliminary plasticization on the wrapped wire material; Step S32, the curing component (31) heats and cures the plasticized wire material to preliminarily fix the shape of the wire material; Step S33: transferring the wire material preformed in step S32 from the second output port of the coating machine (20) to the third input port of the square pressing machine (30).

4. The continuous production process of film-wrapped wire with integrated wrapping, preforming and squaring according to claim 3 is characterized in that: The step S40 includes the following steps: Step S41: the square pressing machine (30) is provided with a second pressing assembly (36), and the second pressing assembly (36) further solidifies the solidified wire material; Step S42: monitoring and controlling the final pressed size of the wire rod by means of the caliper (33); Step S43, using the spark machine (35), performing defect detection on the wire after measuring the outer diameter; Step S44: Length detection and control of the wire material after detection by the spark machine (35) is performed by the meter counter (34).

5. The continuous production process of film-wrapped wire with integrated wrapping, preforming and squaring according to claim 4 is characterized in that: The step S40 further includes the following steps: Step S45, the winding section (321) winds the processed wire; Step S46, controlling the total winding length D0 of each winding section (321) by setting the meter counter (34), setting a transition threshold N, and performing a real-time comparison of the length D of the wire passing through the meter counter (34); Step S47: When the length D reaches the transition threshold N, the wire take-up machine (32) is rotated to drive the auxiliary part (322) to contact the wire, and the auxiliary part (322) guides the wire to the other idle winding part (321); Step S48: When the length D reaches the total winding length D0, the auxiliary part (322) is started for slitting, the winding part (321) that is fully loaded is offline, and the winding part (321) that is unloaded is started for the next round of winding.

6. The continuous production process of film-wrapped wire integrating wrapping, preforming and squaring according to claim 5 is characterized in that: A guide is provided at the second output port of the coating machine (20) for guiding the wire material from the second output port into the third input port.

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