A stretch-resistant enameled wire manufacturing system and process

Abstract

This invention relates to the field of enameled wire production technology, specifically to a tensile-resistant enameled wire manufacturing system and process. It aims to solve technical problems in existing enameled wire manufacturing processes, such as uneven enamel film, insufficient bonding strength, poor tensile performance, and low production efficiency caused by enamel flow. The system includes a base, and a wire-splitting and laying mechanism, an extrusion molding mechanism, and a feeding mechanism mounted on the base. The wire-splitting and laying mechanism includes a first support ring, a cutting component, an extrusion component, a first pressing component, a coating unit, and a wire feeding component. It can achieve precise cutting, activation treatment, and close bonding of the separating material with the wire to form a uniform separation zone. The extrusion molding mechanism includes a second support ring, a molding component, and a second pressing component. It can extrude semi-solid enamel material into shape and connect it to the notch in the separating material. The feeding mechanism achieves precise enamel supply, connects various processes, effectively restricts enamel flow, improves enamel film uniformity, and enhances the bonding strength between the enamel material and the wire and separating material.

Description

Technical Field

[0001] This invention relates to the field of enameled wire manufacturing technology, and in particular to a tensile-resistant enameled wire manufacturing system and process. Background Technology

[0002] As a core conductive component in equipment such as motors, transformers, and electronic components, the performance of enameled wire directly affects the operational stability and service life of the equipment. Among them, tensile strength and enamel film uniformity are key quality indicators of enameled wire. The existing manufacturing process of enameled wire mainly follows the process of preheating, coating, and curing. That is, the metal wire is first preheated to improve surface activity, then the enamel is coated on the surface of the wire through a coating device, and finally the enamel film is formed after curing treatment, thus completing the preparation of enameled wire.

[0003] In the prior art, a power enameled wire manufacturing and processing equipment with publication number CN115020042B includes an enameled wire spraying machine. The upper end of the enameled wire spraying machine is equipped with a spray gun, and both ends of the machine are equipped with uniform spraying structures. The inner end of the uniform spraying structure is equipped with a winding and rotating structure. The winding and rotating structure includes a drive gear, the outer end of which is equipped with a connecting structure, and the inner end of which is equipped with a positioning structure and a limiting structure. The uniform spraying structure includes a support rod, the upper end of which is equipped with a main shaft, the outer end of which is equipped with a motor and a tray, the inner end of which is equipped with a winding frame, the outer end of which is equipped with a fixing plate, and the inner end of which is equipped with a groove and a slip ring. This invention avoids the phenomenon of uneven adhesion of paint to the surface of the wire harness under gravity during the spraying process.

[0004] However, existing enameled wire manufacturing processes and related equipment have many technical pain points in practical applications. During the coating process, semi-solid paint is prone to shrinkage and sagging due to its own fluidity, resulting in uneven paint film thickness. Consequently, during the stretching process, the enameled wire experiences stress concentration, leading to paint film cracking and peeling, which significantly reduces the tensile strength of the enameled wire. Therefore, a tensile-resistant enameled wire manufacturing system and process are designed. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by using a cutting component of a wire-laying mechanism to precisely cut the separating material into a material with concave notches. This material is then rolled and bonded to the surface of a preheated wire by an extrusion component, forming multiple independent dividing zones around the circumference of the wire. The physical barrier effect of the separating material strictly confines the semi-solid paint within each dividing zone, completely avoiding beading and sagging caused by macroscopic paint flow. This ensures uniform paint film thickness and solves the problem of uneven paint film thickness caused by beading and sagging of semi-solid paint due to its own fluidity during the painting process. This significantly improves production yield and equipment versatility, demonstrating outstanding inventiveness and industrial applicability.

[0006] To address the above technical issues, the following technical solution is adopted: A tensile-resistant enameled wire manufacturing system includes a base, a wire splitting and laying mechanism mounted on the base, and an extrusion molding mechanism mounted on the base in parallel with the wire splitting and laying mechanism. A dividing line laying mechanism, comprising a first support ring fixed above a base, a cutting assembly installed on one side of the first support ring, and several sets of extrusion assemblies arranged in a ring array inside the first support ring. An extrusion molding mechanism, the extrusion molding mechanism including a second support ring arranged parallel to a first support ring and molding components arranged in a ring array within the second support ring; The cutting assembly includes a cutting blade with an inner groove for cutting cylindrical separator material, and for cutting an inner concave notch on the outer side of the cylindrical separator material; The extrusion assembly includes an extrusion roller with an annular concave surface on its outer surface, used to extrude and adhere a separator material with a concave notch to the outside of the wire. The forming component includes several forming rollers arranged in a ring array inside the second support ring. The forming rollers act on a semi-solid filler material between two separating materials. The filler material is formed in the space between two adjacent separating materials. After deformation, the filler material forms an interlocking shape with the concave notch of the separating material. The filler material and the separating material together surround the outside of the wire.

[0007] Preferably, the extrusion assembly further includes a first roller frame disposed inside the first support ring and used for supporting the installation of the extrusion roller, and a first limiting rod installed on the top side of the first roller frame and slidably mounted inside the first support ring.

[0008] Preferably, the dividing line laying mechanism further includes a first pressing component, which includes a first cylinder mounted on the first support ring and arranged in a circular array, a first piston movably mounted in the first cylinder, and a first piston rod mounted on the bottom side of the first piston and movably passing through the first support ring. The bottom end of the first piston rod is connected to the top of the first roller frame.

[0009] Preferably, the cutting assembly further includes a protective ring located outside the cutting blade for supporting the cutting blade and a coating unit located at the bottom of the protective ring. The coating unit includes a first movable rod that is movably inserted through the bottom of the protective ring and whose axis is oriented towards the center of the cutting blade; a mounting bracket installed at one end of the first movable rod and located inside the protective ring; a coating ball installed in the mounting bracket via a rotating shaft and synchronously located below the inner groove of the cutting blade; a limiting cap installed at the other end of the first movable rod and located outside the protective ring; and a spring acting between the protective ring and the limiting cap.

[0010] Preferably, the mounting bracket has a material guide groove inside, wherein one end of the material guide groove slides in contact with the outer surface of the coating ball, and the other end of the material guide groove is connected to a material supply pipe.

[0011] Preferably, the wire feeding mechanism further includes a wire feeding assembly mounted in a ring array on the side of the first support ring. The wire feeding assembly includes a support frame mounted in a ring array on the side of the first support ring, a wire feeding shaft mounted in parallel on the support frame and having rotational damping, a wire take-up shaft mounted in parallel with the wire feeding shaft and rotatably mounted on the support frame, and a take-up motor mounted on the outside of the support frame and whose output shaft is connected to the take-up shaft.

[0012] Preferably, the molding assembly further includes a second limiting rod that slides through the second support ring and has its axis facing the center of the second support ring, a second roller frame installed at the bottom of the second limiting rod for supporting the rotation of the molding roller, and a second pushing unit for pushing the second roller frame to move toward the axis of the second support ring.

[0013] Preferably, the second pressing unit includes a second cylinder installed on the outside of the second support ring, a second piston movably disposed in the second cylinder, and a second piston rod installed on the bottom side of the second piston and connected to the top side of the second roller frame; The second piston rod is movably inserted through the second support ring, and its bottom end is fixed to the top side of the second roller frame.

[0014] Preferably, the device also includes a feeding mechanism located between the dividing line laying mechanism and the extrusion molding mechanism. The feeding mechanism includes a third support ring fixed between the first support ring and the second support ring, a feeding pipe arranged in a ring array within the third support ring, and a nozzle installed at the end of the feeding pipe.

[0015] A tensile-resistant enameled wire manufacturing process, applied to a tensile-resistant enameled wire manufacturing system, includes the following steps: S1: Wire pretreatment; Perform conventional preheating treatment on the enameled wire, with the preheating temperature controlled at 80-120℃ and the preheating time at 3-5 minutes, to ensure that the wire surface is dry, free of oil and impurities; After preheating, pull the wire above the base so that the wire axis coincides with the center of the first support ring and the second support ring, and keep the wire conveyed at a uniform speed. S2: Feeding and cutting of separator material; The wire feeding assembly starts, and the cylindrical separator material is smoothly released through the wire feeding shaft on the support frame set in a ring array. The wire feeding speed is synchronized with the wire conveying speed. The separator material is conveyed to the cutting assembly, and the cutting blade cuts the cylindrical separator material through the inner groove on it, and a concave notch is processed on the outside of the separator material. After cutting, the winding motor drives the winding shaft to rotate and recycle the excess part of the separator material after cutting. S3: Activation coating of the inner wall of the notch in the separator material; the cut separator material continues to be conveyed, the coating unit starts synchronously, the spring provides elastic force, pushing the first movable rod to drive the mounting frame and coating ball to fit tightly against the outer side of the concave notch in the separator material; the feed pipe continuously conveys plasma activator to the guide groove in the mounting frame, the activator is conveyed to the surface of the coating ball through the guide groove, and as the separator material is conveyed, the coating ball rolls synchronously, coating the inner wall of the notch in the separator material with plasma activator; S4: Separator material extrusion and bonding; The activated separator material is conveyed to the inner side of the first support ring, the first pressing component is activated, the first cylinder is supplied with gas at a preset pressure, pushing the first piston to move, driving the first piston rod to extend and retract synchronously, thereby pushing the first roller frame and the extrusion roller to move towards the wire; The first limiting rod is slidably installed in the first support ring to limit the movement trajectory of the first roller frame, ensuring that the extrusion roller always moves radially along the wire; The annular concave surface of the extrusion roller is adapted to the shape of the separator material, and the separator material is rolled, so that the separator material is bonded to the outside of the preheated wire; Multiple extrusion components arranged in a ring array operate synchronously, maintaining uniform pushing force, so that multiple sets of separating materials are evenly distributed along the circumference of the wire, forming multiple independent separating zones; the air intake pressure of the first cylinder can be adjusted according to the diameter of the wire to ensure that the separating material and the wire are tightly bonded under the action of roller pressing; S5: Semi-solid paint filling; After the separator material is attached to the surface of the wire and an independent separator area is formed, the wire continues to be conveyed to the feeding mechanism; The feeding pipes arranged in a ring array on the inner side of the third support ring convey the semi-solid paint to each independent separator area through the nozzle at the end, and the amount of paint supplied matches the volume of the separator area. S6: Paint extrusion molding and fastening; The wire with separating material and filler paint continues to be fed to the inner side of the second support ring of the extrusion molding mechanism. The second pushing unit is activated, and constant pressure gas is introduced into the second cylinder to drive the second piston to move along the cylinder axis, which drives the second piston rod to extend and retract synchronously, thereby pushing the second roller frame and forming roller to move towards the wire; The second limiting rod slides through the second support ring to limit the movement trajectory of the second roller frame, ensuring that the forming roller always moves radially along the wire; The forming rollers act on the semi-solid paint between the two separating materials, extruding and molding the paint so that the paint and the concave notch on the outside of the separating materials form an interlocking shape. Finally, the paint and the separating materials are combined to surround the outside of the wire, realizing the integrated molding of the dividing structure and the paint. S7: Subsequent curing and finished product processing; After the integrated molding is completed, the wire is pulled into a conventional enameled wire curing equipment for curing; After curing, the enameled wire is cooled to room temperature, and then the surface is cleaned, the dimensions are inspected, and the tensile strength is tested. Unqualified products are rejected. After passing the inspection, the enameled wire is pulled to the topcoat spraying equipment, the spraying system is started, and the topcoat is evenly sprayed along the circumference of the enameled wire using a ring array of nozzles, while the enameled wire is kept at a constant speed. After the spraying is completed, the enameled wire is pulled to the secondary curing equipment for topcoat curing. After the secondary curing is completed, the enameled wire is cooled a second time. After cooling to room temperature, the surface appearance and insulation performance are inspected again. After confirming that there are no topcoat defects, the wire is wound up and packaged.

[0016] The beneficial effects of this invention are: (1) The present invention uses the cutting component of the dividing wire laying mechanism to precisely cut the dividing material to form a dividing material with concave notch. Then, the extrusion component rolls and presses it onto the surface of the preheated wire to form multiple independent dividing areas around the circumference of the wire. By utilizing the physical barrier effect of the dividing material, the semi-solid paint is strictly confined within each dividing area, completely avoiding the shrinkage and sagging phenomena caused by the macroscopic flow of paint, ensuring uniform paint film thickness, and improving the appearance quality and dimensional consistency of the enameled wire.

[0017] Enhanced bonding strength between enamel and wire / splitter material significantly improves the tensile strength of enameled wire: The concave notch in the splitter material forms a tightly interlocking structure with the enamel after extrusion molding, greatly increasing the contact area between the enamel and the splitter material. Simultaneously, the coating unit precisely applies plasma activator to the inner wall and surface of the splitter material notch via coating rollers, achieving in-situ activation, increasing the surface energy of the splitter material, and promoting chemical bonding between the enamel and the splitter material. Combined with the surface activity of the preheated wire, this further enhances the adhesion between the enamel and the wire / splitter material, effectively preventing the enamel film from cracking and peeling due to stress concentration during wire stretching, thus significantly improving the tensile strength and service life of the enameled wire. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the first three-dimensional structure of the production equipment for worm gear screw jack parts.

[0020] Figure 2 This is a schematic diagram of the second three-dimensional structure of the production equipment for worm gear screw jack accessories.

[0021] Figure 3 This is a schematic diagram of the three-dimensional structure of the dividing line laying mechanism.

[0022] Figure 4 for Figure 3 Top view of the structure.

[0023] Figure 5 for Figure 4 Schematic diagram of the structure cut along section AA.

[0024] Figure 6 This is a schematic diagram of the combined structure of the cutting component and the extrusion component.

[0025] Figure 7 This is a cross-sectional view of the cutting component.

[0026] Figure 8 This is a schematic diagram of the extrusion molding mechanism.

[0027] Figure 9 This is a schematic diagram of the front view of the extrusion molding mechanism.

[0028] Figure 10 for Figure 9 Schematic diagram of the cross-section structure along the middle BB.

[0029] Figure 11 This is a schematic diagram of the feeding mechanism.

[0030] Figure 12 This is a cross-sectional view of the wire enameling process.

[0031] Figure 13 This is a process system diagram of the present invention. Detailed Implementation

[0032] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0033] Example 1 like Figure 1-10 As shown, a tensile-resistant enameled wire manufacturing system includes a base 1, characterized in that it further includes a wire splitting and laying mechanism 4 installed on the base 1 and an extrusion molding mechanism 6 installed in parallel with the wire splitting and laying mechanism 4 on the base 1. The dividing line laying mechanism 4 includes a first support ring 41 fixed above the base 1, a cutting component 42 installed on one side of the first support ring 41, and a plurality of extrusion components 43 arranged in a ring array inside the first support ring 41. The extrusion molding mechanism 6 includes a second support ring 61 arranged parallel to the first support ring 41 and a molding assembly 62 arranged in a ring array within the second support ring 61. The cutting component 42 includes a cutting blade 421, which has an inner groove 423 for cutting cylindrical separator materials, and cuts an inner concave notch on the outside of the cylindrical separator materials. The extrusion assembly 43 includes an extrusion roller 431 with an annular concave surface on its outer surface, used to extrude and paste the separator material with the concave notch cut on the outside of the wire. The forming component 62 includes a plurality of forming rollers 621 arranged in a ring array inside the second support ring 61. The forming rollers 621 act on a semi-solid filler material between two separating materials. The filler material is formed in the space between two adjacent separating materials. After deformation, the filler material forms an interlocking shape with the concave notch of the separating material. The filler material and the separating material together surround the outside of the wire.

[0034] In detail, based on the existing enameled wire manufacturing process of preheating, coating, and curing, in the surface treatment stage of the preheated wire, the base 1 supports the wire-splitting and laying mechanism 4 and the extrusion molding mechanism 6 to achieve collaborative operation. First, the first support ring 41 of the wire-splitting and laying mechanism 4 positions the wire, and the cutting component 42 cuts the cylindrical dividing material to process a concave notch. Then, the extrusion component 43 on the inner side of the first support ring 41 rolls and adheres the cut dividing material to the surface of the preheated wire to form multiple independent dividing areas around the circumference of the wire. Subsequently, the second support ring 61 of the extrusion molding mechanism 6 positions the wire, and the molding component 62 extrudes and molds the semi-solid paint between the two dividing materials, so that the filling material and the concave notch of the dividing material are interlocked and finally wrapped together on the outside of the wire to complete the integrated molding of the dividing structure and the paint. To address the issues of beading, sagging, and uneven film thickness caused by paint flow in existing enameling processes, this method uses a physical barrier formed by a separator material to confine the paint within an independent zone, preventing macroscopic paint flow. Simultaneously, the interlocking structure between the filler and separator materials enhances their bonding stability. Combined with the preheated wire surface condition, this improves the adhesion between the paint, the wire, and the separator material, thereby enhancing the tensile strength of the enameled wire and preventing the paint film from cracking due to stress concentration during stretching.

[0035] It should be noted that polyester film and polyester film insulating paper composite foil are preferred for the dividing materials, nitrogen plasma activators or argon-oxygen mixed plasma activators are preferred for the plasma active materials, and polyester paint, polyesterimide paint or modified polyamide-imide paint are preferred for the semi-solid paint. like Figure 5 As shown, the extrusion assembly 43 further includes a first roller frame 432 disposed inside the first support ring 41 and used for supporting the installation of the extrusion roller 431, and a first limiting rod 433 installed on the top side of the first roller frame 432 and slidably installed inside the first support ring 41.

[0036] In detail, the first roller frame 432 provides stable support for the extrusion roller 431, ensuring that the extrusion roller 431 can be accurately aligned with the surface of the preheated wire. At the same time, the first limiting rod 433 is slidably installed in the first support ring 41 to limit the movement trajectory of the first roller frame 432, ensuring that the extrusion roller 431 always moves radially along the wire, avoiding deviation, and ensuring the positional accuracy and pressure uniformity when the separating material is rolled and bonded. Under the extrusion limiting of the extrusion roller 431, the separating material can come into contact with and be extruded by the preheated wire. The separating material is extruded and deformed to bond with the surface of the wire, forming equally sized separating areas on the surface of the wire.

[0037] like Figure 5 As shown, the dividing line laying mechanism 4 further includes a first pushing component 44, which includes a first cylinder 441 installed on the first support ring 41 and arranged in a ring array, a first piston 442 movably installed in the first cylinder 441, and a first piston rod 443 installed on the bottom side of the first piston 442 and movably passing through the first support ring 41. The bottom end of the first piston rod 443 is connected to the top of the first roller frame 432.

[0038] In detail, the first pressing component 44 provides power support for the extrusion component 43. The first cylinder 441 is fixed on the first support ring 41. By controlling the air intake pressure, the first piston 442 inside the first cylinder 441 is pushed to move, which drives the first piston rod 443 to move synchronously. This, in turn, pushes the first roller frame 432 and the extrusion roller 431 to move towards the wire, achieving precise roller pressing and bonding of the separating material. The pushing pressure can be adjusted according to the wire diameter, making the pressure of the extrusion roller 431 adjustable to adapt to preheated wires of different diameters. This ensures that the separating material can be tightly bonded to the surface of wires of different diameters, avoiding the separation material from falling off due to insufficient pressure or damaging the surface of the preheated wire due to excessive pressure. At the same time, the first pressing component 44 arranged in a ring array ensures that the pushing pressure at each position in the circumferential direction is uniform, making the separating area formed by the separating material consistent in size, further improving the uniformity of paint filling.

[0039] like Figure 6-7 As shown, the cutting assembly 42 also includes a protective ring 422 located outside the cutting blade 421 and used to support the cutting blade 421, and a coating unit 45 located at the bottom of the protective ring 422. The coating unit 45 includes a first movable rod 451 that is movably inserted through the bottom of the protective ring 422 and whose axis is oriented towards the center of the cutting blade 421; a mounting bracket 452 installed at one end of the first movable rod 451 and located inside the protective ring 422; a coating ball 453 that is installed in the mounting bracket 452 via a rotating shaft and is synchronously located below the inner groove of the cutting blade 421; a limiting cap 454 installed at the other end of the first movable rod 451 and located outside the protective ring 422; and a spring 455 that acts between the protective ring 422 and the limiting cap 454.

[0040] In detail, the protective ring 422 provides fixed support for the cutting blade 421 to prevent the cutting blade 421 from shifting during cutting and to ensure the cutting accuracy of the concave notch of the separating material; the coating unit 45 operates synchronously, and the spring 455 provides elastic force to push the first movable rod 451 to drive the mounting bracket 452 and the coating ball 453 to fit against the outside of the notch of the cut separating material. The coating ball 453 rolls synchronously with the conveying of the separating material to evenly coat the plasma activator on the inner wall of the notch and the surface of the separating material. The protective ring 422 ensures the cutting stability of the cutting blade 421, ensuring uniform size of the concave notch and providing precise fit for subsequent filling material fastening; the coating ball 453 achieves uniform coating of plasma activator, in-situ activating the inner wall of the notch of the separator material, introducing active functional groups, removing tiny surface impurities, and increasing surface energy. At the same time, through the clamping action of the coating ball 453, the feeding tension of the separator material is ensured, making the separator material adhere more tightly to the preheated wire, creating conditions for the chemical bonding of the subsequent paint and separator material, enhancing the bonding strength, and improving tensile strength.

[0041] like Figure 7As shown, the mounting bracket 452 has a material guide groove 456 inside, one end of the material guide groove 456 slides in contact with the outer surface of the coating ball 453, and the other end of the material guide groove 456 is connected to a material supply pipe.

[0042] One end of the guide groove 456 inside the mounting bracket 452 slides in contact with the coating roller 453, and the other end is connected to the supply pipe. The supply pipe continuously delivers plasma activator. The activator is delivered to the surface of the coating roller 453 through the guide groove 456, and then evenly transferred to the notch of the separating material by the rolling of the roller 453. This achieves continuous and precise supply of activator, avoiding the problems of uneven supply, waste or incomplete coating of plasma activator, and ensuring that the inner wall and surface of the notch of the separating material can be fully covered by activator, thus ensuring stable activation effect.

[0043] like Figure 5 As shown, the dividing line laying mechanism 4 also includes a wire feeding assembly 48 arranged in a ring array on the side of the first support ring 41. The wire feeding assembly 48 includes a support frame 481 arranged in a ring array on the side of the first support ring 41, a wire feeding shaft 483 arranged in parallel on the support frame 481 and having rotational damping, a wire take-up shaft 482 arranged in parallel with the wire feeding shaft 483 and rotatably mounted on the support frame 481, and a take-up motor 484 arranged outside the support frame 481 and whose output shaft is connected to the take-up shaft 482.

[0044] In detail, the wire feeding assembly 48 is fixed to the side of the first support ring 41 by the support frame 481. The wire feeding assemblies 481 arranged in a ring array correspond to different separating materials. The wire feeding shaft 483 has rotational damping to achieve smooth wire feeding of the separating materials and avoid the separating materials from loosening or breaking due to excessively fast or slow feeding. The winding motor 484 drives the winding shaft 482 to rotate and wind up the excess separating materials after cutting, ensuring stable feeding tension of the separating materials and synchronizing with the wire conveying speed. This achieves stable feeding of the separating materials and avoids the separation materials from shifting or wrinkling due to uneven feeding tension. It ensures that the separating materials are evenly distributed along the circumference of the wire, forming a uniformly sized separating area. The winding function of the winding shaft 482 reduces the waste of separating materials and keeps the working environment clean. It can adapt to the synchronous feeding of multiple sets of separating materials to meet the needs of setting multiple separating lines and dividing areas as small as possible.

[0045] like Figure 8-10 As shown, the molding assembly 62 further includes a second limiting rod 623 that slides through the second support ring 61 and has its axis facing the center of the second support ring 61, a second roller frame 622 installed at the bottom of the second limiting rod 623 and used to support the rotation of the molding roller 621, and a second pushing unit 63 used to push the second roller frame 622 toward the axis of the second support ring 61.

[0046] In detail, the second limiting rod 623 slides through the second support ring 61, limiting the second roller frame 622 to ensure that the second roller frame 622 drives the forming roller 621 to move radially along the wire, avoiding deviation. The second pushing unit 63 provides power to push the second roller frame 622 and the forming roller 621 to move towards the wire, so that the forming roller 621 acts precisely on the semi-solid filler material between the two separating materials to achieve extrusion molding. This ensures that the movement trajectory of the forming roller 621 is accurate, avoiding problems such as uneven molding of the filler material and poor interlocking with the gap in the separating material due to deviation. The precise extrusion action of the forming roller 621 enables the semi-solid paint to fully fill the gap between the two separating materials and form a tight interlocking with the gap, avoiding gaps between the paint and the separating materials and enhancing the overall integrity of the structure. At the same time, the limiting structure ensures that the extrusion force of each forming roller 621 in the circumferential direction is uniform, making the paint thickness in each separating area consistent, further optimizing the uniformity of the paint film, and providing structural protection for improving the tensile strength of the enameled wire.

[0047] like Figure 9-10 As shown, the second pushing unit 63 includes a second cylinder 633 installed on the outside of the second support ring 61, a second piston 632 movably disposed in the second cylinder 633, and a second piston rod 631 installed on the bottom side of the second piston 632 and connected to the top side of the second roller frame 622. The second piston rod 631 is movably inserted through the second support ring 61, and its bottom end is fixed to the top side of the second roller frame 622.

[0048] In detail, the second cylinder 633 is fixed to the outside of the second support ring 61. By introducing constant pressure gas into the second cylinder 633, the second piston 632 is driven to move along the cylinder axis, thereby driving the second piston rod 631 to extend and retract synchronously. Since the second piston rod 631 moves through the second support ring 61 and its bottom end is fixedly connected to the second roller frame 622, it can push the second roller frame 622 and the forming roller 621 to move radially along the wire, thereby adjusting the extrusion pressure of the forming roller 621 to meet the filling requirements of different thicknesses of paint. This allows for the adjustment of the extrusion pressure of the forming roller 621 to accommodate semi-solid paints of different viscosities and thicknesses, avoiding problems such as insufficient paint filling and loose connection with the separator material due to insufficient extrusion pressure, or paint overflow and deformation of the separator material due to excessive extrusion pressure. Combined with the limiting effect of the second limiting rod 623, the extrusion pressure of each forming roller 621 is kept consistent, ensuring uniform paint forming quality in each separator area in the circumferential direction, and improving the overall tensile strength and appearance consistency of the enameled wire.

[0049] Example 2 like Figure 11As shown, components that are the same as or corresponding to those in Embodiment 1 are referred to using the same reference numerals as in Embodiment 1. For simplicity, only the differences from Embodiment 1 are described below. The difference between Embodiment 2 and Embodiment 1 is as follows: Furthermore, it also includes a feeding mechanism 5 located between the dividing line laying mechanism 4 and the extrusion molding mechanism 6. The feeding mechanism 5 includes a third support ring 51 fixed between the first support ring 41 and the second support ring 61, a feeding pipe 52 arranged in a ring array within the third support ring 51, and a nozzle 53 installed at the end of the feeding pipe 52.

[0050] In detail, the feeding pipes 52 arranged in a ring array inside the third support ring 51 correspond to the separation areas between the two separating materials. The feeding pipes 52, through the nozzles 53, deliver semi-solid paint to each independent separation area, providing sufficient and uniform paint supply for the subsequent extrusion molding of the forming component 62. This achieves continuous operation of wire laying, feeding, and molding. The nozzles 53 accurately deliver paint to the separation areas, avoiding paint waste and contamination of the wire and separation material surfaces. The ring array of feeding pipes 52 and nozzles 53 ensures that the paint supply to each separation area is consistent, providing a uniform foundation for the extrusion molding of the forming component 62. This avoids insufficient paint leading to a thin paint film and insufficient tensile strength, or excessive paint leading to overflow and uneven surface after molding. At the same time, the feeding mechanism 5 achieves seamless connection between wire laying and molding, improving overall operation efficiency and ensuring the continuity and stability of enameled wire production.

[0051] Example 3 like Figure 12 , 13 As shown, components that are the same as or corresponding to those in Embodiment 1 are referred to using the same reference numerals as those in Embodiment 1. For simplicity, only the differences from Embodiment 1 are described below. The difference between Embodiment 4 and Embodiment 1 is as follows: Furthermore, a tensile-resistant enameled wire manufacturing process, applied to a tensile-resistant enameled wire manufacturing system, includes the following steps: S1: Wire pretreatment; Perform conventional preheating treatment on the enameled wire, with the preheating temperature controlled at 80-120℃ and the preheating time at 3-5 minutes, to ensure that the wire surface is dry, free of oil and impurities; After preheating, pull the wire above the base 1 so that the wire axis coincides with the center of the first support ring 41 and the second support ring 61, and keep the wire conveyed at a uniform speed; S2: Feeding and cutting of the dividing material; the wire feeding assembly 48 starts and smoothly releases the cylindrical dividing material through the wire feeding shaft 483 on the support frame 481 set in a ring array, and the wire feeding speed is synchronized with the wire conveying speed; the dividing material is conveyed to the cutting assembly 42, and the cutting blade 421 cuts the cylindrical dividing material through the inner groove 423 on it, and processes an inner concave notch on the outside of the dividing material; after the cutting is completed, the winding motor 484 drives the winding shaft 482 to rotate and recycle the excess part of the dividing material after cutting; S3: Activation coating of the inner wall of the notch in the separator material; the cut separator material continues to be conveyed, the coating unit 45 starts synchronously, the spring 455 provides elastic force, pushes the first movable rod 451 to drive the mounting frame 452 and the coating ball 453, which are tightly fitted to the outer side of the concave notch in the separator material; the feed pipe continuously conveys plasma activator to the guide groove 456 in the mounting frame 452, and the activator is conveyed to the surface of the coating ball 453 through the guide groove 456. As the separator material is conveyed, the coating ball 453 rolls synchronously, coating the inner wall of the notch in the separator material with plasma activator; S4: Separator material extrusion and bonding; The activated separator material is conveyed to the inner side of the first support ring 41, the first pressing component 44 is activated, the first cylinder 441 is supplied with gas at a preset pressure, pushing the first piston 442 to move, driving the first piston rod 443 to extend and retract synchronously, thereby pushing the first roller frame 432 and the extrusion roller 431 to move towards the wire; The first limiting rod 433 is slidably installed in the first support ring 41 to limit the movement trajectory of the first roller frame 432, ensuring that the extrusion roller 431 always moves radially along the wire; The annular concave surface of the extrusion roller 431 is adapted to the shape of the separator material, and the separator material is rolled and pressed, so that the separator material is bonded to the outside of the preheated wire; Multiple extrusion components 43 arranged in a ring array operate synchronously, maintaining uniform pushing force, so that multiple sets of separating materials are evenly distributed along the circumference of the wire, forming multiple independent separating zones; the air intake pressure of the first cylinder 441 can be adjusted according to the diameter of the wire to ensure that the separating material and the wire are tightly bonded under the action of roller pressing; S5: Semi-solid paint filling; After the separator material is attached to the surface of the wire and an independent separator area is formed, the wire continues to be conveyed to the feeding mechanism 5; The feeding pipe 52 arranged in a ring array on the inner side of the third support ring 51 conveys the semi-solid paint to each independent separator area through the nozzle 53 at the end, and the supply of paint matches the volume of the separator area. S6: Paint extrusion molding and fastening; The wire with separating material and filler paint continues to be fed to the inner side of the second support ring 61 of the extrusion molding mechanism 6. The second pushing unit 63 is activated, and constant pressure gas is introduced into the second cylinder 633, driving the second piston 632 to move along the cylinder axis, which drives the second piston rod 631 to extend and retract synchronously, thereby pushing the second roller frame 622 and the forming roller 621 to move towards the wire; The second limiting rod 623 slides through the second support ring 61 to limit the movement trajectory of the second roller frame 622, ensuring that the forming roller 621 always moves radially along the wire; The forming roller 621 acts on the semi-solid paint between the two separating materials to extrude and form the paint, so that the paint and the concave notch on the outside of the separating material form an interlocking shape. Finally, the paint and the separating material are combined to surround the outside of the wire, realizing the integrated forming of the dividing structure and the paint. S7: Subsequent curing and finished product processing; After the integrated molding is completed, the wire is pulled into a conventional enameled wire curing equipment for curing; After curing, the enameled wire is cooled to room temperature, and then the surface is cleaned, the dimensions are inspected, and the tensile strength is tested. Unqualified products are rejected. After passing the inspection, the enameled wire is pulled to the topcoat spraying equipment, the spraying system is started, and the topcoat is evenly sprayed along the circumference of the enameled wire using a ring array of nozzles, while the enameled wire is kept at a constant speed. After the spraying is completed, the enameled wire is pulled to the secondary curing equipment for topcoat curing. After the secondary curing is completed, the enameled wire is cooled a second time. After cooling to room temperature, the surface appearance and insulation performance are inspected again. After confirming that there are no topcoat defects, the wire is wound up and packaged.

[0052] In the description of this invention, it should be understood that the terms "front and back", "left and right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0053] Of course, those skilled in the art should understand that the term "a" should be understood as "at least one" or "one or more". That is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple. The term "a" should not be understood as a limitation on the quantity.

[0054] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art under the technical guidance 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 determined by the scope of the claims.

Claims

1. A tensile-resistant enameled wire manufacturing system, comprising a base (1), characterized in that: It also includes a dividing line laying mechanism (4) installed on the base (1) and an extrusion molding mechanism (6) installed on the base (1) in parallel with the dividing line laying mechanism (4). The dividing line laying mechanism (4) includes a first support ring (41) fixed above the base (1), a cutting component (42) installed on one side of the first support ring (41), and a number of extrusion components (43) arranged in a ring array inside the first support ring (41). The extrusion molding mechanism (6) includes a second support ring (61) arranged parallel to the first support ring (41) and a molding assembly (62) arranged in a ring array within the second support ring (61). The cutting assembly (42) includes a cutting blade (421) with an inner groove (423) for cutting cylindrical separator material, and cutting an inner concave notch on the outer side of the cylindrical separator material; The extrusion assembly (43) includes an extrusion roller (431) with an annular concave surface on its outer surface, used to extrude and paste a separator material with a concave notch onto the outside of the wire. The forming component (62) includes a plurality of forming rollers (621) arranged in a ring array inside the second support ring (61). The forming rollers (621) act on a semi-solid filling material between two separating materials. The filling material is formed in the space between two adjacent separating materials. After the filling material is deformed, it forms an interlocking shape with the concave notch of the separating material. The filling material and the separating material together surround the outside of the wire.

2. A stretch resistant enameled wire manufacturing system according to claim 1, characterized in that: The extrusion assembly (43) further includes a first roller frame (432) disposed inside the first support ring (41) and used for supporting the installation of the extrusion roller (431), and a first limiting rod (433) installed on the top side of the first roller frame (432) and slidably installed inside the first support ring (41).

3. The tensile-resistant enameled wire manufacturing system according to claim 1, characterized in that: The dividing line laying mechanism (4) further includes a first pushing assembly (44), which includes a first cylinder (441) installed on the first support ring (41) and arranged in a ring array, a first piston (442) movably installed in the first cylinder (441), and a first piston rod (443) installed on the bottom side of the first piston (442) and movably passing through the first support ring (41). The bottom end of the first piston rod (443) is connected to the top of the first roller frame (432).

4. The stretch-resistant enameled wire manufacturing system according to claim 1, wherein: The cutting assembly (42) also includes a protective ring (422) located outside the cutting blade (421) and used to support the cutting blade (421), and a coating unit (45) located at the bottom of the protective ring (422). The coating unit (45) includes a first movable rod (451) that is movably inserted into the bottom of the protective ring (422) and whose axis is oriented toward the center of the cutting blade (421), a mounting bracket (452) installed at one end of the first movable rod (451) and located inside the protective ring (422), a coating ball (453) installed in the mounting bracket (452) via a rotating shaft and synchronously located below the groove in the cutting blade (421), a limiting cap (454) installed at the other end of the first movable rod (451) and located outside the protective ring (422), and a spring (455) acting between the protective ring (422) and the limiting cap (454).

5. A stretch-resistant enameled wire manufacturing system according to claim 4, characterized in that: The mounting bracket (452) has a material guide groove (456) inside, one end of the material guide groove (456) slides in contact with the outer surface of the coating ball (453), and the other end of the material guide groove (456) is connected to a material supply pipe.

6. A stretch resistant enameled wire manufacturing system according to claim 1, characterized in that: The wire feeding mechanism (4) further includes a wire feeding assembly (48) arranged in a ring array on the side of the first support ring (41). The wire feeding assembly (48) includes a support frame (481) arranged in a ring array on the side of the first support ring (41), a wire feeding shaft (483) arranged in parallel on the support frame (481) and having rotational damping, a wire take-up shaft (482) arranged in parallel with the wire feeding shaft (483) and rotatably mounted on the support frame (481), and a take-up motor (484) arranged outside the support frame (481) and whose output shaft is connected to the take-up shaft (482).

7. A stretch-resistant enameled wire manufacturing system according to claim 1, characterized in that: The molding assembly (62) further includes a second limiting rod (623) that slides through the second support ring (61) and has its axis facing the center of the second support ring (61), a second roller frame (622) installed at the bottom of the second limiting rod (623) and used to support the rotation of the molding roller (621), and a second pushing unit (63) used to push the second roller frame (622) to move toward the axis of the second support ring (61).

8. The tensile-resistant enameled wire manufacturing system according to claim 7, characterized in that: The second pushing unit (63) includes a second cylinder (633) installed on the outside of the second support ring (61), a second piston (632) movably disposed in the second cylinder (633), and a second piston rod (631) installed on the bottom side of the second piston (632) and connected to the top side of the second roller frame (622). The second piston rod (631) is movably inserted through the second support ring (61), and its bottom end is fixed to the top side of the second roller frame (622).

9. The tensile-resistant enameled wire manufacturing system according to claim 1, characterized in that: It also includes a feeding mechanism (5) located between the dividing line laying mechanism (4) and the extrusion molding mechanism (6). The feeding mechanism (5) includes a third support ring (51) fixed between the first support ring (41) and the second support ring (61), a feeding pipe (52) arranged in a ring array in the third support ring (51), and a nozzle (53) installed at the end of the feeding pipe (52).

10. A manufacturing process for tensile-resistant enameled wire, applied to a tensile-resistant enameled wire manufacturing system as described in any one of claims 1-9, characterized in that: Includes the following steps: S1: Wire pretreatment; Perform conventional preheating treatment on the enameled wire, with the preheating temperature controlled at 80-120℃ and the preheating time at 3-5 minutes, to ensure that the wire surface is dry, free of oil and impurities; After preheating, pull the wire above the base (1) so that the wire axis coincides with the center of the first support ring (41) and the second support ring (61), and keep the wire conveyed at a uniform speed; S2: Feeding and cutting of the dividing material; the wire feeding assembly (48) is started, and the cylindrical dividing material is smoothly released through the wire feeding shaft (483) on the support frame (481) set in a ring array. The wire feeding speed is synchronized with the wire conveying speed. The dividing material is conveyed to the cutting assembly (42), and the cutting blade (421) cuts the cylindrical dividing material through the inner groove (423) on it, and a concave notch is processed on the outside of the dividing material. After the cutting is completed, the winding motor (484) drives the winding shaft (482) to rotate and rewind the excess part of the dividing material after cutting. S3: Activation coating of the inner wall of the notch in the separator material; the cut separator material continues to be conveyed, the coating unit (45) starts synchronously, the spring (455) provides elastic force, pushes the first movable rod (451) to drive the mounting frame (452) and the coating ball (453) to fit tightly against the outer side of the concave notch in the separator material; the feed pipe continuously conveys plasma activator to the guide groove (456) in the mounting frame (452), the activator is conveyed to the surface of the coating ball (453) through the guide groove (456), and as the separator material is conveyed, the coating ball (453) rolls synchronously, coating the plasma activator on the inner wall of the notch in the separator material; S4: The separator material is extruded and bonded; the activated separator material is transported to the inside of the first support ring (41), the first pushing assembly (44) is activated, the first cylinder (441) is supplied with gas at a preset pressure, the first piston (442) is pushed to move, and the first piston rod (443) is driven to extend and retract synchronously, thereby pushing the first roller frame (432) and the extrusion roller (431) to move towards the wire; the first limiting rod (433) is slidably installed in the first support ring (41) to limit the movement trajectory of the first roller frame (432) and ensure that the extrusion roller (431) always moves radially along the wire; the annular concave surface of the extrusion roller (431) is adapted to the shape of the separator material to roll the separator material, so that the separator material is bonded to the outside of the preheated wire; Multiple extrusion components (43) in the ring array operate synchronously, and the pushing force is kept uniform, so that multiple sets of separating materials are evenly distributed along the circumference of the wire, forming multiple independent separating areas; the air pressure of the first cylinder (441) can be adjusted according to the diameter of the wire to ensure that the separating material and the wire are tightly bonded under the action of roller pressing. S5: Semi-solid paint filling; After the wire surface is properly bonded with the separating material and an independent separating area is formed, the wire continues to be conveyed to the feeding mechanism (5); The feeding pipe (52) arranged in the inner ring array of the third support ring (51) conveys the semi-solid paint to each independent separating area through the nozzle (53) at the end, and the amount of paint supplied matches the volume of the separating area. S6: Paint extrusion molding and fastening; The wire with separator material and filler paint is continued to be conveyed to the inner side of the second support ring (61) of the extrusion molding mechanism (6). The second pushing unit (63) is started, and the second cylinder (633) is supplied with constant pressure gas, which drives the second piston (632) to move along the cylinder axis, which drives the second piston rod (631) to extend and retract synchronously, thereby pushing the second roller frame (622) and the forming roller (621) to move in the direction of the wire; The second limiting rod (623) slides through the second support ring (61) to limit the movement trajectory of the second roller frame (622) and ensure that the forming roller (621) always moves radially along the wire; The forming roller (621) acts on the semi-solid paint between the two separating materials to extrude and form the paint, so that the paint and the concave notch on the outside of the separating material form an interlocking shape. Finally, the paint and the separating material are combined to surround the outside of the wire, realizing the integrated forming of the dividing structure and the paint. S7: Subsequent curing and finished product processing; After the integrated molding is completed, the wire is pulled into a conventional enameled wire curing equipment for curing; After curing, the enameled wire is cooled to room temperature, and then the surface is cleaned, the dimensions are inspected, and the tensile strength is tested. Unqualified products are rejected. After passing the inspection, the enameled wire is pulled to the topcoat spraying equipment, the spraying system is started, and the topcoat is evenly sprayed along the circumference of the enameled wire using a ring array of nozzles, while the enameled wire is kept at a constant speed. After the spraying is completed, the enameled wire is pulled to the secondary curing equipment for topcoat curing. After the secondary curing is completed, the enameled wire is cooled a second time. After cooling to room temperature, the surface appearance and insulation performance are inspected again. After confirming that there are no topcoat defects, the wire is wound up and packaged.

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