A flat copper wire production method, a production system and a flat copper wire produced by the same

Abstract

The present invention relates to the technical field of special equipment or methods for manufacturing conductors or cables, and specifically discloses a flat copper wire production method, a production system and the flat copper wire produced by the same. The production method includes two parts: preliminary processing and deep processing, wherein the preliminary processing includes continuously extruding round copper wires into flat wire blanks; the deep processing includes drawing and annealing the flat wire blanks to obtain flat copper wires. Between the preliminary processing and the deep processing, cold welding operation is used to connect the flat wire blanks. The beneficial effect of the present invention is that the object in the connection process between the preliminary processing and the deep processing is a flat wire blank with a low Vickers hardness, which can facilitate the smooth cold welding connection operation, ensure that the connection can be used for drawing processing, reduce material waste, and reduce the production cost of the flat copper wire; at the same time, the flat wire blank can reduce the loss of the drawing die and reduce the drawing power consumption, so that the processing method can be dedicated to the processing of flat copper wires of different specifications.

Description

Technical Field

[0001] The invention relates to the technical field of special equipment or methods for manufacturing conductors or cables, and in particular to a flat copper wire production method, a production system and the flat copper wire produced by the same. Background Art

[0002] Enameled wire is an important electronic special material, mainly used for winding electromagnetic coils, so it is also called electromagnetic wire, which is a major variety of winding wire. Enameled wire is mainly composed of conductor (usually copper wire or aluminum wire) and insulation layer (insulating varnish), in which the insulation layer is coated on the surface of the conductor to form a dense protective film to prevent current leakage and external environment from corroding the conductor. Enameled wire has four major properties: mechanical properties, chemical properties, electrical properties and thermal properties. These properties enable enameled wire to work stably in various harsh environments and ensure the normal operation of electrical equipment.

[0003] Among the many enameled wire categories, there is flat enameled wire, which is characterized by a flat cross-section, in sharp contrast to the traditional round enameled wire. Due to its unique shape and structure, the flat enameled wire has a higher slot fill rate, that is, under the same winding space conditions, the slot fill rate of the flat enameled wire can reach more than 95%, which is much higher than the approximately 78% of ordinary enameled wire. This allows the flat enameled wire to carry more current in the same space and improve the power density of electrical equipment. Especially in the field of new energy vehicles, flat enameled wire has become an important choice for electromagnetic wire in drive motors due to its excellent softness, flexibility, current carrying capacity and heat dissipation performance. The use of flat enameled wire can increase the service life and performance stability of the motor, so it is very popular.

[0004] In the production process of flat enameled wire, the core conductor part, i.e. flat copper wire, needs to be produced first. In the existing production process of flat copper wire, including the production process of large-size flat copper wire (referring to the flat copper wire with a larger width-to-width ratio of the wire cross section, usually refers to the flat copper wire with a width-to-width ratio greater than 4.0 times, and in some fields, it is even required to have a width-to-width ratio of 20~30 times), it is usually necessary to firstly roll the copper round wire and obtain the initial flat copper wire, and then draw the initial flat copper wire to obtain the final required flat copper wire.

[0005] In the actual production process, in order to reduce the complexity and risk of material management, the complexity and risk of equipment management, etc., it is necessary to divide the production process of flat copper wire. At present, the initial processing of the initial flat copper wire is usually separated from the deep processing of the final flat copper wire, that is, after the copper round wire is cold-rolled to obtain the initial flat copper wire, it is collected on the take-up reel to complete the production of the initial flat copper wire; then the take-up reel is transferred to the initial end of the production line of the final flat copper wire and subsequent drawing, annealing and other processing steps are carried out to finally obtain the required flat copper wire.

[0006] Therefore, in the final production process of flat copper wire, when the initial flat copper wire carried by the current take-up reel at the initial end is almost used up, it is necessary to connect the end of the current initial flat copper wire with the beginning of the initial flat copper wire on the next take-up reel, and then release the initial flat copper wire on the latest take-up reel to start a new round of processing and production. The joint formed on the initial flat copper wire after the connection also needs to pass through the drawing die in the subsequent processing link, so its size is required to be consistent with that of the non-joint, otherwise it is easy to cause accidents such as wire breakage during the drawing process, and the firmness of the joint must also be able to withstand strong pulling.

[0007] In the existing production methods, the connection method used is difficult to make the joint meet the above-mentioned drawing requirements. Therefore, in actual production, some materials at the joint and its vicinity will not be drawn, but directly transmitted until the final flat copper wire storage place is cut off, which actually causes a lot of material waste. Therefore, there is an urgent need for a special production method for flat copper wire, which can achieve standard-compliant production of flat copper wire and improve the material utilization efficiency in the production process of flat copper wire. Summary of the invention

[0008] The technical problem to be solved by the present invention is to provide a method for producing flat copper wire, which can be specially used for the production of flat copper wire, especially large-sized flat copper wire. During the production process, it can ensure that the quality of the wire joints meets the relevant requirements of the drawing process, so that the waste of materials in the processing process is improved.

[0009] The present invention is achieved through the following technical solutions.

[0010] A method for producing a flat copper wire comprises the following steps:

[0011] S1. In a preliminary processing system, round copper wire is continuously extruded into flat wire stock, and stored on a first wire take-up reel, wherein the processing temperature during the continuous extrusion process is 500-600°C; S2. The first wire take-up reel carrying the flat wire stock is transferred to a deep processing system and the flat wire stock is released, and the flat wire stock is subjected to drawing and annealing to obtain a flat copper wire, which is stored on a second wire take-up reel; S3. When the flat wire stock on the first wire take-up reel in S2 is insufficient, the drawing and annealing processes are suspended, the starting end of the flat wire stock on the fully loaded first wire take-up reel is cold-welded to the end of the flat wire stock on the current first wire take-up reel, and the cold-welded connection is polished, and then the flat wire stock is released again and the drawing and annealing processes are performed.

[0012] The main improvements of the present invention include:

[0013] (1) A flat wire blank having a shape similar to the final copper flat wire but larger in size is obtained by continuous extrusion processing at 500-600°C;

[0014] (2) Separating the continuous extrusion process from subsequent processing steps such as drawing;

[0015] (3) In the case described in S3, the cold welding connection method was adopted.

[0016] First, improvements (1) and (3) each have their own advantages.

[0017] As for the improvement point (1), the flat wire blank obtained by continuous extrusion processing has straight edges and rounded corners on both sides (that is, when observing from the cross section of the flat copper wire, a transition arc is formed at the intersection of the wide side and the narrow side), and the flat copper wire finally obtained is generally required to have straight edges and rounded corners; in addition, the processed flat wire blank can have a lower cold working rate than the initial flat copper wire obtained by rolling in the prior art, that is, the flat wire blank has a lower Vickers hardness and better toughness and plasticity. Therefore, during the drawing process, the flat wire blank can more easily fill the rounded corners in the drawing die, so that the drawing power required for the drawing process is smaller and the wear rate of the drawing die is also lower.

[0018] In the prior art flat copper wire processing technology, a process of "rolling first and then drawing" is adopted, wherein the initial flat copper wire obtained by rolling has a large curvature on both sides and no rounded corners. Therefore, when the initial flat copper wire is drawn, in order to fill the rounded corners in the drawing die and remove the curvature on both sides of the initial flat copper wire, a larger drawing power is required, and the wear rate of the drawing die is also higher in the process.

[0019] Therefore, the flat wire blank has a greater advantage in the subsequent drawing process than the initial flat copper wire, and this advantage is further improved in the production of large-sized flat copper wires requiring greater drawing power, ensuring that the production method can be specifically used for the production of multi-sized flat copper wires.

[0020] As for the improvement point (3), the principle of the cold welding connection described in S3 is to use a mold to clamp the two sections of flat wire blanks respectively, and push the starting ends and the ending ends of the two sections of flat wire blanks that need to be welded toward each other, and complete the connection by extrusion after the two sections come into contact.

[0021] The advantage of the improvement (3) for the present invention is that, compared with the defects of hot welding, which is extremely difficult to control the size of the connection of the flat wire blank and the strongness of the connection after welding is also very fluctuating, the cold welding process requires clamping the flat wire blank and aligning it before extrusion, which can ensure that the size uniformity of the flat wire blank after cold welding is high. At the same time, according to the inventor's inspection, the strength of the connection after cold welding can meet the drawing requirements. Therefore, in the method of the present invention, the improvement (3) is the best welding option.

[0022] Secondly, each improvement point will affect each other.

[0023] For example, the limitations of parameters such as processing temperature in improvement point (1) also affect the division of production steps in improvement point (2).

[0024] Specifically, in the improvement point (1), the processing temperature is limited to 500-600°C during the continuous extrusion process, which exceeds the recrystallization temperature of the copper material in the copper round wire. Only after reaching the current processing temperature will the grains inside the copper begin to rearrange and grow again to form a new and more uniform grain structure. However, in order to ensure that the continuous extrusion process eliminates defects such as work hardening (such as increased hardness and strength but reduced plasticity and toughness) caused by the round copper wire in its own production process, and to ensure that the flat wire blank obtained by the process can regain the original plasticity and toughness of the copper material, it is necessary not only to obtain a suitable processing temperature, but also to cooperate with an appropriate cooling rate, such as controlling the production rate of the flat wire blank within the range of 12-15 m / min to obtain an appropriate cooling rate.

[0025] In general, the drawing speed in the production process of flat copper wire is limited by the drawing die and other factors and is relatively slow. If the continuous extrusion process and the drawing process are carried out in succession, the production speed of the continuous extrusion process needs to be greatly reduced to match the drawing process. After the continuous extrusion process rate is greatly reduced, the coordination relationship between parameters such as the processing temperature and the cooling rate will be disturbed, resulting in the deterioration of the performance of the flat wire blank obtained by the above-mentioned continuous extrusion process, and thus the beneficial effect of the improvement point (1) will also be reduced or even disappear.

[0026] Therefore, in the method of the present invention, improvement point (1) is closely combined with improvement point (2).

[0027] For another example, the flat wire blank produced in improvement point (1) can be better adapted to the cold welding process in improvement point (3).

[0028] Specifically, in the improvement point (1), the processed flat wire stock can have a lower cold working rate than the initial flat copper wire obtained by rolling in the prior art, that is, the flat wire stock has a lower Vickers hardness and better toughness and plasticity. The excellent plasticity of the flat wire stock makes it easy to bend and maintain deformation, and it is not easy to rebound. Therefore, when the flat wire stock participates in the cold welding connection process in the improvement point (3), the flat wire stock is easier to bend and adjust the shape by the operator, and then placed in the cold welding mold. It ensures that the starting and ending ends of the two sections of flat wire stock can be accurately aligned during cold welding, and then ensures that the size of the connection is consistent with the non-joint part after cold welding and grinding, ensuring that the flat wire stock at the cold welding connection and its vicinity can participate in the drawing work without causing material waste.

[0029] Therefore, in the method of the present invention, improvement point (1) is also closely combined with improvement point (3).

[0030] Finally, improvements (1) to (3) will affect each other.

[0031] Specifically, for improvement point (2), since it is necessary to reduce the complexity and risk of material management, the complexity and risk of equipment management, etc., it is necessary to divide the production steps of flat copper wire. If the continuous extrusion process and the drawing process are carried out in succession, it is limited by the length of the production line, and the production process needs to be divided after the drawing process, and the flat copper wire after drawing needs to be stored.

[0032] After the cold processing of drawing, the cold working rate of the corresponding wire will be improved. Therefore, in the subsequent processing, if cold welding connection is required under the situation described in S3, the harder wire with a high cold working rate will not have the advantage of flat wire blank in the cold welding process, that is, the harder wire with a high cold working rate is likely to fail to be accurately aligned during cold welding at its end, which will lead to problems with the uniformity of the size of the flat copper wire finally produced.

[0033] After the production of copper flat wire, it needs to be painted in the mold. The mold painting has strict requirements on the uniformity of the size of the flat copper wire before painting. Some flat copper wires are too large and will cause mold jams, while those that are too small will cause air paint nodules. Therefore, poor uniformity of the size of the flat copper wire will cause the materials at the connection and its vicinity on the flat copper wire to be abandoned because they do not meet the use requirements, which will also cause material waste.

[0034] Therefore, the division of production steps in improvement point (2) is also affected by improvements (1) and (3).

[0035] The three improvements each have a beneficial effect and influence each other, and together drive the production method of the present invention to be dedicated to the production and processing of flat copper wires of different specifications.

[0036] As a further improvement of the present invention, the flat wire blank is subjected to the drawing process to obtain a first flat copper wire of a preset cross-sectional size, so the cross-sectional size of the first flat copper wire is consistent with the size of the flat copper wire finally obtained, wherein when the flat wire blank is processed into the first flat copper wire, the cross-sectional reduction rate is 23-27%. The cross-sectional reduction rate can reduce the loss of the drawing die during the drawing process, and can also reduce the requirement for the drawing power, thereby making the processing method applicable to the processing and production of large-sized flat copper wires.

[0037] As a further improvement of the present invention, in the drawing process, the flat wire blank is subjected to at least two consecutive drawing processes to obtain the first flat copper wire, which can reduce the loss of a single drawing die and ensure the long-term stable operation of the drawing process.

[0038] As a further improvement of the present invention, the flat copper wire in S2 is temporarily stored in a temporary wire storage device and then stored on the second wire take-up drum. When the drawing process and the annealing process are suspended in S3, the flat copper wire temporarily stored in the temporary wire storage device is released and the wire take-up process of the second wire take-up drum is maintained unstopped; when the cold welding is completed and the flat wire blank on the first wire take-up drum is released again and the drawing process and the annealing process are performed, the speed of the drawing process and the annealing process is increased until the amount of wire stored in the temporary wire storage device reaches a preset amount, and then the speed of the drawing process and the annealing process is restored. This method can ensure that the wire take-up process of the flat copper wire will not stagnate, while usually the final wire take-up process of the flat copper wire needs time for preheating, debugging, stabilization and other operations after stagnation, which will increase the production cycle and cost of the flat copper wire.

[0039] In a second aspect, the present invention provides a flat copper wire production system, a preliminary processing system, which is at least provided with a first pay-off device, a continuous extrusion device and a first take-up device in sequence, wherein the first take-up device is used to receive the flat wire blank processed by the continuous extrusion device onto a first take-up reel;

[0040] The deep processing system is at least provided with a flat wire cold welding device, a second wire release device, a drawing device, an annealing device and a second wire take-up device in sequence, wherein the second wire release device is used to release the flat wire stock on the first wire take-up reel, and the flat wire cold welding device is used to cold weld the beginning end of the flat wire stock on the fully loaded first wire take-up reel with the end of the flat wire stock on the current first wire take-up reel. The production system can be adapted to any of the above production methods and is dedicated to the production and processing of flat copper wire.

[0041] As a further improvement of the present invention, the continuous extrusion device includes an extrusion wheel, a compacting wheel, an extrusion cavity and an extrusion mold, wherein the compacting block of the compacting wheel and the embedding groove of the extrusion wheel are adapted to fit at the wire entrance of the extrusion wheel, and the size of the embedding groove is adapted to the size of the round copper wire; the extrusion cavity is arranged at the wire exit of the extrusion wheel for heating the round copper wire; the mold is connected to the extrusion cavity for shaping the heated round copper wire.

[0042] As a further improvement of the present invention, the drawing device includes at least two groups of continuously arranged drawing dies and traction devices, and the traction device includes at least two traction wheels.

[0043] As a further improvement of the present invention, a temporary wire storage device is provided between the drawing device and the second wire taking-up device, and the temporary wire storage device includes a first wire storage disk, a second wire storage disk, and a positioning kit connected to the second wire storage disk, wherein the positioning kit is used to adjust the wire storage spacing provided between the first wire storage disk and the second wire storage disk. After the flat copper wire enters the temporary wire storage device, it is wound on the second wire storage disk, guided and then wound on the first wire storage disk, and finally output to the second wire taking-up disk. Therefore, a large amount of flat copper wire is stored in the space between the second wire storage disk and the first wire storage disk, that is, the wire storage amount of the temporary wire storage device is affected by the wire storage spacing. When a temporary wire storage operation is required, the positioning kit is used to drive the second wire storage disk away from the first wire storage disk, that is, to expand the wire storage spacing to achieve the temporary wire storage effect; and during the cold welding operation, the positioning kit is used to drive the second wire storage disk close to the first wire storage disk, that is, to reduce the wire storage spacing, and release the temporarily stored flat copper wire.

[0044] As a further improvement of the present invention, the flat wire cold welding device includes a cold welding mold, the cold welding mold includes two groups of clamping block groups, the clamping block group includes two clamping blocks, a clamping channel is formed between the two clamping blocks in the same clamping block group, and a clamping groove is provided on one side of the single clamping block close to the clamping channel, the clamping groove includes a supporting surface and a clamping surface, wherein the supporting surface is used to contact the narrow surface of the flat wire blank, and the clamping surface is used to contact the wide surface of the flat wire blank.

[0045] In a third aspect, the present invention provides a flat copper wire obtained by processing using any one of the flat copper wire production methods described above.

[0046] The beneficial effects of the present invention include:

[0047] (1) The material used in the connection process between preliminary processing and deep processing is a flat wire blank with a low Vickers hardness, which can facilitate the smooth cold welding connection operation and ensure that the cold welding connection can meet the corresponding drawing requirements, reduce material waste, and reduce the production cost of flat copper wire;

[0048] (2) Using flat wire blanks with lower Vickers hardness for drawing can reduce the wear on the drawing die and the power consumption required for drawing, thereby making the processing method and processing system of the present invention applicable to flat copper wires of different specifications, especially large-size flat copper wires. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] The following drawings are provided for combining with the preferred implementation examples of the present invention to help understand the purpose and advantages of the present invention, wherein:

[0050] Figure 1 This is a schematic diagram of the preliminary processing system;

[0051] Figure 2 It is a schematic diagram of the deep processing system;

[0052] Figure 3 It is a schematic diagram of the structure of a continuous extrusion device;

[0053] Figure 4 This is a schematic diagram of the cold welding mold structure from the first perspective;

[0054] Figure 5 This is a schematic diagram of the cold welding mold structure from the second perspective;

[0055] Figure 6 It is a schematic diagram of the structure of the drawing device;

[0056] Figure 7 This is a schematic diagram of the temporary storage line device structure. DETAILED DESCRIPTION

[0057] The present invention is further described in detail below based on the accompanying drawings and implementation examples.

[0058] The directional terms such as up, down, left, right, front, back, front, back, top, bottom, etc. mentioned or may be mentioned in this specification are defined relative to the structures shown in the drawings. The words "inside" and "outside" refer to the direction toward or away from the geometric center of a specific component, respectively. They are relative concepts, and therefore may change accordingly according to different locations and different usage conditions. Therefore, these or other directional terms should not be interpreted as restrictive terms.

[0059] In this embodiment, a round copper wire with a diameter of 12.5 mm is used as the initial raw material for processing, and the size of the flat copper wire obtained by the final processing is 16*3=48 mm.2 , its width-to-width ratio can reach about 5.33, which belongs to large-sized flat copper wire. In the production process of flat copper wire, the flat copper wire with a larger width-to-width ratio has higher requirements for the production method and system thereof, specifically including high drawing power requirements in the drawing process, large losses in the drawing die, and difficult cold welding process. Therefore, in this embodiment, the target manufacturing objects selected are all large-sized flat copper wires to demonstrate the superiority of the production method and production system in the present invention.

[0060] Embodiment 1:

[0061] A production process of flat copper wire mainly includes the following parts:

[0062] S1. The round copper wire is continuously extruded into a flat wire blank through the preliminary processing system A. Specifically, in the preliminary processing system A, the first wire-releasing device A01 is used to release the raw round copper wire to be processed, and the round copper wire is fed into the continuous extrusion device A02. During the feeding process, the round copper wire collides with the compaction block on the compaction wheel A02-2, so that the compaction wheel A02-2 can press the round copper wire into the embedding groove of the extrusion wheel A02-1 and establish static friction between the embedding groove and the round copper wire, ensuring that the subsequent rotation of the extrusion wheel A02-1 can drive the round copper wire thereon to move. Here, the part where the embedding groove and the compaction block are embedded forms a wire entry port, which is the beginning of the round copper wire entering the embedding groove.

[0063] Subsequently, the extrusion wheel A02-1 rotates to drive the round copper wire and drive it to the connection between the extrusion wheel A02-1 and the extrusion cavity A02-3. Then the round copper wire is sent into the extrusion cavity A02-3. The connection between the extrusion wheel A02-1 and the extrusion cavity A02-3 is the wire outlet. The round copper wire is separated from the embedded groove here and enters the next stage.

[0064] After the round copper wire enters the extrusion cavity A02-3, the extrusion cavity A02-3 heats the round copper wire to about 512°C to make it have better plasticity. At the same time, due to the continuous rotation of the extrusion wheel A02-1, more round copper wires are driven into the extrusion cavity A02-3. The heated round copper wire that previously entered the extrusion cavity A02-3 is extruded through the extrusion die A02-4, and the opening on the extrusion die A02-4 realizes the shaping of the heated round copper wire to make it a flat wire blank.

[0065] Finally, the first wire take-up device A03 is used to rotate the first wire take-up drum to store the produced flat wire stock on the first wire take-up drum. In this embodiment, the production rate of the flat wire stock is 12.5 m / min.

[0066] S2. Transfer the first take-up drum carrying the flat wire stock to the second pay-off device B02 of the deep processing system B, open the second pay-off device B02 to pay out the flat wire stock, guide the flat wire stock to the drawing device B03, and first carry out the drawing process.

[0067] During the drawing process, a traction device B03-2 with a double traction wheel B03-2-1 is used to traction-drive the flat wire blank, driving the flat wire blank to pass through two sets of drawing dies B03-1 in sequence. Among them, the opening of the drawing die B03-1 that passes first is larger, so that the flat wire blank is initially drawn; the opening size of the drawing die B03-1 that passes subsequently is consistent with the cross-sectional size of the final required flat copper wire, so that the flat wire blank is finally drawn to form the first flat copper wire, and the cross-sectional reduction rate of the first flat copper wire is about 25% compared with the flat wire blank. During the drawing process, the traction device B03-2 needs to use two motors with a power of 7.5KW, and the output power of the motor is about 55%. In this embodiment, the drawing rate of the flat wire blank is 4.5 m / min.

[0068] Subsequently, the first flat copper wire is guided to the annealing device B04 for annealing to obtain the desired flat copper wire. After the flat copper wire is processed, it is guided into the temporary wire storage device B06. After entering the temporary wire storage device B06, the flat copper wire first contacts the contact surface of the second wire storage disk B06-2 located at the top of the device, and then moves downward under the guidance of the second wire storage disk B06-2 until it contacts the contact surface of the first wire storage disk B06-1 located at the bottom of the temporary wire storage device B06, and then moves upward again under the guidance of the first wire storage disk B06-1 until it contacts the second wire storage disk B06-2 again, forming a complete flat copper wire loop. Repeat the above-mentioned flat copper wire movement method until four groups of parallel flat copper wire loops are formed on the first wire storage disk B06-1 and the second wire storage disk B06-2. At this time, the temporary wire storage device is in the wire storage state, and the wire storage spacing L1 between the first wire storage disk B06-1 and the second wire storage disk B06-2 is 12 m. After forming four groups of flat copper wire loops, the flat copper wire is finally guided by the first wire storage drum B06 - 1 to leave the temporary wire storage device B06 , and is stored on the second wire take-up drum by the second wire take-up device B05 .

[0069] S3. When the flat wire stock on the first wire taking-up disk in S2 is insufficient, the processing steps in the deep processing system B such as drawing and annealing are suspended, but the continuous operation of the second wire taking-up device B05 is still retained. At the same time, the second wire storage disk B06-2 is gradually moved down through the positioning kit B06-3 in the temporary wire storage device B06 to reduce the wire storage spacing L1, and the flat copper wire in the temporary wire storage device B06 is released for the second wire taking-up device B05 to store the flat wire stock.

[0070] At the same time, in the front end of the deep processing system B, the beginning of the flat wire stock on the fully loaded first take-up reel and the end of the flat wire stock on the current first take-up reel that is about to be exhausted are respectively placed in the two groups of clamping block groups B01-1-1 of the cold welding mold B01-1 of the flat wire cold welding device B01. Specifically, one end of any flat wire stock is placed in the clamping channel B01-1-3, and the narrow surface of the flat wire stock is placed on the supporting surface B01-1-4a in the clamping groove B01-1-4, so that the supporting surface B01-1-4a plays a role in positioning and supporting the flat wire stock, and then approaches the two clamping blocks B01-1-2 in the same clamping block group B01-1-1, so that the two wide surfaces of the flat wire stock are both in contact with the clamping surface B01-1-4b in the clamping groove B01-1-4 to establish strong static friction.

[0071] After the clamping work in the clamping block group B01-1-1 is completed, the two groups of clamping block groups B01-1-1 are pushed close to each other, driving one end of each flat wire blank on them to approach, collide and squeeze until the cold welding is completed. After the cold welding is completed, the clamping of the flat wire blank by the clamping block B01-1-2 is released, and the cold welding connection is polished. After the polishing is completed, the second pay-off device B02 is turned on and the pay-off speed is increased to exceed the normal operating speed, and the related devices for drawing and annealing processing are restarted, and the operating speed is also accelerated. In the back end of the deep processing system B, the second wire storage disk B06-2 is gradually moved up through the adjustment kit B06-3 in the temporary wire storage device B06, the wire storage spacing L1 is expanded, and the wire storage amount in the temporary wire storage device B06 is restored to the preset value. Then, the wire-paying speed, drawing processing speed and annealing processing speed of the second wire-paying device B02 are restored to normal processing speeds, and the movement of the second wire storage disk B06-2 by the positioning kit B06-3 is stopped.

[0072] Embodiment 2:

[0073] The difference between this embodiment and embodiment 1 is that in this embodiment, the heating temperature of the round copper wire by the extrusion cavity A02-3 is about 546° C. In this embodiment, the production rate of the flat wire blank is 13.5 m / min.

[0074] Embodiment 3:

[0075] The difference between this embodiment and embodiment 1 is that in this embodiment, the heating temperature of the round copper wire by the extrusion cavity A02-3 is about 597° C. In this embodiment, the production rate of the flat wire blank is 14.5 m / min.

[0076] Embodiment 4:

[0077] The difference between this embodiment and embodiment 1 is that, in this embodiment, the cross-sectional reduction rate of the first flat copper wire compared to the flat wire blank is about 27%, and during the drawing process, the traction device B03-2 needs to use 2 motors with a power of 7.5 KW, and the output power is about 63%.

[0078] Embodiment 5:

[0079] The difference between this embodiment and embodiment 1 is that, in this embodiment, the cross-sectional reduction rate of the first flat copper wire compared to the flat wire blank is about 24%, and during the drawing process, the traction device B03-2 needs to use 2 motors with a power of 7.5 KW, and the output power is about 53%.

[0080] Comparative Example 1:

[0081] The difference between this comparative example and comparative example 1 is that in this comparative example, the heating temperature of the round copper wire in the extrusion cavity A02-3 is about 498° C. The production rate of the flat wire blank is 11 m / min.

[0082] Meanwhile, during the deep processing, in this comparative example, the drawing rate of the flat wire blank is 4.5 m / min.

[0083] Comparative Example 2:

[0084] The difference between this comparative example and comparative example 1 is that in this comparative example, the heating temperature of the round copper wire in the extrusion cavity A02-3 is about 613° C. The production rate of the flat wire blank is 15 m / min.

[0085] Meanwhile, during the deep processing, in this comparative example, the drawing rate of the flat wire blank is 4.5 m / min.

[0086] Comparative Example 3:

[0087] The difference between this comparative example and comparative example 1 is that in this comparative example, the cross-sectional reduction rate of the first flat copper wire compared to the flat wire blank is about 29%. During the drawing process, although the traction device B03-2 still uses two motors with a power of 7.5 KW, the motor output power is about 75%, and the drawing rate of the flat wire blank is maintained at 4.5 m / min.

[0088] Comparative Example 4:

[0089] The difference between this comparative example and comparative example 1 is that in this comparative example, the cross-sectional reduction rate of the first flat copper wire compared to the flat wire blank is about 21%, and the traction device B03-2 still uses two motors with a power of 7.5 KW during the drawing process, but the motor output power is about 48%, and the drawing rate of the flat wire blank is 4.5 m / min.

[0090] Testing steps:

[0091] The Vickers hardness of the flat wire blanks prepared in Examples 1 to 5 and Comparative Examples 1 to 4 was tested. The specific steps of the test are as shown in GB / T 4340.1-2009 "Vickers hardness test for metallic materials Part 1: Test method".

[0092] The product qualification rates of the flat copper wires prepared in Examples 1 to 5 and Comparative Examples 1 to 4 were statistically analyzed, wherein the qualified requirements for the production of flat copper wires were that the uniformity of every 100 m of flat copper wire reached 99.9%, the hardness reached ≤68, etc., and the raw material utilization rate was calculated at the same time, and the calculation formula was: n=M1 / M2, wherein n was the utilization rate, M1 was the quality of the output flat wire, and M2 was the quality of the input raw materials. The test results of the above two tests were statistically analyzed as shown in Table 1.

[0093] Table 1 Statistics of the qualified rate and raw material utilization rate of the flat copper wire products in each comparative example or embodiment

[0094] Label Pass rate (%) Raw material utilization rate (%) Example 1 99.6 95.3 Example 2 99.5 95.5 Example 3 99.7 96.1 Example 4 99.5 95.9 Example 5 99.8 96.2 Comparative Example 1 95.6 77.2 Comparative Example 2 96 75.4 Comparative Example 3 90.6 94.3 Comparative Example 4 99.2 95.2

[0095] Test result analysis:

[0096] By comparing the test results of the flat wire blanks obtained under the processing technology in Examples 1 to 3 and Comparative Examples 3 to 4, it can be found that within the processing temperature range described in the present invention, the prepared flat wire blank can exhibit better toughness and plasticity, and therefore has corresponding processing advantages.

[0097] The test results of the products obtained under the processing technology in Comparative Example 1 show that it is difficult to obtain a flat wire blank with excellent toughness and plasticity even if the processing rate of the flat wire blank is further slowed down and the cooling time of the flat wire blank is extended when the processing is carried out at a temperature lower than the corresponding processing temperature. The inventors speculate that it is difficult to promote the growth of metal grains in the flat wire blank to a suitable size at the heating temperature, and when the grain size is too small, the grain boundary itself may become the source of crack initiation; and the lower processing temperature is also difficult to better promote the rearrangement of grains to form a new and more uniform grain structure, so the toughness of the flat wire blank cannot meet the required requirements.

[0098] The test results of the products obtained under the processing technology in Comparative Example 2 show that it is difficult to obtain a flat wire blank with excellent toughness and plasticity even if the processing rate of the flat wire blank is further increased and the cooling time of the flat wire blank is shortened when the processing is carried out at too high a processing temperature. Because at this heating temperature, the metal grains will grow rapidly and eventually form larger grains, and too large grains in the metal will also lead to a decrease in toughness. This is because the internal defects of coarse grains (such as dislocations, holes, etc.) may be more likely to gather and form crack sources, and the resistance to crack expansion in coarse grains is also small, which ultimately reduces the toughness and plasticity of the flat wire blank.

[0099] By comparing the inspection results of the flat copper wires obtained under the processing techniques in Examples 1 to 3, it can be found that under the processing method described in the present invention, the qualified rate of the flat copper wires processed is generally above 99.5%. At the same time, the raw material utilization rate can also reach above 95%, which can avoid wasting raw materials and greatly reduce the production cost of the enterprise.

[0100] From the statistical inspection results of the flat copper wires obtained under the processing technology in Comparative Example 3, it can be found that the qualified rate of the processed flat copper wires will be reduced and maintained at about 90.5%. The main reason is that when the cross-sectional reduction rate is appropriate, the scratches and other minor defects on the flat wire blank can be eliminated during the drawing process, so the quality requirements for the flat wire blank are lower; while in Comparative Example 3, the cross-sectional reduction rate is too low, resulting in the scratches and other minor defects on the surface of the flat wire blank being retained on the first flat copper wire produced after drawing, and ultimately resulting in a decrease in the qualified rate of the flat copper wire.

[0101] The test results of the flat copper wire obtained by the processing technology in Comparative Example 4 show that the qualified rate of the processed flat copper wire can generally reach more than 99%, and the utilization rate of raw materials can also reach 99.9%. However, the motor output power of the traction device in Comparative Example 4 is greatly improved. At the same time, in the actual production process, the inventors found that the wear rate of the drawing die will also be greatly increased under the cross-sectional reduction rate. The above defects have greatly increased the production cost of the flat copper wire.

[0102] By comparing the flat copper wire test results obtained under the processing technology in Comparative Examples 1 and 2, it can be found that the qualified rate of the processed flat copper wire can reach more than 95%, but the utilization rate of raw materials has dropped to about 75%. According to the inventor's statistics, in at least 4 of the 10 consecutive cold welding connections, the flat wire blanks were difficult to put in place, which resulted in the cold welding connection being difficult to meet the drawing requirements in shape. Therefore, a large amount of flat wire blanks were still wasted, resulting in a significant decrease in the utilization rate of raw materials, which greatly increased the company's production costs.

[0103] Finally, it should be noted that the above implementation cases are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned implementation cases, those skilled in the art should understand that they can still modify the technical solutions recorded in the aforementioned implementation cases, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the implementation cases of the present invention.

Claims

1. A flat copper wire production system, characterized in that: Contains: The preliminary processing system (A) is at least provided with a first pay-off device (A01), a continuous extrusion device (A02) and a first take-up device (A03) in sequence, wherein the first take-up device (A03) is used to collect the flat wire blank processed by the continuous extrusion device (A02) onto a first take-up drum; The continuous extrusion device (A02) comprises an extrusion wheel (A02-1), a compacting wheel (A02-2), an extrusion cavity (A02-3) and an extrusion die (A02-4), wherein the compacting block of the compacting wheel (A02-2) and the embedding groove of the extrusion wheel (A02-1) are adapted to fit at the wire inlet of the extrusion wheel (A02-1), and the size of the embedding groove is adapted to the size of the round copper wire; The extrusion cavity (A02-3) is arranged at the wire outlet of the extrusion wheel (A02-1) and is used to heat the round copper wire; the extrusion die (A02-4) is connected to the extrusion cavity (A02-3) and is used to shape the heated round copper wire; A deep processing system (B) is provided with at least a flat wire cold welding device (B01), a second wire paying-off device (B02), a drawing device (B03), an annealing device (B04) and a second wire taking-up device (B05) in sequence, wherein the second wire paying-off device (B02) is used to pay out the flat wire stock on the first wire taking-up disk, and the flat wire cold welding device (B01) is used to cold weld the starting end of the flat wire stock on the fully loaded first wire taking-up disk with the end of the flat wire stock currently on the first wire taking-up disk; The flat wire cold welding device (B01) comprises a cold welding mold (B01-1), the cold welding mold (B01-1) comprises two groups of clamping block groups (B01-1-1), the clamping block group (B01-1-1) comprises two clamping blocks (B01-1-2), a clamping channel (B01-1-3) is formed between the two clamping blocks (B01-1-2) in the same group, and a single clamping block (B01-1-2) ) is provided with a clamping groove (B01-1-4) on one side close to the clamping channel (B01-1-3), and the clamping groove (B01-1-4) includes a supporting surface (B01-1-4a) and a clamping surface (B01-1-4b), wherein the supporting surface (B01-1-4a) is used to contact with the narrow surface of the flat wire blank, and the clamping surface (B01-1-4b) is used to contact with the wide surface of the flat wire blank.

2. A flat copper wire production system according to claim 1, characterized in that: The drawing device (B03) comprises at least two groups of continuously arranged drawing dies (B03-1) and a traction device (B03-2), and the traction device (B03-2) comprises at least two traction wheels (B03-2-1).

3. A flat copper wire production system according to claim 1, characterized in that: A temporary wire storage device (B06) is provided between the drawing device (B03) and the second wire taking-up device (B05), and the temporary wire storage device (B06) comprises a first wire storage drum (B06-1), a second wire storage drum (B06-2), and a position adjustment kit (B06-3) connected to the second wire storage drum (B06-2), wherein the position adjustment kit (B06-3) is used to adjust a wire storage distance (L1) provided between the first wire storage drum (B06-1) and the second wire storage drum (B06-2).

4. A method for producing a flat copper wire, characterized in that: A flat copper wire production system for operating any one of claims 1 to 3, comprising the following steps: S1. In the preliminary processing system (A), the round copper wire is continuously extruded into a flat wire blank, and the flat wire blank is stored on the first take-up reel, wherein the processing temperature of the flat wire blank during the continuous extrusion process is 500-600° C., and the production rate is 12-15 m / min; S2. transferring the first take-up drum carrying the flat wire stock to the deep processing system (B) and releasing the flat wire stock, drawing and annealing the flat wire stock to obtain a flat copper wire, and storing it on a second take-up drum; S3. When the flat wire stock on the first wire taking-up drum in S2 is insufficient, the drawing process and the annealing process are suspended, the starting end of the flat wire stock on the fully loaded first wire taking-up drum is cold-welded with the end of the flat wire stock on the current first wire taking-up drum, and the cold-welded joint is polished, and then the flat wire stock is released again and the drawing process and the annealing process are performed.

5. A method for producing a flat copper wire according to claim 4, characterized in that: The flat wire blank is subjected to the drawing process to obtain a first flat copper wire with a preset cross-sectional size, wherein when the flat wire blank is processed into the first flat copper wire, the cross-sectional reduction rate is 23-27%.

6. A method for producing a flat copper wire according to claim 5, characterized in that: During the drawing process, the flat wire blank is subjected to at least two consecutive drawing processes to obtain the first flat copper wire.

7. A method for producing a flat copper wire according to claim 4, characterized in that: The flat copper wire in S2 is temporarily stored in the temporary wire storage device (B06) and then stored on the second wire take-up drum; When the drawing process and the annealing process in S3 are suspended, the flat copper wire temporarily stored in the temporary wire storage device (B06) is released and the wire taking-up process of the second wire taking-up reel is maintained without stopping; after the cold welding is completed, the flat wire blank on the first wire taking-up reel is released again and the drawing process and the annealing process are carried out, and the speed of the drawing process and the annealing process is increased until the wire storage amount in the temporary wire storage device (B06) reaches a preset amount, and then the speed of the drawing process and the annealing process is restored.

8. A rectangular copper wire, characterized in that: The flat copper wire is obtained by using the flat copper wire production method described in any one of claims 4 to 7.

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