A production process for high semi-hard enameled wire

Abstract

This invention discloses a production process for high semi-hard enameled wire, relating to the field of enameled wire production technology, including the following specific steps: bare wire processing, online annealing of bare wire, semi-hardening of bare wire, online coating, semi-hardening of enameled wire, and winding. The enameled wire after semi-hardening treatment undergoes multiple online coating processes. The pressure roller is set after the third-to-last online coating process. By controlling the yield strength value of the finished product through enameling, the processing steps in the enameling production process are greatly reduced, improving the production efficiency of the workshop. By performing semi-hardening treatment on the conductor in sections, the problem of yield strength reduction after the enameled wire passes through the oven is further reduced. By semi-hardening the enameled wire before coating, damage to the enamel film caused by semi-hardening is avoided.

Description

Technical Field

[0001] This invention relates to the field of enameled wire production technology, specifically to a production process for high semi-hard enameled wire. Background Technology

[0002] Semi-rigidity refers to the yield strength of a conductor. Yield strength is the yield limit of a metallic material when it undergoes yielding, that is, the stress that resists a small amount of plastic deformation. For metallic materials that do not exhibit obvious yielding, the stress value that produces 0.2% residual deformation is defined as its yield limit, called the conditional yield limit or yield strength. External forces exceeding the yield strength will cause permanent and irreversible failure of the component.

[0003] Traditional methods for manufacturing high-semi-rigid enameled wire rely on secondary processing using bare wire and annealing equipment. This process involves multiple bare wire processing steps, which is cumbersome and carries numerous risks. If any intermediate product is defective, subsequent processes will also produce defective products, ultimately leading to substandard finished products, impacting production efficiency and customer satisfaction. By reducing the number of processing steps and minimizing the risks in enameled wire production, production capacity and efficiency can be significantly improved.

[0004] To address the above problems, this invention provides a manufacturing process for high semi-hard enameled wire. Summary of the Invention

[0005] The purpose of this invention is to provide a production process for high semi-hard enameled wire. By controlling the yield strength value of the finished product through enameling, the processing steps in the enameling production process are greatly reduced, and the production efficiency of the workshop is improved. By performing semi-hardening treatment on the conductor in sections, the conductor is pre-treated by semi-hardening before coating (first pressing to 70-80% of the target value). After multiple coatings, the yield strength of the conductor will decrease by 5-20%. The second pressing can compensate for the decrease in yield strength of the conductor after coating and baking. At the same time, the second semi-hardening results in small conductor dimensional deformation, which can effectively reduce the problems of excessive stretching and damage of the enamel film caused by semi-hardening, thereby solving the problems in the background technology.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a manufacturing process for high semi-hard enameled wire, comprising the following specific steps:

[0007] Step 1: Bare wire processing. The copper rod is processed into a conductor with the required cross-sectional area using bare wire processing equipment. The process from copper rod to conductor with the required cross-sectional area is completed in one step. Multiple sets of bare wire processing equipment are set up in series according to the cross-sectional area of ​​the copper rod to the cross-sectional area of ​​the conductor with the required cross-sectional area. The process of processing the copper rod material into a conductor by multiple sets of bare wire processing equipment in series is completed in one step. After the bare wire processing step, a bare conductor that meets the process cross-sectional requirements is obtained.

[0008] Step 2: Bare wire online annealing. The bare wires obtained in Step 1 are passed through the online annealing equipment by actively feeding them out using a wire feeding frame. The online annealing equipment is used to anneal the bare wires.

[0009] Step 3: Bare wire semi-hardening. After cooling, the bare conductor that has undergone online annealing in Step 2 is passed through a set of pressure rollers for semi-hardening treatment. The pressure rollers are connected to the adjusting screw, which is set with a scale. The appropriate clamping scale is selected according to the bare conductor with different specifications and different yield strength requirements. After the bare conductor passes through the pressure rollers, it undergoes bending deformation, which hardens the bare conductor.

[0010] Step 4: Online coating. The bare wires after the semi-hardening treatment are passed through the coating equipment. The coating equipment evenly coats the bare wires with paint. The coated bare wires are then passed through an oven for curing and shaping. After the paint on the bare wires passes through the oven, the solvent in the paint will evaporate to obtain enameled wire.

[0011] Step 5: Semi-hardening of enameled wire. After the enameled wire that has been coated online and cured in Step 4 has cooled, it is passed through a set of pressure rollers for semi-hardening treatment. The pressure rollers are connected to an adjusting screw with a scale. The appropriate pressing scale is selected according to the different specifications and yield strength requirements of the enameled wire. After the enameled wire passes through the pressure rollers, it undergoes bending deformation, thus achieving hardening of the enameled wire.

[0012] Step Six: Winding up the wire. The finished enameled wire is wound up using a winding rack.

[0013] Furthermore, in step one, the copper rod is either oxygen-free copper rod or low-oxygen copper rod. The bare wire processing equipment is equipped with a high-precision polycrystalline mold. During processing, the cross-sectional compression of the conductor in a single pass is set within 15%-32%, and the conductor drawing speed in the bare wire processing equipment is set within 30-75 m / min. The diameter of the conductor before and after processing by a single bare wire processing equipment is measured by two sets of online diameter measuring devices. By comparing the difference in diameter, the cross-sectional compression of a single bare wire processing equipment can be obtained. The conductor drawing speed is adaptively adjusted according to the cross-sectional compression of the conductor in a single pass. The number of sets of bare wire processing equipment is selected according to the copper rod raw material, the target size of the conductor, and the cross-sectional compression of the conductor in a single pass.

[0014] Furthermore, based on the deformation of the conductor cross-section and the cross-sectional shape of the conductor, one of the following is selected: a wire drawing machine, a rolling mill, or a precision rolling mill. Based on different conductor cross-sectional shapes, a high-precision polycrystalline die with the corresponding cross-sectional shape is selected, and the conductor is formed in one step through a series of bare wire processing equipment.

[0015] Furthermore, in step two, the annealing temperature in the online annealing equipment is set within the range of 450-650℃. The annealing temperature is adjusted adaptively according to the specifications of the bare wire and the actual machine speed. When the temperature inside the online annealing equipment is constant, the machine speed increases as the specifications of the bare wire decreases, and the annealing equipment is filled with nitrogen.

[0016] Furthermore, in step three, the pressure rollers are arranged in two rows, staggered vertically. The bare conductor is threaded between the two rows of pressure rollers. By adjusting the screw, the downward pressure scale of the pressure roller on the upper side of the bare conductor is adjusted to regulate different degrees of compression. The compression amount of the bare conductor is set between 0.050mm and 0.200mm. The compression amount of the pressure rollers is adjusted according to the different specifications and sizes of the bare conductor so that the yield strength of the bare conductor after semi-hardening treatment is in the range of 180-220N / mm. 2 .

[0017] Furthermore, in step four, the temperature of the inlet zone of the oven is set between 120-220℃, the temperature of the lower zone of the oven is set between 220-320℃, the temperature of the evaporation zone of the oven is set between 250-380℃, and the temperature of the curing zone of the oven is set between 380-480℃.

[0018] Furthermore, the enameled wire passes sequentially through the inlet zone, lower zone, evaporation zone, and curing zone of the oven.

[0019] Furthermore, in step five, the pressure rollers are arranged in two rows, staggered vertically. The enameled wire is threaded between the two rows of pressure rollers. By adjusting the screw, the downward pressure scale of the pressure roller above the enameled wire is adjusted to achieve different degrees of compression. The compression amount of the enameled wire is set between 0.080mm and 0.170mm. The compression amount of the pressure rollers is adjusted according to the different specifications and sizes of the enameled wire to ensure that the yield strength of the enameled wire after semi-hardening treatment is ≥230N / mm. 2 .

[0020] Furthermore, in step five, the enameled wire that has undergone semi-hardening treatment is subjected to the online coating process in step four multiple times, with the pressure roller in step five being positioned after the third-to-last online coating process.

[0021] Furthermore, the speed of the bare conductor and enameled wire in steps two to six is ​​set to 5-17 m / min. The speed of each process in steps two to six is ​​kept consistent. The overall speed of steps two to six is ​​adjusted by the active wire feeding of the wire feeding frame and the active wire taking-up of the wire taking-up frame.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0023] This invention provides a production process for high semi-hard enameled wire. By controlling the yield strength value of the finished product through enameling, the processing steps in the enameling production process are greatly reduced, and the production efficiency of the workshop is improved. By performing semi-hardening treatment on the conductor in sections, the problem of the yield strength value of the enameled wire decreasing after passing through the oven is further reduced. By applying the enamel coating after semi-hardening the enameled wire, the enamel film damage caused by semi-hardening is avoided. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the process flow of the present invention. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] Please see Figure 1 A manufacturing process for high semi-hard enameled wire includes the following specific steps:

[0027] Step 1: Bare wire processing. The copper rod is processed into a conductor with the required cross-sectional area using bare wire processing equipment. The process from copper rod to conductor with the required cross-sectional area is completed in one step. Multiple sets of bare wire processing equipment are set up in series according to the cross-sectional area of ​​the copper rod and the amount of cross-sectional compression of the conductor with the required cross-sectional area. The process of processing copper rod material into conductor can be completed in one step by multiple sets of bare wire processing equipment. After the bare wire processing process, a bare conductor that meets the process cross-sectional requirements is obtained.

[0028] Step 2: Online annealing of bare wires. The bare wires obtained in Step 1 are passed through the online annealing equipment by actively feeding the wires through the wire feeding frame. The online annealing equipment is used to anneal the bare wires, which can eliminate the internal stress generated in the wires due to the bare wire processing in Step 1, making the bare wires less prone to deformation in subsequent production processes.

[0029] Step 3: Bare wire semi-hardening. After cooling, the bare conductor that has undergone online annealing in Step 2 is passed through a set of pressure rollers for semi-hardening treatment. The pressure rollers are connected to an adjusting screw, which is set with a scale. The appropriate clamping scale is selected according to the bare conductor with different specifications and different yield strength requirements. The bare conductor undergoes bending deformation after passing through the pressure rollers, thereby hardening the bare conductor.

[0030] Step 4: Online coating. The bare wires, after being semi-hardened, are passed through the coating equipment. The coating equipment is equipped with a movable mold to prevent the joint from being broken due to the fixed mold after the joint. The bare wires are placed inside the movable mold, and the coating equipment evenly coats the bare wires with paint. The coated bare wires are then passed through an oven for curing and shaping. After passing through the oven, the solvent in the paint on the bare wires will evaporate, resulting in an enameled layer on the bare wires, thus obtaining enameled wire.

[0031] Step 5: Semi-hardening of enameled wire. After the enameled wire that has been coated online in Step 4 and whose enamel film has been cured has cooled, it is passed through a set of pressure rollers for semi-hardening treatment. The pressure rollers are connected to an adjusting screw, which is set with a scale. The appropriate pressing scale is selected according to the enameled wire with different specifications and different yield strength requirements. The enameled wire undergoes bending deformation after passing through the pressure rollers, thereby hardening the enameled wire.

[0032] Step Six: Winding up the wire. The finished enameled wire is wound up using a winding rack.

[0033] In step one, the copper rod used is either oxygen-free copper rod or low-oxygen copper rod. A 6mm oxygen-free copper rod is used for processing flat copper wire, and a 3mm oxygen-free copper rod is used for processing round copper wire. The bare wire processing equipment is equipped with a high-precision polycrystalline mold. During processing, the cross-sectional compression of the conductor in a single pass is set between 15% and 32%, and the conductor drawing speed is set between 30 and 75 m / min. Two sets of online diameter measuring devices are used to measure the diameter of the conductor before and after processing. By comparing the diameter difference, the cross-sectional compression of a single pass can be obtained. The conductor drawing speed is adaptively adjusted based on the cross-sectional compression of the conductor in a single pass, thereby ensuring high-speed, high-quality wire drawing production. The number of sets of bare wire processing equipment is selected based on the copper rod raw material, the target size of the conductor, and the cross-sectional compression of the conductor in a single pass.

[0034] Based on the amount of deformation of the conductor cross-section and the shape of the conductor cross-section, one of the following can be selected: wire drawing machine, rolling mill, and precision rolling mill. Based on different conductor cross-section shapes, a high-precision polycrystalline die with the corresponding cross-section shape can be selected. The conductor can be formed and produced in one step by connecting bare wire processing equipment.

[0035] In step two, the annealing temperature in the online annealing equipment is set within the range of 450-650℃. The annealing temperature is adjusted adaptively according to the specifications of the bare wire and the actual machine speed. When the temperature inside the online annealing equipment is constant, the machine speed is increased when the specifications of the bare wire decreases to prevent the conductor from deforming due to excessive temperature. The annealing equipment is filled with nitrogen to isolate the bare wire from external oxygen during the annealing process, so as to prevent oxidation reaction of the bare wire and avoid the formation of oxides on the bare wire that would affect subsequent processing.

[0036] In step three, the pressure rollers are arranged in two rows, staggered vertically. The bare conductor is threaded between the two rows of pressure rollers. By adjusting the screw, the pressure scale of the pressure roller on the upper side of the bare conductor can be adjusted to achieve different degrees of compression. The compression amount of the bare conductor is set between 0.050mm and 0.200mm. The compression amount of the pressure rollers is adjusted according to the different specifications and sizes of the bare conductor so that the yield strength of the bare conductor after semi-hardening treatment is in the range of 180-220N / mm. 2 This allows for the semi-hardening treatment of bare conductors.

[0037] In step four, the temperature of the inlet zone of the oven is set between 120-220℃, the temperature of the lower zone is set between 220-320℃, the temperature of the evaporation zone is set between 250-380℃, and the temperature of the curing zone is set between 380-480℃. The enameled wire passes through the inlet zone, lower zone, evaporation zone, and curing zone of the oven in sequence, and the enameled layer on the wire is cured and shaped by gradually increasing and decreasing the temperature.

[0038] In step five, the pressure rollers are arranged in two rows, staggered vertically. The enameled wire is threaded through the rollers between the two rows. By adjusting the screw, the pressure setting of the roller above the enameled wire can be adjusted to achieve different degrees of compression. The compression amount is set between 0.080mm and 0.170mm. The compression amount is adjusted according to the different specifications and sizes of the enameled wire to ensure that the yield strength of the semi-hardened enameled wire is ≥230N / mm². 2 This allows for the semi-hardening treatment of enameled wire.

[0039] In step five, the enameled wire, after undergoing semi-hardening treatment, undergoes the online coating process in step four multiple times. This avoids cracks and other defects on the surface of the enameled layer caused by semi-hardening of the enameled wire. After the online coating process in step four, the enameled wire passes through an oven for volatilization to achieve curing and shaping, thereby ensuring the integrity of the enameled layer. The pressure roller in step five is located after the third-to-last online coating process, which ensures that the thickness of the enameled layer meets the process requirements while ensuring the integrity and insulation performance of the enameled layer through multi-layer coating.

[0040] The speed of the bare conductors and enameled wires in steps two through six is ​​set to 5-17 m / min. The speed of each process in steps two through six is ​​kept consistent. The overall speed of steps two through six is ​​adjusted by the active wire feeding of the wire feeding frame and the active wire taking-up of the wire taking-up frame.

[0041] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for high semi-hard enameled wire, characterized in that: The specific steps include the following: Step 1: Bare wire processing. The copper rod is processed into a conductor with the required cross-sectional area using bare wire processing equipment. The process from copper rod to conductor with the required cross-sectional area is completed in one step. Multiple sets of bare wire processing equipment are set up in series according to the cross-sectional area of ​​the copper rod to the cross-sectional area of ​​the conductor with the required cross-sectional area. The process of processing the copper rod material into a conductor by multiple sets of bare wire processing equipment in series is completed in one step. After the bare wire processing step, a bare conductor that meets the process cross-sectional requirements is obtained. Step 2: Bare wire online annealing. The bare wires obtained in Step 1 are passed through the online annealing equipment by actively feeding them out using a wire feeding frame. The online annealing equipment is used to anneal the bare wires. Step 3: Bare wire semi-hardening. After cooling, the bare conductor that has undergone online annealing in Step 2 is passed through a set of pressure rollers for semi-hardening treatment. The pressure rollers are connected to the adjusting screw, which is set with a scale. The appropriate clamping scale is selected according to the bare conductor with different specifications and different yield strength requirements. After the bare conductor passes through the pressure rollers, it undergoes bending deformation, which hardens the bare conductor. Step 4: Online coating. The bare wires after the semi-hardening treatment are passed through the coating equipment. The coating equipment evenly coats the bare wires with paint. The coated bare wires are then passed through an oven for curing and shaping. After the paint on the bare wires passes through the oven, the solvent in the paint will evaporate to obtain enameled wire. Step 5: Semi-hardening of enameled wire. After the enameled wire that has been coated online and cured in Step 4 has cooled, it is passed through a set of pressure rollers for semi-hardening treatment. The pressure rollers are connected to an adjusting screw with a scale. The appropriate pressing scale is selected according to the different specifications and yield strength requirements of the enameled wire. After the enameled wire passes through the pressure rollers, it undergoes bending deformation and hardening. Step Six: Winding up the wire. The finished enameled wire is wound up using a winding rack.

2. The manufacturing process of high semi-hard enameled wire according to claim 1, characterized in that: In step one, the copper rod used is either oxygen-free copper rod or low-oxygen copper rod. The bare wire processing equipment is equipped with a high-precision polycrystalline mold. During processing, the cross-sectional compression of the conductor in a single pass is set between 15% and 32%, and the conductor drawing speed in the bare wire processing equipment is set between 30 and 75 m / min. The diameter of the conductor before and after processing is measured by two sets of online diameter measuring devices. By comparing the difference in diameter, the cross-sectional compression of a single pass can be obtained. The conductor drawing speed is adaptively adjusted according to the cross-sectional compression of the conductor in a single pass. The number of sets of bare wire processing equipment is selected according to the copper rod raw material, the target size of the conductor, and the cross-sectional compression of the conductor in a single pass.

3. The manufacturing process of high semi-hard enameled wire according to claim 2, characterized in that: Based on the amount of deformation of the conductor cross-section and the cross-sectional shape of the conductor, one of the following is selected: wire drawing machine, rolling mill, and precision rolling mill. Based on different conductor cross-sectional shapes, a high-precision polycrystalline die with the corresponding cross-sectional shape is selected. The conductor is then produced in one step by connecting bare wire processing equipment.

4. The manufacturing process of high semi-hard enameled wire according to claim 1, characterized in that: In step two, the annealing temperature in the online annealing equipment is set within the range of 450-650℃. The annealing temperature is adjusted adaptively according to the specifications of the bare wire and the actual machine speed. When the temperature inside the online annealing equipment is constant, the machine speed increases as the specifications of the bare wire decreases. The annealing equipment is filled with nitrogen.

5. The manufacturing process of high semi-hard enameled wire according to claim 1, characterized in that: In step three, the pressure rollers are arranged in two rows, staggered vertically. The bare conductor is threaded through between the two rows of pressure rollers. The pressure scale of the upper pressure roller on the bare conductor is adjusted by adjusting the screw to adjust different degrees of compression. The compression amount of the bare conductor is set between 0.050mm and 0.200mm. The compression amount of the pressure rollers is adjusted according to the different specifications and sizes of the bare conductor so that the yield strength of the bare conductor after semi-hardening treatment is in the range of 180-220N / mm. 2 .

6. The manufacturing process of high semi-hard enameled wire according to claim 5, characterized in that: In step four, the temperature of the inlet zone of the oven is set between 120-220℃, the temperature of the lower zone is set between 220-320℃, the temperature of the evaporation zone is set between 250-380℃, and the temperature of the curing zone is set between 380-480℃.

7. The manufacturing process of high semi-hard enameled wire according to claim 6, characterized in that: The enameled wire passes sequentially through the inlet zone, lower zone, evaporation zone, and curing zone of the oven.

8. The manufacturing process of high semi-hard enameled wire according to claim 1, characterized in that: In step five, the pressure rollers are arranged in two rows, staggered vertically. The enameled wire is threaded through the rollers between the two rows. The pressure setting of the roller above the enameled wire is adjusted by adjusting the screw to adjust the different levels of compression. The compression amount is set between 0.080mm and 0.170mm. The compression amount is adjusted according to the different specifications and sizes of the enameled wire to ensure that the yield strength of the semi-hardened enameled wire is ≥230N / mm². 2 .

9. The manufacturing process of high semi-hard enameled wire according to claim 8, characterized in that: In step five, the enameled wire that has undergone semi-hardening treatment is subjected to the online coating process in step four multiple times. The pressure roller in step five is located after the third-to-last online coating process.

10. The manufacturing process of high semi-hard enameled wire according to claim 1, characterized in that: The speed of the bare conductors and enameled wires in steps two through six is ​​set to 5-17 m / min. The speed of each process in steps two through six is ​​kept consistent. The overall speed of steps two through six is ​​adjusted by the active wire feeding of the wire feeding frame and the active wire taking-up of the wire taking-up frame.

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