Technology for eliminating copper powder and burrs of enameled wire

Abstract

The invention provides a process for eliminating copper powder and burrs of an enameled wire, and relates to the technical field of metal wire production. The method comprises the following steps: S1, controlling a wire rod to form an inclined conveying path by using two guide wheels, sleeving the outer side of the wire rod with a defect eliminating and collecting device, and fixing the defect eliminating and collecting device; s2, the wire is controlled to move directionally from bottom to top, and the wire penetrates through an eliminating block to remove copper powder and burrs; and S3, gas in the collecting assembly is directionally pumped into the eliminating shell through a gas flow circulating device, the interior of the eliminating shell is controlled to be in a high-pressure state, and meanwhile continuous collection of the copper powder and the burrs in the collecting assembly is achieved. The felt does not need to be replaced frequently, the continuous production efficiency of enameled wires is improved, copper powder and burrs can be prevented from overflowing to the maximum extent, and efficient and sufficient collection of the copper powder and the burrs is achieved.

Description

Technical Field

[0001] This invention relates to the field of metal wire production technology, and in particular to a process for eliminating copper powder and burrs in enameled wire. Background Technology

[0002] The main processes in enameled wire production include drawing, coating, cooling, inspection, and winding. During production, copper powder and burrs are generated, both of which affect insulation performance and are major factors influencing product quality. Causes of copper powder include: Drawing problems: mold wear, insufficient lubrication, incomplete annealing. Copper material defects: poor quality copper rod, surface scratches. Coating process: impurities in the coating solution, wear of the coating mold. Mechanical damage: excessive winding tension, collisions during handling. Causes of burrs include: Raw material problems: rough copper rod surface or impurities in the coating. Drawing defects: mold wear, insufficient lubrication leading to scratches on the copper wire. Coating process: paint contamination, uneven coating, or improper baking temperature. Mechanical damage: excessive winding tension or wear and scratches on the guide rollers. Environmental factors: high dust levels in the workshop, poor humidity control, etc.

[0003] In the production of enameled wire, the existing method for dealing with copper powder and burrs is to clamp the copper wire with felt after drawing and before entering the coating process. However, this device is difficult to completely remove copper powder and burrs, and the felt needs to be replaced frequently, which affects the production efficiency of enameled wire. Furthermore, as the production process is prolonged, the cleaning effect deteriorates, and some impurities remain on the surface of the enameled wire. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a process for eliminating copper powder and burrs in enameled wire. This invention eliminates the need for frequent felt replacement, improves the efficiency of continuous enameled wire production, and minimizes the overflow of copper powder and burrs, achieving efficient and thorough collection of copper powder and burrs.

[0005] To solve the above problems, the technical solution adopted by the present invention is as follows:

[0006] A process for removing copper powder and burrs from enameled wire uses a defect removal and collection device. The device includes an upper removal component and a lower collection component. The removal component includes a removal housing and a removal block inside the housing. An airflow circulation device with a built-in filter is provided between the removal housing and the collection component. The airflow circulation device includes a pressurizing end connected to the removal housing and a negative pressure end connected to the collection component. The process includes the following steps: S1, using two guide wheels to control the wire to form an inclined conveying path, and fitting the defect removal and collection device onto the outside of the wire and fixing it in place; S2, controlling the wire to move directionally from bottom to top, passing through the removal block to remove copper powder and burrs; S3, using the airflow circulation device to directionally pump gas from the collection component into the removal housing, maintaining a high pressure inside the housing while continuously collecting copper powder and burrs from the collection component.

[0007] Preferably, the elimination housing is further provided with an elastic drive device, which controls the elimination block to rotate oriented around a predetermined axis and controls the rotation speed of the elimination block according to the wire moving speed.

[0008] Preferably, the elastic drive device includes an elastic buffer assembly and a rotary drive assembly, wherein the elastic buffer assembly is located between the rotary drive assembly and the elimination block.

[0009] Preferably, the elastic buffer assembly includes a first buffer plate fixedly connected to the elimination block and a second buffer plate spaced apart from the first buffer plate. The second buffer plate is connected to the elimination housing via a rotating connector, and a plurality of elastic buffer guide rods are provided between the first buffer plate and the second buffer plate.

[0010] Preferably, the rotary drive assembly includes a first gear sleeved on the outside of the second buffer plate, a drive motor is fixed on the outside of the elimination housing, and the end of the output shaft of the drive motor passes through the elimination housing and is fixed with a second gear adapted to the first gear.

[0011] Preferably, a guide pipe is provided between the elimination housing and the collection assembly. The guide pipe has an extraction end and an injection end. The extraction end is connected to the elimination housing, and the injection end extends into the collection assembly and faces the middle position of the elimination block. During the directional movement of the wire, the guide pipe is controlled to intermittently spray clean airflow toward the elimination block.

[0012] Preferably, the sidewall of the elimination block is fixed with a baffle plate located inside the elimination housing, and the extraction end is located on the moving path of the baffle plate.

[0013] Preferably, the elimination block has a first conductive opening at its axis, the collection component has a second conductive opening at its bottom, and both the elimination block and the collection component are arranged at an angle, so that the horizontal projection surface of the second conductive opening is located outside the horizontal projection surface of the second conductive opening.

[0014] The beneficial effects of this invention are as follows:

[0015] Compared with existing technologies, the use of a defect elimination and collection device can replace the traditional method of clamping felt onto copper wires, eliminating the need for frequent felt replacement and improving the efficiency of continuous enameled wire production. The internal holes of the elimination block efficiently clean burrs and copper powder from the surface of the enameled wire, preventing impurity residue. Simultaneously, by coordinating the elimination and collection components, the cleaned copper powder and burrs are prevented from falling into the production workshop, improving the workshop environment and preventing related impurities from re-adhering to the enameled wire surface. In particular, the tilted arrangement of the elimination and collection components, combined with an airflow circulation device to control airflow circulation, utilizes the combined effects of gravity and airflow. With the airflow circulation device located on the lower side, it minimizes the spillage of copper powder and burrs, achieving efficient and thorough collection. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention.

[0017] Figure 2 This is a schematic diagram of the internal structure of the defect elimination and collection device of the present invention.

[0018] Figure 3 For the present invention Figure 2 A magnified structural diagram at point A.

[0019] In the diagram: 100, guide wheel; 200, wire; 300, elimination assembly; 310, elimination block; 311, baffle plate; 320, elimination housing; 400, guide pipe; 410, extraction end; 420, jet end; 500, airflow circulation device; 510, pressurization end; 520, negative pressure end; 600, collection assembly; 700, elastic drive device; 710, rotary drive assembly; 711, drive motor; 712, second gear; 713, first gear; 720, elastic buffer assembly; 721, first buffer plate; 722, elastic buffer guide rod; 723, second buffer plate; 724, rotating connector; Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] See attached document Figure 1 -Appendix Figure 3A process for removing copper powder and burrs from enameled wires uses a defect removal and collection device. The defect removal and collection device includes an upper removal component 300 and a lower collection component 600. The removal component 300 includes a removal housing 320 and a removal block 310 located inside the removal housing 320. An airflow circulation device 500 with a built-in filter component is provided between the removal housing 320 and the collection component 600. The airflow circulation device 500 includes a pressurization end 510 communicating with the removal housing 320 and a negative pressure end 520 communicating with the collection component 600. The process includes the following steps.

[0022] S1. Two guide wheels 100 are used to control the wire 200 to form an inclined conveying path, and the defect elimination and collection device is sleeved on the outside of the wire 200 and fixed. The two guide wheels 100 are arranged at intervals and are rotatably connected to the production line frame. The guide wheels 100 are automatic force wheels that can drive the wire 200 to rotate in a direction. The inclined conveying path can work with the defect elimination and collection device to achieve efficient cleaning of copper powder, burrs and other structures.

[0023] S2. Control the wire 200 to move directionally from bottom to top. The wire 200 passes through the elimination block 310 to remove copper powder and burrs. There are related holes inside the defect elimination and collection device that allow the wire 200 to pass through. The hole size is slightly larger than the diameter of the wire 200, allowing the wire 200 to pass through while cleaning the copper powder and burrs on the surface of the wire.

[0024] S3. The gas in the collection component 600 is directionally pumped into the elimination housing 320 by the airflow circulation device 500. While controlling the inside of the elimination housing 320 to be under high pressure, the copper powder and burrs inside the collection component 600 are continuously collected. By controlling the inside of the elimination housing 320 to be under high pressure, some airflow can be ejected from the gaps in the holes, preventing powder impurities from entering the inside of the elimination housing 320 and affecting the operation of the overall structure. At the same time, the airflow can clean the relevant powder impurities in a timely manner, preventing the long-term adhesion of powder impurities.

[0025] In actual production, first select a suitable removal block 310 based on the diameter of the wire 200 to be treated (common range 0.05-2.5mm). The removal block 310 is preferably made of polyurethane, with a hardness controlled at Shore 70-80D. This ensures effective removal of copper powder and burrs without scratching the paint film on the surface of the wire 200. The two guide wheels 100 are made of nylon to prevent friction with the wire 200 from generating new impurities. During installation, adjust the distance and height between the guide wheels to maintain the bending angle of the wire 200 at 15°-30°. This angle ensures stable contact between the wire 200 and the removal block 310 while preventing excessive stretching of the wire.

[0026] When fixing the defect elimination and collection device, use M8 expansion bolts to connect the device base to the production line frame. After fixing, it is necessary to use a level to calibrate and ensure that the deviation between the device axis and the wire 200 conveying direction does not exceed 0.5mm. This prevents additional friction between the wire and the edge of the elimination block 310 during wire conveying and ensures that the deflection angle of the fixed defect elimination and collection device is consistent with the deflection angle of the wire 200.

[0027] During step S2, the moving speed of wire 200 is controlled by a variable frequency motor on the production line, with the speed set to 3-18 m / min. If there is a lot of copper powder or obvious burrs on the surface of wire 200, the speed can be reduced to 3-8 m / min to give the removal block 310 sufficient time to scrape off the impurities; if there are fewer impurities, the speed can be increased to 10-18 m / min to ensure production efficiency. As wire 200 moves from bottom to top, gravity allows the scraped copper powder and burrs to fall naturally, facilitating subsequent collection.

[0028] In step S3, the pressure at the booster end of the airflow circulation device 500 is adjusted to 0.2-0.3 MPa, creating a high-pressure environment inside the elimination housing 320. This allows gas to flow rapidly out from the hole in the center of the elimination block, promptly blowing the copper powder and burrs scraped off by the elimination block 310 onto the wire surface. The negative pressure at the negative pressure end 520 is controlled between -0.05 and -0.08 MPa, working in conjunction with the built-in 100-mesh stainless steel filter to efficiently adsorb impurities and filter the gas. The filter needs to be checked every 4 hours of operation. If the impurity coverage on the filter surface exceeds 40%, it must be replaced promptly or cleaned by reverse blowing with compressed air to prevent filter blockage and maintain airflow circulation efficiency.

[0029] The housing 320 is also equipped with an elastic drive device 700, which controls the elimination block 310 to rotate around a predetermined axis and controls the rotation speed of the elimination block 310 according to the moving speed of the wire 200.

[0030] The elastic drive device 700 enables dynamic friction between the removal block 310 and the wire 200, improving the impurity removal rate by approximately 25% compared to a fixed removal block. Simultaneously, it avoids significant damage to the wire 200 surface caused by rigid collisions, providing an elastic buffer zone within which efficient surface treatment of the wire 200 is achieved. During actual commissioning, a correlation is established between the wire 200's moving speed and the removal block 310's rotation speed. The rotation speed of the removal block 310 is controlled to increase synchronously with the wire 200's speed: for example, when the wire speed is 3-8 m / min, the removal block's rotation speed is set to 25-40 r / min; when the wire speed is 8-18 m / min, the rotation speed is adjusted to 40-70 r / min. This correlation is stored in the PLC control system and automatically recalled when switching wire specifications or speeds.

[0031] The elastic drive device 700 includes an elastic buffer assembly 720 and a rotary drive assembly 710, with the elastic buffer assembly 720 located between the rotary drive assembly 710 and the elimination block 310.

[0032] The elastic buffer assembly 720 is mainly used to offset the rigid transmission impact of the rotary drive assembly 710, preventing the elimination block 310 from generating irregular friction with the wire surface due to vibration, thus protecting the wire coating. The rotary drive assembly 710 provides stable power, and the combination of the two allows the elimination block 310 to rotate more smoothly, improving the uniformity of impurity removal by 15%.

[0033] During assembly, ensure that the coaxiality deviation between the elastic buffer assembly 720, the rotary drive assembly 710, and the elimination block 310 does not exceed 0.05mm to prevent jamming during transmission. Allow 2-3mm for the expansion and contraction of the elastic buffer assembly 720 to accommodate slight wear of the elimination block 310 after long-term use, ensuring that the elimination block always maintains appropriate contact pressure with the wire surface.

[0034] The elastic buffer assembly 720 includes a first buffer plate 721 fixedly connected to the elimination block 310 and a second buffer plate 723 spaced apart from the first buffer plate 721. The second buffer plate 723 is connected to the elimination housing 320 by a rotating connector 724. A plurality of elastic buffer guide rods 722 are provided between the first buffer plate 721 and the second buffer plate 723.

[0035] Both the first buffer plate 721 and the second buffer plate 723 are made of aluminum alloy plates with a thickness of 2-4mm, which ensures structural strength while reducing overall weight and avoiding affecting rotational flexibility. The distance between them is set to 8-12mm to provide sufficient extension and contraction space for the elastic buffer guide rod 722. When the force on the elimination block 310 exceeds the threshold and moves inward, the elastic buffer guide rod 722 is compressed synchronously. An electrical sensing element can be installed inside the elastic buffer guide rod 722. After the elastic buffer guide rod 722 is compressed, the air volume of the airflow circulation device 500 is increased synchronously. This avoids the pressure drop caused by the increased gap due to airflow overflow, while increasing the airflow rate to achieve adaptive cleaning of falling impurities.

[0036] The rotary drive assembly 710 includes a first gear 713 sleeved on the outside of the second buffer plate 723, a drive motor 711 fixed on the outside of the elimination housing 320, and the end of the output shaft of the drive motor 711 passing through the elimination housing 320 and fixed with a second gear 712 adapted to the first gear 713.

[0037] The first gear 713 and the second gear 712 mentioned above can be selected as mutually cooperating bevel gears. During the rotation of the second gear 712 controlled by the drive motor 711, the first gear 713 is driven to rotate synchronously. Furthermore, the output shaft end of the drive motor 711 is sealed and rotatably connected to the elimination housing 320, which can prevent gas leakage to the greatest extent and maintain the elimination housing 320 in a relatively positive pressure state. At the same time, the above-mentioned drive structure occupies a small volume inside the elimination housing 320, can drive the relevant structure to rotate well, and is simple and convenient.

[0038] A guide pipe 400 is provided between the elimination housing 320 and the collection assembly 600. The guide pipe 400 has an extraction end 410 and an injection end 420. The extraction end 410 is connected to the elimination housing 320, and the injection end 420 extends into the collection assembly 600 and toward the middle position of the elimination block 310. During the directional movement of the wire 200, the guide pipe 400 is controlled to intermittently spray clean airflow toward the elimination block 310.

[0039] The jet end 420 of the guide pipe 400 is processed into a fan-shaped outlet with an outlet width of 1.5-2.5mm, so that the jetted airflow forms a uniform air curtain that covers the contact area between the elimination block 310 and the wire 200. By spraying a uniform air curtain, the residual metal powder between the wire 200 and the elimination block 310 can be cleaned by gas. With the help of gravity, the accumulation of metal powder can be avoided to the greatest extent. Furthermore, as the elimination block 310 rotates, different areas of the elimination block 310 are in a state of airflow cleaning, realizing all-round cleaning of residual metal powder on the surface of the elimination block 310.

[0040] The intermittent jetting frequency is adjusted according to the moving speed of wire 200, generally 1.5-3 times / second, with each jet lasting 0.2-0.4 seconds. The airflow can be controlled by an electromagnetic reversing valve. This design can promptly blow away copper powder and burrs adhering to the surface of the removal block 310, preventing impurities from accumulating and affecting the cleaning effect. Experimental data shows that after adding the guide pipe 400, the cleaning cycle of the removal block 310 can be extended from 1.5 hours to 5 hours, reducing downtime for maintenance.

[0041] Meanwhile, this application also provides a better method for automatic control of intermittent base, specifically, a baffle plate 311 located inside the elimination housing 320 is fixed on the side wall of the elimination block 310, and the extraction end 410 is located on the moving path of the baffle plate 311.

[0042] The baffle plate 311 is fixed on the side wall of the elimination block 310 near the extraction end 410. Its diameter is 8-12mm larger than that of the elimination block 310. It can effectively prevent the high-pressure gas in the elimination housing 320 from flowing directly out of the extraction end 410, and ensure the pressure inside the elimination housing 320 is stable.

[0043] When the removal block 310 rotates, the baffle plate 311 periodically blocks the extraction end 410, causing the airflow in the guide pipe 400 to form a "pulse" jet. Compared with continuous jet, the pulse airflow improves the cleaning effect of the surface impurities of the removal block 310 by 30%, while reducing airflow loss by about 20%.

[0044] The elimination block 310 has a first conductive opening at its axis, and the collection component 600 has a second conductive opening at its bottom. Both the elimination block 310 and the collection component 600 are arranged at an angle, and the horizontal projection surface of the second conductive opening is located outside the horizontal projection surface of the second conductive opening.

[0045] The tilt angle of the elimination block 310 and the tilt angle of the collection component 600 are set to 8°-18° (specifically determined according to the size of the first and second conductive openings). The tilt angle should not be too large, which would cause too much metal powder to remain in the holes of the elimination block. At the same time, the tilt angle should not be too small, which would cause the metal powder to fall directly through the second conductive opening at the bottom and not be completely collected. The copper powder and burrs are guided by gravity to move towards the second conductive opening at the bottom of the collection component 600, but the falling position is staggered from the second conductive opening, so as to achieve efficient collection of metal powder.

[0046] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A process for eliminating copper powder and burrs in enameled wire, characterized in that, Using a defect elimination and collection device, the defect elimination and collection device includes an elimination component (300) located above and a collection component (600) located below. The elimination component (300) includes an elimination housing (320) and an elimination block (310) located inside the elimination housing (320). An airflow circulation device (500) with a built-in filter component is provided between the elimination housing (320) and the collection component (600). The airflow circulation device (500) includes a pressurization end (510) communicating with the elimination housing (320) and a negative pressure end (520) communicating with the collection component (600); including the following steps; S1. Using two guide wheels (100) to control the wire (200) to form an inclined conveying path, and fitting the defect elimination collection device on the outside of the wire (200) and fixing the defect elimination collection device. S2. Control the wire (200) to move directionally from bottom to top, and the wire (200) passes through the elimination block (310) to remove copper powder and burrs; S3. The gas in the collection component (600) is pumped into the elimination housing (320) by the airflow circulation device (500). While controlling the inside of the elimination housing (320) to be in a high-pressure state, the continuous collection of copper powder and burrs in the collection component (600) is achieved.

2. The process for eliminating copper powder and burrs in enameled wire according to claim 1, characterized in that, The elimination housing (320) is also provided with an elastic drive device (700), which controls the elimination block (310) to rotate around a predetermined axis and controls the rotation speed of the elimination block (310) according to the moving speed of the wire (200).

3. The process for eliminating copper powder and burrs in enameled wire according to claim 2, characterized in that, The elastic drive device (700) includes an elastic buffer assembly (720) and a rotary drive assembly (710), the elastic buffer assembly (720) being located between the rotary drive assembly (710) and the elimination block (310).

4. The process for eliminating copper powder and burrs in enameled wire according to claim 3, characterized in that, The elastic buffer assembly (720) includes a first buffer plate (721) fixedly connected to the elimination block (310) and a second buffer plate (723) spaced apart from the first buffer plate (721). The second buffer plate (723) is connected to the elimination housing (320) by a rotating connector (724). A plurality of elastic buffer guide rods (722) are provided between the first buffer plate (721) and the second buffer plate (723).

5. The process for eliminating copper powder and burrs in enameled wire according to claim 4, characterized in that, The rotary drive assembly (710) includes a first gear (713) sleeved on the outside of the second buffer plate (723), and a drive motor (711) is fixed on the outside of the elimination housing (320). The output shaft end of the drive motor (711) passes through the elimination housing (320) and is fixed with a second gear (712) that is adapted to the first gear (713).

6. The process for eliminating copper powder and burrs in enameled wire according to claim 1, characterized in that, A guide pipe (400) is provided between the elimination housing (320) and the collection assembly (600). The guide pipe (400) has an extraction end (410) and an injection end (420). The extraction end (410) is connected to the elimination housing (320), and the injection end (420) extends into the collection assembly (600) and toward the middle position of the elimination block (310). During the directional movement of the wire (200), the guide pipe (400) is controlled to intermittently spray clean airflow toward the elimination block (310).

7. The process for eliminating copper powder and burrs in enameled wire according to claim 6, characterized in that, The side wall of the elimination block (310) is fixed with a baffle plate (311) located inside the elimination housing (320), and the extraction end (410) is located on the moving path of the baffle plate (311).

8. The process for eliminating copper powder and burrs in enameled wire according to claim 1, characterized in that, The elimination block (310) has a first conductive opening at its axis, and the collection component (600) has a second conductive opening at its bottom. Both the elimination block (310) and the collection component (600) are arranged at an angle, and the horizontal projection surface of the second conductive opening is controlled to be located outside the horizontal projection surface of the second conductive opening.

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