A method for manufacturing rigid square litz wire

Abstract

The application provides a processing preparation method for rigid square Litz wire, which comprises the following steps: step 1, twisting the enameled round wire by using self-adhesive enameled wire; step 2, wrapping polyester film as a protective layer after twisting; step 3, carrying out square pressing treatment according to requirements, obtaining square Litz wire with required size after square pressing, and removing the protective layer; step 4, insulating coating the wire; and step 5, feeding the wire into a heat treatment array type forming equipment to carry out heating treatment forming, so that self-adhesion is generated between the enameled wires, the whole Litz wire forms a whole, and rigidity is generated. The application makes the wire have certain rigidity, is easier to be made into a shaped coil, and guarantees the performance of the product.

Description

Technical Field

[0001] This invention relates to the field of Litz wire processing, and more particularly to a method for processing and preparing rigid square Litz wire. Background Technology

[0002] Current shaped coil technology uses flat copper wire as the electromagnetic wire. Compared to round copper wire, it has the disadvantage of higher losses. Flat wire motors inevitably suffer from the "skin effect"—when there is alternating current or an alternating electromagnetic field in the conductor, the current distribution inside the conductor is uneven, and the current tends to concentrate on the surface "skin" of the conductor. This effect results in increased conductor resistance, and consequently, increased power loss. In flat wire motors, this manifests as higher AC copper losses in the flat wire windings at higher frequencies. However, round copper wire has a disadvantage compared to flat copper wire: lower slot fill factor. To improve the slot fill factor, rigid square Litz wire must be used. Traditional Litz wire is soft and lacks rigidity, making it difficult to manufacture shaped coils. Summary of the Invention

[0003] To address the aforementioned issues, this invention discloses a method for processing and preparing rigid square Litz wire. The raw material used is self-adhesive enameled wire, which is stranded, pressed into square, insulated, and hot-pressed to give the wire a certain rigidity, making it easier to form into coils and ensuring product performance.

[0004] A method for fabricating rigid square Litz wire includes the following steps: Step 1: Use self-adhesive enameled wire to twist the enameled round wires together; Step 2: After twisting, wrap with polyester film as a protective layer; Step 3: Perform squaring according to requirements. After squaring, a square Litz wire of the required size is obtained, and the protective layer is removed. Step 4: Insulate the wires; Step 5: The wire is fed into a heat treatment array forming equipment for heat treatment and forming, so that the enameled wires self-adhede and the entire Litz wire becomes a whole, thereby generating rigidity.

[0005] Furthermore, step 3 employs a pressure straightening device for pressure straightening; the pressure straightening device includes an operating table, with a pressure mold positioned above the operating table; the pressure mold is connected via a pressure cylinder; the pressure cylinder is fixed to an upper support platform; straightening plates are provided on both sides of the operating table; each straightening plate is connected and fixed to a straightening cylinder.

[0006] This invention uses a paper wrapping machine to wrap polyester film around stranded wires to protect the wires from damage to the enameled wire insulation during pressing. After pressing, the polyester film is manually peeled off, and then the wires are wrapped with insulation again using the paper wrapping machine. This invention feeds the wires onto the operating table, where a pressing cylinder drives the pressing mold downwards for pressing. Simultaneously, because the straightening cylinders at both ends drive the straightening plates, the pressed wires are straightened and pressed at both ends, further improving the forming degree of the pressing process.

[0007] Furthermore, the heat treatment array forming equipment includes a conveying accuracy adjustment device, an annealing furnace, a heating conveying roller, and an array forming device arranged in sequence; the conveying accuracy adjustment device includes a conveying trough and a conveying plate; the surface of the conveying trough is provided with a plurality of first conveying wheels; auxiliary conveying components are respectively provided on both sides of the conveying trough; each of the auxiliary conveying components includes a connecting plate, a spring plate, and a side conveying plate; wherein the side conveying plate is provided with a plurality of universal wheels.

[0008] The conveyor plate is provided with positioning rollers; several support plates are provided on the outer circumference of each positioning roller at both ends; the end of the conveyor roller is connected to the support plate; a pressure roller is provided next to each conveyor roller; there is a gap between the conveyor roller and the pressure roller; each end of the pressure roller is connected to an arc-shaped support rod; one end of the arc-shaped support rod is rotatably connected to the end of the positioning roller; one end of the spring rod is connected to the positioning roller and the other end is fixedly connected to the arc-shaped support rod.

[0009] The Litz wire is conveyed by the first conveyor wheel on the conveying trough. During the conveying process, an auxiliary conveying component is provided on the side, and the universal wheels on the auxiliary conveying component assist in the conveying. Because there is a spring plate, it can be used with Litz wire of different widths. The purpose of this conveying trough is to further improve the stability of the conveying. Then, it is pressed by the pressure roller and the conveying roller in sequence while ensuring the conveying. This further improves the flatness of the internal structure of the Litz wire and ensures uniform heat treatment. The arc-shaped support rod allows for a wider range of adjustment angles, adjusting the positional relationship between the pressure roller and the conveying roller, and is used with Litz wire of different thicknesses to ensure the stability of the processing operation.

[0010] Furthermore, a transmission roller is provided between the two positioning rollers; one end of the transmission roller is connected to a transmission motor, which drives the transmission roller to rotate, providing the power for conveying. Furthermore, a transverse plate is provided above the heating conveying roller; a first cylinder is provided at both the front and rear ends of the transverse plate; the cylinder shaft of each first cylinder is connected and fixed to the pressure plate; a pressure rod is provided at both ends of each pressure plate; and a pressure roller is connected to the end of the pressure rod.

[0011] Then it is sent into the annealing furnace for the first heat treatment, and then into the heating conveyor roller for the second heat treatment. Since there is a pressure roller above the heating conveyor roller, the first cylinder drives the pressure roller downward to limit the upper part of the Litz wire, ensuring that it can smoothly fit with the heating conveyor roller for the second heating.

[0012] Furthermore, the array-type forming device includes an array box; both the inlet and outlet ends of the array box are equipped with conveyor wheels; array components are provided above and below the array box; each array component includes a lead screw drive mechanism, a lead screw motor, and a heating plate; wherein the lead screw motor is connected to the lead screw drive mechanism; and one end of the heating plate is fixed to the slider of the lead screw drive mechanism.

[0013] The Litz wire undergoes a third heat treatment via an array-type forming device. It is fed into the array box, where a lead screw motor drives the lead screw transmission mechanism to press and heat the Litz wire with heating plates at both ends. This process heats and gels the Litz wire, giving it rigidity and allowing it to be made into a shaped coil. During the operation, the upper and lower heating plates also impact the Litz wire to remove stress from its internal structure.

[0014] Furthermore, the bottom of the conveying trough is connected and fixed to the lifting plate via a lifting device, which facilitates the adjustment of the height of the conveying trough.

[0015] Furthermore, the bottom of the operating table is connected to a rotary motor, which can be used to rotate the angle of the operating table.

[0016] The beneficial effects of this invention are as follows: through stranding, pressing, insulation coating, and hot pressing, the wire has a certain rigidity. After multiple heat treatments, its internal viscosity and rigidity are improved, making it easier to form into shaped coils and ensuring product performance. Attached Figure Description

[0017] Figure 1 The present invention is a pressure correction device; Figure 2 The present invention is a heat treatment array forming device; Figure 3 A top view of the conveying trough of the present invention; Figure 4 , Figure 3 A magnified view of part A in the image; Figure 5 A schematic diagram of the positioning roller; Figure 6 A schematic diagram of the array-type molding device.

[0018] List of reference numerals in the attached diagram: The components are as follows: 1-operating table; 2-pressing mold; 3-pressing cylinder; 4-upper support platform; 5-correcting plate; 6-correcting cylinder; 7-conveyor trough; 8-conveyor plate; 9-first conveyor wheel; 10-connecting plate; 11-spring plate; 12-side conveyor plate; 13-universal wheel; 14-positioning roller; 15-support plate; 17-conveyor roller; 18-pressure roller; 19-arc support rod; 20-spring rod; 21-drive roller; 22-transverse plate; 23-first cylinder; 24-pressure plate; 25-pressure rod; 26-pressure wheel; 27-array box; 28-second conveyor wheel; 29-screw drive mechanism; 30-screw motor; 31-heating plate; 32-slider; a-conveyor accuracy adjustment device; b-annealing furnace; c-heated conveyor roller; d-array forming device. Detailed Implementation

[0019] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that the following specific embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, and the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0020] A method for processing and preparing rigid square Litz wire, characterized by comprising the following steps: Step 1: Use self-adhesive enameled wire to twist the enameled round wires together; Step 2: After twisting, wrap with polyester film as a protective layer; Step 3: Perform squaring according to requirements. After squaring, obtain a square Litz wire of the required dimensions and remove the protective layer; refer to... Figure 1 As shown, step 3 employs a square straightening device for square straightening. The square straightening device includes an operating table 1, with a square straightening mold 2 positioned above the operating table 1. The square straightening mold 2 is connected via a square straightening cylinder 3. The square straightening cylinder 3 is fixed to an upper support platform 4. Straightening plates 5 are provided on both sides of the operating table 1. Each straightening plate 5 is connected and fixed to a straightening cylinder 6. The bottom of the operating table 1 is connected to a rotary motor 35. The angle of the operating table 1 can be adjusted later via the rotary motor to meet different processing requirements.

[0021] The wire is wrapped with polyester film to protect the wire from damage to the enameled wire insulation during sizing. After sizing, the polyester film is manually peeled off, and then the wire is wrapped with insulation using a paper wrapping machine. In this invention, the wire is fed into the operating table, where a sizing cylinder drives the sizing mold downwards for sizing. Simultaneously, because the straightening cylinders at both ends drive the straightening plates, the sizing wire is straightened and pressed at both ends, further improving the sizing shape. Step 4: Insulate the wires; Step 5: The wire is fed into a heat treatment array forming equipment for heat treatment and forming, so that the enameled wires self-adhede and the entire Litz wire becomes a whole, thereby generating rigidity.

[0022] Reference Figures 2-6 The heat treatment array forming equipment includes a conveying accuracy adjustment device a, an annealing furnace b, a heating conveying roller c, and an array forming device d arranged in sequence; the conveying accuracy adjustment device a includes a conveying trough 7 and a conveying plate 8; the surface of the conveying trough 7 is provided with a plurality of first conveying wheels 9; the bottom of the conveying trough 7 is connected and fixed to the lifting plate 34 through a lifting device 33; auxiliary conveying components are respectively provided on both sides of the conveying trough 7. Reference Figure 3 and 4 As shown, each of the auxiliary conveying components includes a connecting plate 10, a spring plate 11, and a side conveying plate 12; wherein the side conveying plate 12 is provided with a plurality of universal wheels 13; the conveying plate 14 is provided with a positioning roller 14; a plurality of support plates 15 are provided on the outer circumferential surface at both ends of each positioning roller 14; wherein the end of the conveying roller 17 is connected to the support plate 15; a pressure roller 18 is provided next to each conveying roller 17; there is a gap between the conveying roller 17 and the pressure roller 18; each end of the pressure roller 18 is connected to an arc-shaped support rod 19; one end of the arc-shaped support rod 19 is rotatably connected to the end of the positioning roller 14; one end of the spring rod 20 is connected to the positioning roller 14 and the other end is fixedly connected to the arc-shaped support rod 19.

[0023] Reference Figure 2 As shown, a transmission roller 21 is provided between the two positioning rollers 14; one end of the transmission roller 21 is connected to a transmission motor. A transverse plate 22 is provided above the heating conveying roller c; a first cylinder 23 is provided at both the front and rear ends of the transverse plate 22; the cylinder shaft of each first cylinder 23 is connected and fixed to a pressure plate 24; a pressure rod 25 is provided at both ends of each pressure plate 24; the end of the pressure rod 25 is connected to a pressure roller 26.

[0024] The Litz wire is conveyed by the first conveyor wheel on the conveying trough. During the conveying process, an auxiliary conveying component is provided on the side, and the universal wheels on the auxiliary conveying component assist in the conveying. Because there is a spring plate, it can be used with Litz wire of different widths. The purpose of this conveying trough is to further improve the stability of the conveying. Then, it is pressed by the pressure roller and the conveying roller in sequence while ensuring the conveying. This further improves the flatness of the internal structure of the Litz wire and ensures uniform heat treatment. The arc-shaped support rod allows for a wider range of adjustment angles, adjusting the positional relationship between the pressure roller and the conveying roller, and is used with Litz wire of different thicknesses to ensure the stability of the processing operation.

[0025] ReferenceFigure 6 As shown, the array forming device includes an array housing 27; the inlet and outlet ends of the array housing 27 are both provided with second conveying wheels 28; array components are provided above and below the array housing 27; each array component includes a lead screw drive mechanism 29, a lead screw motor 30, and a heating plate 31; wherein the lead screw motor 30 is connected to the lead screw drive mechanism 29; wherein one end of the heating plate 31 is fixed on the slider 32 of the lead screw drive mechanism 29.

[0026] The Litz wire undergoes a third heat treatment via an array-type forming device. It is fed into the array box, where a lead screw motor drives the lead screw transmission mechanism to press and heat the Litz wire with heating plates at both ends. This process heats and gels the Litz wire, giving it rigidity and allowing it to be made into a shaped coil. During the operation, the upper and lower heating plates also impact the Litz wire to remove stress from its internal structure.

[0027] The technical means disclosed in this invention are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features.

Claims

1. A method for processing and preparing rigid square Litz wire, characterized in that: Includes the following steps: Step 1: Use self-adhesive enameled wire to twist the enameled round wires together; Step 2: After twisting, wrap with polyester film as a protective layer; Step 3: Perform squaring according to requirements. After squaring, a square Litz wire of the required size is obtained, and the protective layer is removed. Step 4: Insulate the wires; Step 5: The wire is fed into a heat treatment array forming device for heat treatment and forming, so that the enameled wires self-adhede and the entire Litz wire becomes a whole, thereby generating rigidity; the heat treatment array forming device includes a conveying accuracy adjustment device (a), an annealing furnace (b), a heated conveying roller (c), and an array forming device (d) arranged in sequence; the conveying accuracy adjustment device (a) includes a conveying trough (7) and a conveying plate (8); the surface of the conveying trough (7) is provided with a plurality of first conveying wheels (9); auxiliary conveying components are provided on both sides of the conveying trough (7); each of the auxiliary conveying components includes a connecting plate (10) ), spring plate (11) and side conveyor plate (12); wherein the side conveyor plate (12) is provided with several universal wheels (13); the conveyor plate (8) is provided with positioning rollers (14); several support plates (15) are provided on the outer circumference of each positioning roller (14); wherein the end of the conveyor roller (17) is connected to the support plate (15); a pressure roller (18) is provided next to each conveyor roller (17); there is a gap between the conveyor roller (17) and the pressure roller (18); each end of the pressure roller (18) is connected to an arc-shaped support rod (19); one end of the arc-shaped support rod (19) is connected to the positioning roller (14) The ends of the spring rod (20) are rotatably connected; one end of the spring rod (20) is connected to the positioning roller (14) and the other end is connected and fixed to the arc-shaped support rod (19); a transmission roller (21) is provided between the two positioning rollers (14); one end of the transmission roller (21) is connected to the transmission motor; a transverse plate (22) is provided above the heating conveying roller (c); a first cylinder (23) is provided at both the front and rear ends of the transverse plate (22); the cylinder shaft of each first cylinder (23) is connected and fixed to the pressure plate (24); a pressure rod (25) is provided at both ends of each pressure plate (24); the end of the pressure rod (25) is connected to the pressure wheel (2). 6) The array forming device includes an array box (27); the inlet and outlet ends of the array box (27) are provided with second conveying wheels (28); array components are provided above and below the array box (27); each array component includes a screw drive mechanism (29), a screw motor (30) and a heating plate (31); wherein the screw motor (30) is connected to the screw drive mechanism (29); wherein one end of the heating plate (31) is fixed on the slider (32) of the screw drive mechanism (29); the bottom of the conveying groove (7) is connected and fixed to the lifting plate (34) through a lifting device (33).

2. The method for processing and preparing rigid square Litz wire according to claim 1, characterized in that: Step 3 uses a pressure straightening device for pressure straightening; the pressure straightening device includes an operating table (1), and a pressure mold (2) is provided above the operating table (1); the pressure mold (2) is connected by a pressure cylinder (3); the pressure cylinder (3) is fixed on the upper support platform (4); straightening plates (5) are provided on both sides of the operating table (1); each straightening plate (5) is connected and fixed to a straightening cylinder (6).

3. The method for processing and preparing rigid square Litz wire according to claim 2, characterized in that: The bottom of the operating table (1) is connected to the rotary motor (35).

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