A method for manufacturing an ultra-large U-shaped copper busbar and a continuous extrusion die thereof

Abstract

The present invention discloses a method for making an extra-large U-shaped copper busbar and a continuous extrusion die thereof, which comprises a die body, the die body comprising a die base and a die core arranged in the die base, the die core having a W-shaped cross section, comprising a first oblique section and a second oblique section which are smoothly connected, the first oblique section and the second oblique section being in an inverted V shape, the other side of the first oblique section being smoothly connected with a first side arm, the other side of the second oblique section being smoothly connected with a second side arm, the first side arm and the second side arm being symmetrically arranged on both sides of the first oblique section and the second oblique section; the die body extrude a W-shaped profile, and the W-shaped profile is shaped into a U-shaped copper busbar by a forming machine. The present invention uses a W-shaped extrusion die and a horizontal extruder to integrally form a W-shaped copper busbar, and then uses a forming machine to form an extra-wide U-shaped copper busbar with a width of ≥400 mm after unfolding, thereby achieving integral forming and ensuring the uniformity of the overall product.

Description

Technical Field

[0001] The invention relates to the technical field of extrusion dies, in particular to a method for manufacturing an extra-large U-shaped copper busbar and a continuous extrusion die thereof. Background Art

[0002] Copper busbars are essential materials for power transmission in the power transmission and transformation industry. Among them, U-shaped special copper busbars have the characteristics of strong conductivity, deformation resistance, energy saving and material saving, etc. They are suitable for some occasions with special cross-sectional shape requirements for conductor materials, and can meet the requirements of product upgrades in the electrical industry.

[0003] In the production process of U-shaped copper bars, continuous extrusion technology is often used. Copper rods are used as blanks. The friction in the extrusion cavity of the continuous extruder is used to increase the metal temperature, causing the metal strength to decrease and deform. Under the action of traction, the copper rods continuously pass through the die to form U-shaped copper bars. Continuous extrusion technology has the advantages of production continuity, low energy consumption and low cost. However, in the production process, the design of the die plays an extremely important role in the continuity of production and the quality of the product.

[0004] Due to the limitations of equipment and process, traditional continuous extrusion and horizontal extrusion cannot form larger U-shaped copper bars with a width of more than 250mm. Therefore, the existing large U-shaped copper bars are made by welding. They are easy to deform after welding, and there are coarse grains in the welding parts, which affects the conductivity and product strength. In severe cases, cracks may occur, resulting in a short service life and corresponding safety hazards. Summary of the invention

[0005] In order to solve the above problems, the purpose of the present invention is to provide a method for making an extra-large U-shaped copper busbar and a continuous extrusion die thereof, which can improve the integrity of the copper busbar, greatly increase the safety factor, and extend the service life of the U-shaped copper busbar.

[0006] The technical solution adopted by the present invention to solve the above-mentioned problem is: a method for manufacturing an extra-large U-shaped copper busbar and a continuous extrusion die thereof, which comprises a die body, the die body comprises a die base and a die core arranged in the die base, the cross-section of the die core is W-shaped, comprising a first oblique section and a second oblique section which are smoothly connected, the first oblique section and the second oblique section are in an inverted V shape, the other side of the first oblique section is smoothly connected with a first side arm, the other side of the second oblique section is smoothly connected with a second side arm, the first side arm and the second side arm are symmetrically arranged on both sides of the first oblique section and the second oblique section; the die body extrude a W-shaped profile, and the W-shaped profile becomes a U-shaped copper busbar after being shaped by a forming machine.

[0007] A continuous extrusion die for an extra-large U-shaped copper bar. The die base is also provided with two limiting holes, which are respectively arranged above and below the die core.

[0008] A continuous extrusion die for an extra-large U-shaped copper busbar, wherein the angle between the first oblique section and the second oblique section is 20° to 45°.

[0009] A continuous extrusion die for an extra-large U-shaped copper busbar, wherein the angle between the first side arm and the first oblique section is 15°-45°, and the angle between the second side arm and the second oblique section is the same as the angle between the first side arm and the first oblique section.

[0010] A continuous extrusion die for an extra-large U-shaped copper busbar, wherein the thickness of the first side arm and the second side arm is 10-15 mm.

[0011] A continuous extrusion die for an extra-large U-shaped copper busbar, wherein the thickness of the first oblique section and the second oblique section is 10-12 mm.

[0012] A continuous extrusion die for an extra-large U-shaped copper busbar, wherein the heights of the first side arm and the second side arm are 75-85 mm.

[0013] A continuous extrusion die for an extra-large U-shaped copper busbar, wherein the width of the U-shaped copper busbar is not less than 400 mm.

[0014] A method for making an extra-large U-shaped copper busbar comprises the following contents:

[0015] Step 1, ingot casting;

[0016] Step 2: Extrusion: using a continuous extruder to extrude a W-shaped profile;

[0017] Step 3: Shaping: Place the extruded W-shaped profile on the workbench of the shaping machine. The hydraulic cylinder drives the shaping die to descend. By switching the fixture, pressure is applied to the W-shaped profile to achieve shaping. After the shaping is completed, the hydraulic cylinder drives the shaping die to reset, and the W-shaped profile is transformed into a U-shaped copper bar.

[0018] A method for manufacturing an extra-large U-shaped copper busbar, wherein in step 2, the heating temperature of the mold and the mold sleeve of the continuous extruder is 450° C. to 550° C., and the heating time is 3.5 to 4.5 hours.

[0019] Due to the application of the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0020] (1) The present invention uses a W-shaped extrusion die and a horizontal extruder to integrally form a W-shaped copper busbar, and then uses a forming machine to unfold the W-shaped copper busbar to form an ultra-wide U-shaped copper busbar with a width of ≥400 mm, thereby achieving integral molding and ensuring the uniformity of the entire product.

[0021] (2) The present invention changes the traditional process of welding and forming a large U-shaped copper busbar, greatly reducing the production cost. While improving the overall performance of the copper busbar, the safety factor is greatly improved and the service life of the U-shaped copper busbar can be extended.

[0022] (3) The extrusion die and the support pad of the present invention are matched with each other by means of positioning pins, so that the support pad does not deviate from the center during the extrusion process. At the same time, the cooperation between the two can increase the bearing pressure during the horizontal extrusion process. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 The structural schematic diagram of the continuous extruder of the present invention is

[0024] Figure 2 It is a schematic structural diagram of the extrusion die of the present invention.

[0025] Figure 3 It is a structural schematic diagram of the W-shaped profile of the present invention.

[0026] Figure 4 It is a schematic structural diagram of the U-shaped copper busbar of the present invention.

[0027] Figure 5 It is a schematic structural diagram of the support pad of the present invention.

[0028] Figure 6 It is a structural schematic diagram of the shaping machine of the present invention.

[0029] Figure 7 It is the front view of the shaping machine of the present invention.

[0030] In the figure:

[0031] Mold body 1, mold base 1.1, mold core 1.2, first oblique section 1.21, second oblique section 1.22, first side arm 1.23, second side arm 1.24, limit hole 1.3, W-shaped profile 2, U-shaped copper bar 3, continuous extruder 4, machine base 4.1, pay-off reel 4.11, guide wheel 4.12, extrusion box 4.2, placement table 4.3, support pad 4.4, pad 4.41, inner hole 4.42, mounting hole 4.43, shaping machine 5, frame 5.1, workbench 5.2, hydraulic cylinder 5.3, piston rod 5.4, column 5.5, top plate 5.6, shaping mold 5.7, clamping cylinder 5.8. DETAILED DESCRIPTION

[0032] The present invention is further described in detail below with reference to the accompanying drawings.

[0033] Embodiment 1:

[0034] See also Figure 1 to Figure 7 A production device for an extra-large U-shaped copper bar comprises a continuous extruder 4 and a shaping machine 5 which are arranged in sequence.

[0035] The continuous extruder 4 includes a machine base 4.1, and the machine base 4.1 also includes an extrusion box 4.2 and a placement table 4.3. The extrusion box 4.2 is arranged at the upper end of the machine base 4.1 and is fixedly connected to the machine base 4.1; a wire pay-off drum 4.11 and a guide wheel 4.12 are provided on the machine base 4.1, and a connecting rod is provided on the guide wheel 4.12; a wire inlet pipe is provided on one side of the extrusion box 4.2, and an extrusion die is provided in the middle of the other side; the wire pay-off drum 4.11 is arranged on the left side of the machine base 4.1, and is connected to the machine base 4.1 through a rotating rod; the wire pay-off drum 4.11 and the placement table 4.3 are respectively arranged on both sides of the extrusion box 4.2.

[0036] The guide wheel 4.12 is arranged at the upper left end of the machine base 4.1 and is connected to the machine base 4.1 through a connecting rod to play a role of limiting guidance.

[0037] The extrusion die is arranged on the extrusion box 4.2 through a die seat, a support pad 4.4 is fixed on the die seat, and the support pad 4.4 comprises a pad 4.41, an inner hole 4.42 is arranged on the pad 4.41, and a mounting hole 4.43 is respectively arranged above and below the inner hole 4.42.

[0038] See also Figure 1-4 The extrusion die includes a die body 1, the die body 1 includes a die base 1.1 and a die core 1.2 arranged in the die base 1.1, the cross-section of the die core 1.2 is W-shaped, including a first oblique section 1.21 and a second oblique section 1.22 which are smoothly connected, the first oblique section 1.21 and the second oblique section 1.22 are in an inverted V shape, the other side of the first oblique section 1.21 is smoothly connected to a first side arm 1.23, the other side of the second oblique section 1.22 is smoothly connected to a second side arm 1.24, the first side arm 1.23 and the second side arm 1.24 are symmetrically arranged on both sides of the first oblique section 1.21 and the second oblique section 1.22.

[0039] The mold base 1.1 is also provided with two limiting holes 1.3, which are respectively arranged above and below the mold core 1.2 for connecting with the support pad.

[0040] The angle between the first oblique section 1.21 and the second oblique section 1.22 is 20° to 45°.

[0041] The angle between the first side arm 1.23 and the first oblique section 1.21 is 15° to 45°, and the angle between the second side arm 1.24 and the second oblique section 1.22 is the same as the angle between the first side arm 1.23 and the first oblique section 1.21.

[0042] The thickness of the first side arm 1.23 and the second side arm 1.24 is 10-15 mm.

[0043] The thickness of the first oblique section 1.21 and the second oblique section 1.22 is 10-12 mm.

[0044] The height of the first side arm 1.23 and the second side arm 1.24 is 75-85 mm.

[0045] The die body 1 extrude a W-shaped profile 2, and the W-shaped profile 2 is shaped into a U-shaped copper bar 3 after being shaped by a forming machine. The width of the U-shaped copper bar 3 is not less than 400 mm.

[0046] The inner hole 4.42 of the support pad 4.4 has the same cross-sectional shape as the mold core 1.2, and is slightly larger in size than the mold core 1.2.

[0047] See also Figure 6 and Figure 7 The shaping machine 5 comprises a frame 5.1, on the top of which a horizontal workbench 5.2 is fixed; a hydraulic mechanism, comprising a top plate 5.6, columns 5.5 and a hydraulic cylinder 5.3, wherein the top plate 5.6 is fixed above the workbench 5.2 through four columns 5.5, the hydraulic cylinder 5.3 is mounted on the top plate 5.6, a piston rod 9 is mounted inside the hydraulic cylinder 5.3, and the piston rod 9 of the hydraulic cylinder 5.3 passes vertically downward through the top plate 5.6 and is connected to a shaping die 5.7;

[0048] The workbench 5.2 is also provided with a clamping cylinder 5.8, which is located on one side below the shaping die 5.7 and is used to clamp the W-shaped profile 2.

[0049] A method for making an extra-large U-shaped copper busbar comprises the following contents:

[0050] (1) Ingot casting: The ingot temperature is controlled at 800℃

[0051] (1) Extrusion: The W-shaped profile is extruded by the above-mentioned continuous extruder. First, the wire is wound on the guide wheel by unwinding, and then connected to the extrusion box through the wire inlet pipe. The heating temperature of the mold and the mold sleeve is 500°C, and the heating time is 4 hours. After continuous extrusion, it is extruded through the extrusion mold and finally placed on the placement table.

[0052] (2) Shaping: The extruded W-shaped profile is placed on the workbench of the above-mentioned shaping machine. The hydraulic cylinder drives the shaping die to descend. By switching the fixture, pressure is applied to the W-shaped profile to achieve shaping. After the shaping is completed, the hydraulic cylinder drives the shaping die to reset, and the W-shaped profile is transformed into a U-shaped copper bar.

[0053] In addition to the above embodiments, the present invention also includes other implementation modes. Any technical solutions formed by equivalent transformation or equivalent replacement should fall within the protection scope of the claims of the present invention.

Claims

1. A method for making an extra-large U-shaped copper busbar. It is characterized in that Includes the following: Step 1, ingot casting; Step 2: Extrusion: using a continuous extrusion die of a continuous extruder (4) to extrude a W-shaped profile (2); The continuous extrusion die comprises a die body (1), the die body (1) comprising a die base (1.1) and a die core (1.2) arranged in the die base (1.1), the die core (1.2) having a W-shaped cross section, comprising a first oblique section (1.21) and a second oblique section (1.22) which are smoothly connected, the first oblique section (1.21) and the second oblique section (1.22) being in an inverted V shape, the other side of the first oblique section (1.21) being smoothly connected to a first side arm (1.23), the other side of the second oblique section (1.22) being smoothly connected to a second side arm (1.24), the first side arm (1.23) and the second side arm (1.24) being symmetrically arranged on both sides of the first oblique section (1.21) and the second oblique section (1.22); Step 3: Shaping: The extruded W-shaped profile (2) is placed on the workbench of the shaping machine (5). The hydraulic cylinder of the shaping machine (5) drives the shaping die to descend. By switching the fixture, pressure is applied to the W-shaped profile (2) to achieve shaping. After the shaping is completed, the hydraulic cylinder drives the shaping die to reset, and the W-shaped profile (2) is transformed into a U-shaped copper bar (3).

2. A method for making an extra-large U-shaped copper busbar according to claim 1, Features: In step 2, the heating temperature of the mold and the mold sleeve of the continuous extruder (4) is 450° C. to 550° C., and the heating time is 3.5 to 4.5 hours; The mold base (1.1) in step 2 is also provided with two limiting holes (1.3), which are respectively arranged above and below the mold core (1.2); The included angle between the first oblique section (1.21) and the second oblique section (1.22) is 20° to 45°; The included angle between the first side arm (1.23) and the first oblique section (1.21) is 15° to 45°, and the included angle between the second side arm (1.24) and the second oblique section (1.22) is the same as the included angle between the first side arm (1.23) and the first oblique section (1.21); The thickness of the first side arm (1.23) and the second side arm (1.24) is 10-15 mm; The thickness of the first oblique section (1.21) and the second oblique section (1.22) is 10-12 mm; The height of the first side arm (1.23) and the second side arm (1.24) is 75-85 mm; The width of the U-shaped copper busbar (3) is not less than 400 mm.

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