Preparation process of high-strength copper wire

Abstract

The invention discloses a preparation process of a high-strength copper wire, and relates to the technical field of copper wire preparation, and the preparation process comprises the following steps: S1, smelting raw materials, removing impurities, and casting into a copper blank; s2, the copper billet is subjected to heat treatment; s3, the copper blank subjected to heat treatment is cut into blocks with proper lengths; s4, under monitoring of the real-time monitoring system, the copper block is gradually drawn into the copper wire with the required diameter through a plurality of drawing dies by using a wire drawing machine; s5, carrying out annealing treatment on the drawn copper wire; and S6, the annealed copper wire is subjected to surface treatment, and a finished product is obtained. Through the real-time monitoring system, the temperature, tension and displacement key parameters can be monitored in real time in the drawing process, the abnormal risk occurring in the production process is effectively reduced, the need of manual intervention is reduced, the automation and efficiency of the production process are improved, the abnormal situation can be quickly treated, long-time production stagnation is avoided, and the production efficiency is improved. Therefore, the overall production efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of copper wire preparation, and in particular to a preparation process of high-strength copper wire. Background Art

[0002] Copper wire is a common metal wire. It is made of copper and has good electrical and thermal conductivity. It can be used in electrical and electronic fields, such as wires and cables, and electronic components. Its production process includes smelting and drawing processes, and after processing, it can meet different usage requirements.

[0003] Existing copper wire is generally prepared by a wire drawing machine, but the wire drawing machine cannot perform real-time monitoring during drawing. Due to the lack of real-time monitoring of key parameters such as tension, displacement and temperature, abnormal conditions cannot be discovered and corrected in time, which may cause the copper wire to break, deform or have surface defects. This not only affects the product qualification rate, but also increases production costs and wastes resources. Summary of the Invention

[0004] The object of the present invention is to provide a process for preparing high-strength copper wire to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: a process for preparing high-strength copper wire, comprising the following steps: S1: smelting the raw materials, removing impurities, and casting into copper billets; S2: heat treating the copper billet; S3: cutting the heat-treated copper billet into blocks of appropriate length; S4: Under the monitoring of the real-time monitoring system, a wire drawing machine is used to gradually draw the copper block through multiple drawing dies into copper wire of the required diameter; S5: annealing the drawn copper wire; S6: performing surface treatment on the annealed copper wire to obtain a finished product.

[0006] Preferably, the raw materials in step S1 mainly include chromium, zirconium, aluminum and copper, and the weight percentages of the raw materials are: 0.1-0.8% chromium, 0.1-0.6% zirconium, 0.1-0.25% aluminum, and the balance is copper. Chromium, zirconium, aluminum and copper are mixed according to the ratio, added to a smelting furnace at a temperature of 1100-1350°C for vacuum smelting, and kept warm until completely melted to obtain a melt. After refining for 40-50 minutes, the smelting furnace is stopped from being vacuumed, and an inert gas is introduced for magnetic stirring to obtain a mixed copper liquid. After magnetic stirring, the slag is skimmed and then refined for 5-10 minutes. The melt is filtered using a ceramic filter, and the refined and filtered melt is poured into a preheated copper billet mold to obtain a copper billet.

[0007] Preferably, the heat treatment in step S2 includes solution treatment, aging treatment and annealing treatment, and after the heat treatment, rapid cooling is used to refine the grains, and the copper billet is subjected to gradient heat treatment.

[0008] Preferably, the real-time monitoring system includes: The data acquisition module monitors the copper block during the drawing process and collects relevant data through sensors at various key nodes of the wire drawing machine; The data processing module transmits the data collected by the monitoring to the data processing center in real time for preprocessing and removes noise data; Data analysis module, which analyzes the pre-processed data through data analysis algorithms; Abnormal processing and feedback control module: when the data analysis structure shows an abnormality, the real-time monitoring system immediately sends out an audible and visual warning signal. At the same time, the system feeds back the abnormal data and related information to the control system, and the control system automatically adjusts the operating parameters of related equipment according to the warning information.

[0009] Preferably, the sensor includes: Temperature sensor, used to monitor the temperature changes of the copper block and subsequent copper wire during the drawing process; Displacement sensor, used to monitor the tension on the copper wire during the drawing process; Tensile force sensor is used to monitor the displacement and length change of copper wire during the drawing process.

[0010] Preferably, the data processing module removes noise data using a moving average filtering algorithm: Among them, is the smoothed value, is the original value of the current moment and the previous moment, and is the window size.

[0011] Preferably, the data analysis module uses the Z-score method to analyze the pre-processed data: Where X is the current monitoring value, μ is the mean of the historical monitoring values, and σ is the standard deviation of the historical monitoring values; Set the threshold to 3. If the condition is met, it is considered abnormal and the buzzer is triggered to issue an audio and visual warning.

[0012] Preferably, the system in the abnormality processing and feedback control module feeds back abnormal data and related information to the control system, and the control system automatically adjusts the operating parameters of related equipment according to the early warning information, including the following steps: S41: Receive an abnormal signal from the data analysis module, use the machine learning model to classify the abnormality, determine the abnormality type, and output the specific type and severity of the abnormality; S42: Record the abnormal data and related information into a database and transmit them to the decision module of the control system. Select a predefined control strategy based on the abnormality type and severity. S43: Generate specific parameter adjustment instructions based on the selected control strategy, send control instructions through the industrial computer, and drive the PID controller to control related equipment; S44: Monitor the adjusted equipment operating status, collect equipment operating data in real time, and compare it with the preset target value to verify whether the abnormality has been eliminated. If the abnormality has not been eliminated, reselect the control strategy; S45: The exception handling process is recorded in the log, including the exception type, handling measures and adjustment results.

[0013] Preferably, in the annealing treatment in step S5, the drawn copper wire is first placed in a controlled atmosphere annealing furnace, the temperature is first raised to 500° C. and kept warm for 10 minutes, and then the temperature is slowly lowered while controlling the introduction and discharge of gas in the furnace.

[0014] Preferably, the surface treatment in step S6 first cleans and activates the annealed copper wire to remove surface oil and oxides, then immerses the copper wire in a chemical plating solution, and deposits a nickel-phosphorus alloy on the surface of the copper wire to form a coating by controlling the composition, temperature, pH value and plating time parameters of the plating solution. Finally, the plated copper wire is cleaned and dried.

[0015] Technical effects and advantages of the present invention: The present invention uses a real-time monitoring system to monitor key parameters such as temperature, tension, and displacement in real time during the drawing process, effectively reducing the risk of abnormalities in the production process. At the same time, through the data analysis module and feedback control mechanism, it can promptly identify and handle abnormal situations and automatically adjust equipment parameters, thereby reducing the production of defective products. The control system can automatically adjust operating parameters according to real-time data, reducing the need for manual intervention and improving the automation and efficiency of the production process. Through real-time monitoring and rapid response mechanisms, it can quickly handle abnormalities when they occur, avoiding long-term production stagnation, thereby improving overall production efficiency. The present invention utilizes chromium, zirconium, aluminum and copper in a certain weight percentage ratio to improve the strength, toughness and corrosion resistance of the copper wire, significantly improving the overall performance of the copper wire. In addition, through a combination of solid solution treatment, aging treatment and annealing treatment, the grain structure is refined, the mechanical properties and electrical conductivity of the copper wire are further improved, and the quality of the finished product is ensured to be stable. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 This is a flow chart of the preparation process of the high-strength copper wire of the present invention.

[0017] Figure 2This is a block diagram of the real-time monitoring system of the present invention.

[0018] Figure 3 This is a flow chart of exception handling and feedback control of the present invention. DETAILED DESCRIPTION

[0019] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0020] The present invention provides Figure 1-3 A process for preparing a high-strength copper wire is shown, comprising the following steps: S1: smelting the raw materials, removing impurities, and casting into copper billets; S2: heat treating the copper billet; S3: cutting the heat-treated copper billet into blocks of appropriate length; S4: Under the monitoring of the real-time monitoring system, a wire drawing machine is used to gradually draw the copper block through multiple drawing dies into copper wire of the required diameter; S5: annealing the drawn copper wire; S6: performing surface treatment on the annealed copper wire to obtain a finished product.

[0021] By optimizing raw materials, introducing advanced real-time monitoring and feedback control mechanisms, improving automation levels, reducing scrap rates and improving safety, these advantages not only improve product quality and production efficiency, but also reduce production costs and enhance the safety and environmental friendliness of the entire production process.

[0022] In step S1, the raw materials mainly include chromium, zirconium, aluminum and copper, and the weight percentages of the raw materials are: 0.1-0.8% chromium, 0.1-0.6% zirconium, 0.1-0.25% aluminum, and the balance is copper. Chromium, zirconium, aluminum and copper are mixed according to the ratio, added to a smelting furnace at a temperature of 1100-1350°C for vacuum smelting, and kept warm until completely melted to obtain a melt. After refining for 40-50 minutes, the smelting furnace is stopped from being vacuum-evacuated, and an inert gas is introduced for magnetic stirring to obtain a mixed copper liquid. After magnetic stirring, the slag is skimmed and then refined for 5-10 minutes. The melt is filtered using a ceramic filter, and the refined and filtered melt is poured into a preheated copper billet mold to obtain a copper billet. Chromium, zirconium, aluminum and copper are mixed in proportion for vacuum melting and casting of the copper billet, which can improve the performance of the material and improve the strength, toughness and corrosion resistance of the copper by adding alloying elements. At the same time, vacuum melting removes impurities, improves the purity of copper, and ensures that the cast copper billets are of high quality and uniform composition, thus laying a good foundation for subsequent processing.

[0023] In step S2, the heat treatment includes solution treatment, aging treatment and annealing treatment. After the heat treatment, the grains are refined by rapid cooling, and the copper billet is subjected to gradient heat treatment. The copper billet is subjected to solution treatment, aging treatment and annealing treatment, which can effectively refine the grains and improve the strength and plasticity of the material. The heat treatment improves the mechanical properties of the copper, ensuring good strength and toughness during wire drawing and use, while annealing eliminates internal stress and improves the stability of the material, making it more suitable for subsequent processing. Cutting the heat-treated copper billet into blocks of appropriate length can ensure the smooth progress of the subsequent wire drawing process and avoid processing difficulties caused by inappropriate length. At the same time, high-precision cutting improves material utilization, reduces waste, and thus improves production efficiency.

[0024] In step S4, the process of gradually drawing the copper block into copper wire of the desired diameter using a wire drawing machine includes several key steps: First, carry out preparation work, ensure that the wire drawing machine and related equipment are in good condition, and set appropriate initial parameters; Next, the sensors are calibrated to ensure that the real-time monitoring system accurately captures data. If necessary, the copper block can be preheated to improve its plasticity and reduce energy consumption and wear during the drawing process. Subsequently, the copper block is placed in the wire drawing machine and the machine is started. The pulling force, temperature and diameter are monitored in real time to ensure that they are within a safe range and meet the specifications. The wire drawing process is divided into multiple stages, and a drawing die of different diameters is used in each stage. The machine parameters are dynamically adjusted to optimize the effect. After drawing is completed, the machine is stopped and the copper wire is removed. At the same time, real-time monitoring data throughout the entire process is recorded and analyzed to identify potential problems and improve future production processes. Through these steps, the copper block drawing process is ensured to be safe and efficient, and high-strength copper wire that meets the standards is produced.

[0025] The real-time monitoring system includes: The data acquisition module monitors the copper block during the drawing process and collects relevant data through sensors at various key nodes of the wire drawing machine. This module should have a high sampling frequency to capture dynamically changing data in real time to ensure the accuracy and timeliness of monitoring. Through multi-channel data acquisition, multiple parameters can be monitored simultaneously, providing a comprehensive information foundation for subsequent data analysis. This multi-channel data acquisition capability provides a comprehensive information foundation for subsequent data analysis, allowing potential problems in the production process to be identified and handled in a timely manner; The data processing module transmits the data collected by the monitoring to the data processing center in real time for preprocessing and noise removal. In addition to moving average filtering, other filtering algorithms can be combined to improve the denoising effect and ensure data reliability, taking into account different types of noise. Through effective denoising, the accuracy of subsequent analysis is ensured, and the risk of misjudgment due to data interference is reduced, thus providing solid data support for the stable operation of the production process. The data analysis module analyzes pre-processed data using data analysis algorithms. The data analysis module should have self-learning capabilities and be able to continuously optimize the analysis model based on historical data to improve the accuracy of identifying abnormal situations and the speed of response. Intelligent data analysis not only improves the accuracy of abnormality detection, but also provides data support for production optimization, prompting continuous improvement of the production process; Abnormal processing and feedback control module: when the data analysis structure shows an abnormality, the real-time monitoring system immediately sends out an audible and visual warning signal. At the same time, the system feeds back the abnormal data and related information to the control system. The control system automatically adjusts the operating parameters of related equipment according to the warning information. This module has a multi-level early warning mechanism and takes different response measures according to the severity of the abnormality in order to more effectively deal with emergencies.

[0026] Sensors include: Temperature sensors are used to monitor the temperature changes of the copper block and subsequent copper wire during the drawing process. The temperature sensors should have fast response characteristics to ensure timely feedback when temperature changes occur and be able to achieve accurate temperature measurement to facilitate accurate process adjustments. Displacement sensors are used to monitor the tension exerted on the copper wire during the drawing process. The accuracy of the displacement sensor is crucial for controlling the wire drawing process. High-precision sensors must be selected to ensure accurate displacement monitoring during the drawing process, thereby avoiding product defects caused by improper displacement. The tension sensor is used to monitor the displacement and length change of the copper wire during the drawing process. The tension sensor should have anti-interference ability to reduce the impact of external factors on the monitoring results, ensure that the tension data is accurate and reliable, and facilitate reasonable process adjustments.

[0027] The moving average filtering algorithm is used to remove noise data in the data processing module: Among them, is the smoothed value, is the original value of the current moment and the previous moment, and is the window size.

[0028] The Z-score method is used to analyze the preprocessed data in the data analysis module: Where X is the current monitoring value, μ is the mean of the historical monitoring values, and σ is the standard deviation of the historical monitoring values; Set the threshold to 3. If the condition is met, it is considered abnormal and the buzzer is triggered to issue an audio and visual warning.

[0029] The moving average filter and Z-score method used in the data processing module provide effective tools for anomaly detection. The moving average filter smooths data and eliminates random noise, while the Z-score method effectively identifies abnormal data outside the normal range by setting a reasonable threshold. This combined approach improves the robustness of the monitoring system and ensures efficient anomaly detection.

[0030] In the abnormality handling and feedback control module, the system feeds back abnormal data and related information to the control system. The control system automatically adjusts the operating parameters of related equipment according to the early warning information, including the following steps: S41: Receives abnormal signals from the data analysis module, uses machine learning models to classify the abnormalities, determines the abnormality type, and outputs the specific type and severity of the abnormality. The intelligent classification method improves the accuracy of abnormality identification, enabling the production team to quickly locate problems, reduce response time, and more effectively take targeted solutions to reduce potential losses. S42: Record the abnormal data and related information into the database and transmit them to the decision module of the control system. Select a predefined control strategy based on the abnormality type and severity. Select a predefined control strategy based on the abnormality type and severity to ensure that existing response measures can be quickly called upon when facing similar problems, thereby improving decision-making efficiency and reducing errors caused by human judgment; S43: Generates specific parameter adjustment instructions based on the selected control strategy. These instructions are sent via the industrial computer to drive the PID controller to control related equipment, achieving automation and intelligence in the production process. It can adjust equipment operating parameters in real time to quickly respond to abnormalities and ensure the stability of the production process and product quality. S44: Monitors the adjusted equipment operating status, collects equipment operating data in real time, and compares it with preset target values ​​to verify whether the anomaly has been eliminated. This continuous monitoring and feedback mechanism ensures the effectiveness of anomaly handling. If the anomaly is not eliminated, the system can quickly reselect the control strategy to ensure that the production process remains under control and reduce the risk of downtime and losses. S45: Record the exception handling process in a log, including the exception type, handling measures, and adjustment results. This not only provides data support for subsequent analysis and improvement, but also lays the foundation for quality control and process optimization, helping the team identify potential systemic problems so that they can continuously improve and optimize the process in future production.

[0031] The control system plays a vital role in the exception handling and feedback control module. Through real-time monitoring, exception detection, control algorithm execution and continuous feedback, the control system can quickly respond to abnormal situations, automatically adjust equipment operating parameters, and ensure the stability and safety of the production process. Its working mechanism includes control strategy selection, execution of control commands, real-time monitoring and data recording and analysis, ultimately achieving efficient and intelligent production management.

[0032] In step S5, the drawn copper wire is first placed in a controlled atmosphere annealing furnace. The temperature is first raised to 500°C and held for 10 minutes, then slowly lowered while controlling the flow of gas into and out of the furnace. Annealing effectively eliminates the internal stress generated during the drawing process and improves the copper wire's plasticity and electrical conductivity. Annealing in a controlled atmosphere also prevents oxidation, improves the copper wire's surface quality and corrosion resistance, and ensures product reliability during use.

[0033] In step S6, the surface treatment first cleans and activates the annealed copper wire to remove surface oil and oxides. The copper wire is then immersed in a chemical plating solution. By controlling the composition, temperature, pH value, and plating time of the plating solution, a nickel-phosphorus alloy is deposited on the copper wire surface to form a coating. Finally, the plated copper wire is cleaned and dried. Cleaning, activation, and chemical plating the annealed copper wire enhances its corrosion resistance and electrical conductivity. Cleaning and activation remove surface contaminants, and the formation of the coating enhances the copper wire's durability and stability, ensuring the final product has good adhesion and service life, thereby meeting the performance requirements of high-strength copper wire.

[0034] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein. Any modifications, replacements, and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A process for preparing high-strength copper wire, characterized in that: The following steps are involved: S1: smelting the raw materials, removing impurities, and casting into copper billets; S2: heat treating the copper billet; S3: cutting the heat-treated copper billet into blocks of appropriate length; S4: Under the monitoring of the real-time monitoring system, a wire drawing machine is used to gradually draw the copper block through multiple drawing dies into copper wire of the required diameter; S5: annealing the drawn copper wire; S6: performing surface treatment on the annealed copper wire to obtain a finished product.

2. The process for preparing a high-strength copper wire according to claim 1, wherein: The raw materials in step S1 mainly include chromium, zirconium, aluminum and copper, and the weight percentages of the raw materials are: 0.1-0.8% chromium, 0.1-0.6% zirconium, 0.1-0.25% aluminum, and the balance is copper. The chromium, zirconium, aluminum and copper are mixed according to the proportions, added to a melting furnace at a temperature of 1100-1350° C. for vacuum melting, and kept warm until completely melted to obtain a melt. After refining for 40-50 minutes, the melting furnace is stopped from being vacuumed, and an inert gas is introduced for magnetic stirring to obtain a mixed copper liquid. After magnetic stirring, slag is skimmed and then refined for 5-10 minutes. The melt is filtered using a ceramic filter, and the refined and filtered melt is poured into a preheated copper billet mold to produce a copper billet.

3. The process for preparing a high-strength copper wire according to claim 1, wherein: The heat treatment in step S2 includes solution treatment, aging treatment and annealing treatment. After the heat treatment, rapid cooling is used to refine the grains, and the copper billet is subjected to gradient heat treatment.

4. The process for preparing a high-strength copper wire according to claim 1, wherein: The real-time monitoring system includes: The data acquisition module monitors the copper block during the drawing process and collects relevant data through sensors at various key nodes of the wire drawing machine; The data processing module transmits the data collected by the monitoring to the data processing center in real time for preprocessing and removes noise data; Data analysis module, which analyzes the pre-processed data through data analysis algorithms; Abnormal processing and feedback control module: when the data analysis structure shows an abnormality, the real-time monitoring system immediately sends out an audible and visual warning signal. At the same time, the system feeds back the abnormal data and related information to the control system, and the control system automatically adjusts the operating parameters of related equipment according to the warning information.

5. The process for preparing a high-strength copper wire according to claim 4, characterized in that: The sensor comprises: Temperature sensor, used to monitor the temperature changes of the copper block and subsequent copper wire during the drawing process; Displacement sensor, used to monitor the tension on the copper wire during the drawing process; Tensile force sensor is used to monitor the displacement and length change of copper wire during the drawing process.

6. The process for preparing a high-strength copper wire according to claim 4, characterized in that: The data processing module uses a moving average filtering algorithm to remove noise data: Among them, is the smoothed value, is the original value of the current moment and the previous moment, and is the window size.

7. The process for preparing a high-strength copper wire according to claim 4, characterized in that: The data analysis module uses the Z-score method to analyze the pre-processed data: Where X is the current monitoring value, μ is the mean of the historical monitoring values, and σ is the standard deviation of the historical monitoring values; Set the threshold to 3. If the condition is met, it is considered abnormal and the buzzer is triggered to issue an audio and visual warning.

8. The process for preparing a high-strength copper wire according to claim 4, characterized in that: The system in the abnormality processing and feedback control module feeds back abnormal data and related information to the control system, and the control system automatically adjusts the operating parameters of related equipment according to the early warning information, including the following steps: S41: Receive an abnormal signal from the data analysis module, use the machine learning model to classify the abnormality, determine the abnormality type, and output the specific type and severity of the abnormality; S42: Record the abnormal data and related information into a database and transmit them to the decision module of the control system. Select a predefined control strategy based on the abnormality type and severity. S43: Generate specific parameter adjustment instructions based on the selected control strategy, send control instructions through the industrial computer, and drive the PID controller to control related equipment; S44: Monitor the adjusted equipment operating status, collect equipment operating data in real time, and compare it with the preset target value to verify whether the abnormality has been eliminated. If the abnormality has not been eliminated, reselect the control strategy; S45: The exception handling process is recorded in the log, including the exception type, handling measures and adjustment results.

9. The process for preparing a high-strength copper wire according to claim 1, characterized in that: In the annealing treatment in step S5, the drawn copper wire is first placed in a controlled atmosphere annealing furnace, heated to 500° C. and kept warm for 10 minutes, and then slowly cooled while controlling the flow and exhaust of gas in the furnace.

10. The process for preparing high-strength copper wire according to claim 1, characterized in that: In step S6, the surface treatment first cleans and activates the annealed copper wire to remove surface oil and oxides, then immerses the copper wire in a chemical plating solution. By controlling the composition, temperature, pH value, and plating time parameters of the plating solution, a nickel-phosphorus alloy is deposited on the surface of the copper wire to form a coating. Finally, the plated copper wire is cleaned and dried.

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