Processing and manufacturing method of 220 grade enameled aluminum flat wire

Abstract

The present invention belongs to the technical field of wire processing, and specifically relates to a processing and manufacturing method of a 220-grade enameled aluminum flat wire, comprising the following steps: Step 1, material preparation, using a 1A60 electrical round aluminum rod, using an extrusion process to produce a bare aluminum flat wire 1.50×8.00mm semi-finished product, the bare aluminum flat wire fillet radius R mutual difference is controlled within 30μm, and the conductor mutual difference is controlled within 10μm; Step 2, the bare aluminum flat wire is released through an active release device, and then the surface is processed by felt rubbing; Step 3, enter the paint room, use a mold to paint, and the paint mold uses an integrated fixed mold; Step 4, after 8-10 times of painting, the high-temperature paint film is cross-linked, solidified and cooled; then by traction, winding, winding to the take-up reel to form a finished product. The method is reasonably designed, stable and reliable in performance, can effectively improve the quality and output of production, and the application effect is very significant.

Description

Technical Field

[0001] The invention belongs to the technical field of wire processing, and in particular relates to a processing and manufacturing method of a 220-grade enameled aluminum flat wire. Background Art

[0002] At present, the windings used in the design of photovoltaic inverter inductor coils are mainly copper; mainly because the conductivity of copper is about 1.6 times that of aluminum, which means that the resistance value of copper wire is lower than that of aluminum wire at the same length and cross-sectional area; therefore, copper wire is better in conductivity, which helps to reduce energy consumption and improve thermal performance. However, the price of copper is relatively high, while the price of aluminum is low. The use of aluminum can reduce manufacturing costs, especially in large-scale power projects, where aluminum conductors can save a lot of costs. Therefore, in the case of limited budgets, the use of aluminum wire may be more economical; at the same time, copper and aluminum are conductive materials, and the enameling process has been precipitated and accumulated for many years. Compared with aluminum enameled wire, copper enameled wire has a high degree of process maturity, stable product quality, and is widely used. This time, we received a request from a customer to use 220-grade enameled aluminum flat wire for the winding of the photovoltaic inverter inductor coil. In order to control the overall size of the inductor coil, reduce the weight of the coil, save costs, and ensure the conductivity of the conductor and the electrical properties of the insulation, aluminum is used as the conductor material. The thickness of the enameled wire film is in accordance with the standard of Grade 1 in IEC60317-0-9 (0.06-0.11mm). However, the breakdown voltage performance is required to meet the standard of Grade 2 film thickness in IEC 60317-0-9 (reaching more than 2000V at room temperature and more than 1500kV at 220℃); currently, the breakdown voltage performance of the paint film thickness of Grade 1 in the IEC standard is more than 1000V at room temperature and more than 750V at 220℃, which can no longer cover the requirements of this product and cannot meet the design requirements. Summary of the invention

[0003] The purpose of the present invention is to provide a processing and manufacturing method for 220-grade enameled aluminum flat wire to solve the problems existing in the prior art.

[0004] To achieve the above object, the present invention provides the following technical solution: a processing and manufacturing method of a 220-grade enameled aluminum flat wire, comprising the following steps: step 1, preparing materials, using a 1A60 electrical round aluminum rod, and using an extrusion process to produce a 1.50×8.00mm semi-finished bare aluminum flat wire, wherein the fillet radius R of the bare aluminum flat wire is controlled within 30μm, and the conductor difference is controlled within 10μm;

[0005] Step 2: The bare aluminum flat wire is paid out through an active pay-off device, and then the surface is treated by felt wiping;

[0006] Step 3: Enter the painting room and paint using a mold. The painting mold uses an integrated fixed mold;

[0007] Step 4: After 8-10 coats of painting, the high-temperature paint film is cross-linked, solidified and cooled; then it is pulled and wound onto the take-up reel to form a finished product.

[0008] Preferably, the method further includes step 5, wherein each batch of wires is tested for film thickness, dimensions, adhesion, flexibility, breakdown voltage, soldering and resistivity; the test indicators are as follows:

[0009] (1) Paint film thickness 0.06~0.11mm;

[0010] (2) Maximum dimensions: 1.62×8.12mm;

[0011] (3) Elongation: ≥15%;

[0012] (4) Adhesion: After the enameled wire is stretched by 15%, the distance at which the paint film loses adhesion should be ≤1b;

[0013] (5) Flexibility: The enameled wire should not crack when its wide side is bent 180° on a rod diameter 1.5 times its thickness or when it is bent 180° on a round rod diameter of φ16.4 mm;

[0014] (6) Breakdown voltage: ≥2000V at room temperature, ≥1500V at 220℃;

[0015] (7) Soldering test: 350℃±3℃, 3s, the paint film should not show delamination, blistering, cracking, etc.;

[0016] (8) Resistivity ρ at 20℃ 20 :≤0.02801Ω·mm 2 / m.

[0017] Wires that meet the above performance tests and the requirements of IEC60317-0-9 are qualified products.

[0018] Preferably, in step 3, the sizing area of ​​the paint mold of the integrated fixed mold is controlled within 1.5-2 mm, the difference between the fillet of the paint mold and the fillet of the conductor is controlled within 16.5 μm, and the difference between the area of ​​the paint mold and the fillet of the conductor is controlled within 0.011 mm. 2 Within.

[0019] The beneficial effects of the present invention are: the method is reasonably designed, has stable and reliable performance, can effectively improve the quality and output of production, and has a very significant application effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1It is a schematic diagram of the integrated painting mold and conductor in the present invention;

[0021] Figure 2 It is a cross-sectional schematic diagram of the integrated painting mold in the present invention;

[0022] Figure 3 It is a schematic diagram of the winding coil in the present invention. DETAILED DESCRIPTION

[0023] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0024] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0025] In the description of the invention, it should be noted that, unless otherwise clearly specified and limited, the terms "install", "connect", "connect", "fixed connection" and "fixed connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the invention can be understood according to specific circumstances.

[0026] The specific implementation of the present invention is described in detail below with reference to the accompanying drawings and preferred embodiments.

[0027] like Figure 1As shown, a processing and manufacturing method of 220-grade enameled aluminum flat wire is provided to solve the problem that the breakdown voltage performance (above 1000V at room temperature and above 750V at 220°C) of Grade 1 paint film thickness (0.06-0.11mm) in the current IEC60317-0-9 standard cannot meet the breakdown voltage performance (above 2000V at room temperature and above 1500kV at 220°C) requirements of 220-grade enameled aluminum flat wire for photovoltaic inverter inductor coils. Therefore, a processing method of 220-grade enameled aluminum flat wire with thin paint film and high electrical strength for photovoltaic inverter inductor coils with reasonable design and performance that meets the requirements is provided.

[0028] In order to achieve the above-mentioned purpose, the present invention adopts a technical solution: a processing and manufacturing method of 220-grade enameled aluminum flat wire, characterized in that the specific implementation steps of the method are as follows:

[0029] (I) Material preparation: electrical round aluminum rod of grade 1A60 is used to produce bare aluminum flat wire 1.50×8.00mm semi-finished products by extrusion process. The difference of fillet radius R of bare aluminum flat wire is controlled within 30μm.

[0030] The conductor difference is controlled within 10μm.

[0031] (ii) The bare aluminum flat wire is paid out through an active pay-off device and then the surface is treated by felt rubbing;

[0032] (III) Enter the painting room and use mold painting. The painting mold adopts an integrated fixed mold, and the sizing area is controlled at 1.5-2mm; the difference between the fillet of the painting mold and the fillet of the conductor is controlled at 16.5

[0033] μm; the area difference between the paint mold and the conductor fillet is controlled within 0.011mm 2 within;

[0034] (iv) After 8-10 coats of painting, the high-temperature paint film is cross-linked, solidified, and cooled; then the wire is pulled and wound onto a take-up drum to form a finished product;

[0035] (V) Each batch of wires must be tested for film thickness, dimensions, adhesion, flexibility, breakdown voltage, soldering and resistivity; the test indicators are as follows:

[0036] (1) Paint film thickness 0.06~0.11mm;

[0037] (2) Maximum dimensions: 1.62×8.12mm;

[0038] (3) Elongation: ≥15%;

[0039] (4) Adhesion: After the enameled wire is stretched by 15%, the distance at which the paint film loses adhesion should be ≤1b;

[0040] (5) Flexibility: The enameled wire should not crack when its wide side is bent 180° on a rod diameter 1.5 times its thickness or when it is bent 180° on a round rod diameter of φ16.4 mm;

[0041] (6) Breakdown voltage: ≥2000V at room temperature, ≥1500V at 220℃;

[0042] (7) Soldering test: 350℃±3℃, 3s, the paint film should not show delamination, blistering, cracking, etc.;

[0043] (8) Resistivity ρ at 20℃ 20 :≤0.02801Ω·mm 2 / m.

[0044] Wires that meet the above performance tests and the requirements of IEC60317-0-9 are qualified products.

[0045] At present, the commonly used paint dies for enameled copper flat wire are threaded movable dies, adjustable movable dies and fixed dies; threaded movable dies are flexible to adjust, in direct contact with the conductor, and the paint thickness is controlled by the thread gap, thereby achieving the purpose of controlling the thickness of the paint film; after the threaded movable dies come into contact with copper, due to the factor of friction resistance, the thread gap will be worn out after long-term use, and it needs to be replaced regularly; threaded movable dies are more suitable for copper flat wire. If threaded movable dies are used for aluminum flat wire, after the first coat of paint comes into contact with the conductor, due to the factor of friction resistance, aluminum powder will accumulate and stick to aluminum, which will affect the quality of the paint and seriously affect the performance of the enameled wire. Due to its structural characteristics, the adjustable movable die cannot guarantee the uniform coating of the insulating paint, resulting in uneven paint film, and even seriously affecting the performance of the enameled wire. The fixed die needs to have a high degree of coordination with the conductor to ensure the uniformity of the paint coating. At present, when the fixed die is configured, it is extremely difficult to evenly coat the paint film because the flat wire is an irregular rectangular cross-section, especially at the rounded corners. Poor uniformity of the paint film will lead to performance discreteness differences and unstable electrical performance; especially this time the customer requires the paint film thickness to meet Grade 1 (0.06-0.11mm) and the breakdown voltage performance to reach Grade 2 (above 2000V at room temperature and above 1500kV at 220°C), which cannot meet the customer's design requirements. The present invention adopts an integrated fixed mold 1 to reduce the mold assembly structure and greatly improve the precision error caused by the mold assembly, thereby improving the uniformity of the paint film coating; at the same time, through repeated and large-scale verification, the difference in the radius R of the fillet of the bare aluminum flat wire 2 is controlled within 30μm, and the difference in the conductor is controlled within 10μm; the sizing area 3 of the painting mold is controlled at 1.5-2mm, the difference in the spacing between the fillet of the painting mold and the fillet of the conductor is controlled within 16.5μm, and the difference in the area between the fillet of the painting mold and the conductor is controlled within 0.011mm2 Within; ensure the uniformity of paint film coating, thereby ensuring the electrical properties of the enameled wire.

[0046] The present invention adopts an integrated fixed mold, the sizing area of ​​the painting mold is controlled at 1.5-2mm, the difference between the fillet of the painting mold and the fillet of the conductor is controlled within 16.5μm, and the difference between the area of ​​the painting mold and the fillet of the conductor is controlled within 0.011mm. 2 The uniformity of the coating is greatly guaranteed; while the coating thickness meets the requirements of Grade 1 (0.06-0.11mm) in IEC60317-0-9, the breakdown voltage of the enameled wire is guaranteed to meet customer requirements (above 2000V at room temperature and above 1500kV at 220°C). So far, there is no record of using an integrated fixed mold, the sizing area of ​​the painting mold is controlled at 1.5-2mm, the difference between the fillet of the painting mold and the fillet of the conductor is controlled within 16.5μm, and the difference between the area of ​​the paint mold and the fillet of the conductor is controlled within 0.011mm 2 Publications on methods for controlling paint film uniformity.

[0047] The present invention adopts an integrated fixed mold, the sizing area of ​​the painting mold is controlled at 1.5-2mm, the difference between the fillet of the painting mold and the fillet of the conductor is controlled within 16.5μm, and the difference between the area of ​​the painting mold and the fillet of the conductor is controlled within 0.011mm. 2 "Within;" is formulated after repeated research and is creative.

[0048] In summary, the main distinguishing technical feature of the present invention is the method for producing 220-grade enameled aluminum flat wire with thin paint film and high electrical performance, that is, the process and parameters have not been implemented so far, and there is no relevant public publication with records. It provides a new method for producing 220-grade enameled aluminum flat wire with thin paint film and high electrical performance, and produces a new type of enameled aluminum flat wire product. The production of the 220-grade enameled aluminum flat wire fills the gap in the production process of enameled aluminum flat wire with a paint film thickness that meets Grade 1 (0.06-0.11mm) in IEC60317-0-9, and a breakdown voltage performance that meets the requirements of Grade 2 in IEC60317-0-9 (reaching more than 2000V at room temperature and more than 1500kV at 220°C).

[0049] It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the principles of the present invention, and these improvements and modifications should also be regarded as within the scope of protection of the present invention.

Claims

1. A method for processing and manufacturing 220-grade enameled aluminum flat wire, characterized in that: The following steps are involved: Step 1: Prepare materials, use 1A60 electrical round aluminum rod, and use extrusion process to produce 1.50×8.00mm bare aluminum flat wire semi-finished products, the fillet radius R of the bare aluminum flat wire is controlled within 30μm, and the conductor difference is controlled within 10μm; Step 2: The bare aluminum flat wire is paid out through an active pay-off device, and then the surface is treated by felt wiping; Step 3: Enter the painting room and paint using a mold. The painting mold uses an integrated fixed mold; Step 4: After 8-10 coats of painting, the high-temperature paint film is cross-linked, solidified and cooled; then it is pulled and wound onto the take-up reel to form a finished product.

2. The method for processing and manufacturing the 220-grade enameled aluminum flat wire according to claim 1, characterized in that: It also includes step 5. Each batch of wires must be tested for paint film thickness, dimensions, adhesion, flexibility, breakdown voltage, soldering and resistivity; the test indicators are as follows: (1) Paint film thickness 0.06~0.11mm; (2) Maximum dimensions: 1.62×8.12mm; (3) Elongation: ≥15%; (4) Adhesion: After the enameled wire is stretched by 15%, the distance at which the paint film loses adhesion should be ≤1b; (5) Flexibility: The enameled wire should not crack when its wide side is bent 180° on a rod diameter 1.5 times its thickness or when it is bent 180° on a round rod diameter of φ16.4 mm; (6) Breakdown voltage: ≥2000V at room temperature, ≥1500V at 220℃; (7) Soldering test: 350℃±3℃, 3s, the paint film should not show delamination, blistering, cracking, etc.; (8) 20℃ resistivity ρ 20 :≤0.02801Ω·mm 2 / m. Wires that meet the above performance tests and the requirements of IEC60317-0-9 are qualified products.

3. The method for processing and manufacturing the 220-grade enameled aluminum flat wire according to claim 2, characterized in that: In step 3, the sizing area of ​​the paint mold of the integrated fixed mold is controlled at 1.5-2 mm, the difference between the fillet of the paint mold and the fillet of the conductor is controlled within 16.5 μm, and the difference between the area of ​​the paint mold and the fillet of the conductor is controlled within 0.011 mm. 2 Within.

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