A high-performance ceramic fiber insulation coated flat wire preparation system and process

Abstract

The present invention relates to the technical field of motor manufacturing, and in particular to a high-performance ceramic fiber insulation coating flat wire preparation system and process, wherein the preparation system comprises an alumina copper rod rolling preparation stage, an alumina copper flat wire surface nickel plating preparation stage, an alumina copper flat wire ceramic fiber insulation coating preparation stage, a detection and post-processing preparation stage, and a finished product delivery preparation stage; the various stages of the preparation system are connected through corresponding transmission and collaborative work to achieve a continuous and automated production process to prepare composite flat wires for motors; the present invention realizes efficient preparation from alumina copper rods to finished flat wires through a continuous and automated production process, and the optimized control of each stage ensures product quality and performance, improves the corrosion resistance and physical properties of the flat wire surface, and ensures the cleanliness and safety of the production environment, while meeting environmental protection requirements, providing strong support for the manufacture and application of motors.

Description

Technical Field

[0001] The invention relates to the technical field of motor manufacturing, and in particular to a system and process for preparing a high-performance ceramic fiber insulating coated flat wire. Background Art

[0002] With the continuous development of motor technology, the requirements for motor wire are getting higher and higher. Traditional round wire winding motors have problems such as low slot fill rate, high copper loss, and severe motor heating. These problems limit the performance and efficiency of the motor; therefore, in order to improve the performance of the motor and reduce energy consumption, the round wire design is changed to flat wire design; however, the traditional flat wire preparation process has problems such as low production efficiency and unstable product quality, which cannot meet the needs of modern motor manufacturing. For example, when pickling is performed during the processing to remove surface oxides, the existing technology has problems such as insufficient contact between the coil and the acid solution, and a large amount of acid solution and reactants are easily left in the coil after pickling; in addition, for flat wires with a relatively high aspect ratio, the general stamping process cannot be used due to structural reasons, and the line shape of the flat wire also needs to be improved to meet the process requirements. Summary of the invention

[0003] In order to solve some of the problems existing in the above-mentioned prior art, the present invention provides a high-performance ceramic fiber insulation coated flat wire preparation system, which realizes the efficient preparation from alumina copper rods to finished flat wires, ensures product quality and performance, improves the corrosion resistance and physical properties of the flat wire surface, and provides strong support for the manufacture and application of motors.

[0004] To achieve the above-mentioned purpose, the present invention provides a high-performance ceramic fiber insulation coating flat wire preparation system, the preparation system includes an alumina copper rod rolling preparation stage, an alumina copper flat wire surface nickel plating preparation stage, an alumina copper flat wire ceramic fiber insulation coating preparation stage, a detection and post-processing preparation stage and a finished product delivery preparation stage; the various stages of the preparation system are connected through corresponding transmission and collaborative work to achieve a continuous and automated production process to prepare composite flat wires for motors.

[0005] As a further improvement of the present invention, in order to achieve continuous preparation from raw materials to flat wires and improve production efficiency and product quality; the alumina copper rod rolling preparation stage includes a raw material unwinding device and the alumina copper rod raw material is placed and transported through the raw material unwinding device; the downstream of the raw material unwinding device is equipped with a bar straightening mechanism and a rolling mechanism, and the alumina copper flat wire is prepared through the bar straightening mechanism and the rolling mechanism; the bar straightening mechanism includes an upper adjusting roller and a lower adjusting roller, and a straightness measurement detection device is provided between the upper adjusting roller and the lower adjusting roller, and the straightness of the bar is detected through the straightness measurement detection device; the rolling mechanism includes a front roller assembly and a rear roller assembly, and the front roller assembly and the rear roller assembly are both provided with multiple groups; the rolling mechanism also includes a front extrusion die device and a rear extrusion die device arranged corresponding to the front roller assembly and the rear roller assembly, and extrusion molding is performed through the front extrusion die device and the rear extrusion die device.

[0006] As a further improvement of the present invention, in order to enhance the temperature control capability, optimize the power and control system, and realize the refined control of the alumina copper rod rolling preparation stage; a cooling box is arranged between the front roller assembly and the rear roller assembly, and the rolled rod is cooled by the cooling box; a zone temperature control device is arranged in the cooling box, and the cooling temperature of the rod during and after rolling is accurately controlled by the zone temperature control device to ensure the quality and performance of the product; a smoke hood is arranged on the outside of the rolling mechanism, and the smoke hood is connected to the WESP system for treating the exhaust gas generated during the preparation process; a roller drive device and a hydraulic system are also arranged on the rod straightening mechanism and the rolling mechanism, and the roller drive device and the hydraulic system provide power for the roller and control its rotation speed and direction; the alumina copper rod rolling preparation stage also includes a DCS system, and the DCS system can adjust the working state of each component by connecting with each actuator to ensure the stability and accuracy of the preparation process.

[0007] As a further improvement of the present invention, in order to achieve comprehensive cleaning and improve the nickel plating effect; the surface nickel plating preparation stage of the alumina copper flat wire includes a pickling and polishing treatment unit, a passivation cleaning treatment unit and a neutralization cleaning treatment unit; the pickling and polishing treatment unit includes a pickling tank and a solution tank, and the pickling tank and the solution tank are connected; the outside of the pickling tank and the solution tank are provided with a first solution storage tank, and the first solution storage tank is connected to the solution tank; the downstream of the pickling tank is provided with a turbid circulating water tank, a sedimentation water tank and a waste liquid tank, and the turbid circulating water tank, the sedimentation water tank and the waste liquid tank are connected and controlled by pipes and valves; the sedimentation water tank is provided with a turbid circulating water tank, a sedimentation water tank and a waste liquid tank. A process water pool is also provided downstream of the stagnant water pool, and water that has been treated to meet the reuse standards is stored in the process water pool; the pickling and polishing treatment unit also includes a spray flushing device, on which a first cleaning agent storage tank is provided; the passivation cleaning treatment unit includes a passivation tank and a second cleaning agent storage tank, and a second solution storage tank is also provided on the outside of the passivation tank; the neutralization cleaning treatment unit includes a neutralization tank and a third cleaning agent storage tank, and a third solution storage tank is also provided on the outside of the neutralization tank; the surface nickel plating preparation stage of the alumina copper flat wire also includes a heat treatment and shaping treatment unit and a drying and nickel plating treatment unit.

[0008] As a further improvement of the present invention, in order to more accurately measure and control the temperature, ensure the heat treatment effect and improve the quality; the heat treatment and shaping treatment unit includes a heating zone, and a thermocouple is correspondingly arranged in the heating zone, and the thermocouple is arranged in a plurality; the thermocouple is also connected to a heating control device and accurate temperature measurement and control is achieved through the heating control device; the drying and nickel plating treatment unit includes an air heater and the treated alumina copper flat wire is heated and dried through the air heater; the drying and nickel plating treatment unit also includes a nickel plating device and a flat wire winding device, and the alumina copper flat wire is surface nickel plated and wound through the nickel plating device and the flat wire winding device.

[0009] As a further improvement of the present invention, in order to carry out multiple spraying and drying treatments on the flat wire to ensure the uniformity and adhesion of the coating; at the same time, it is convenient for the supply of coating and the treatment of hazardous waste, and the safety and convenience of the production process are improved; the preparation stage of the alumina copper flat wire ceramic fiber insulation coating includes spraying equipment and drying equipment, and several spraying equipment and drying equipment are correspondingly arranged, and the spraying equipment and drying equipment can carry out multiple spraying and drying treatments; the outside of the spraying equipment is also provided with a coating storage tank and a hazardous goods recovery device.

[0010] As a further improvement of the present invention, in order to comprehensively detect the coating thickness and insulation performance of the flat wire to ensure that the product quality meets the requirements; at the same time, the integration of waste treatment and post-processing operations is realized to improve production efficiency and workshop environmental quality; the detection and post-processing preparation stage includes a detection part, which includes a coating thickness detection device and an insulation performance detection device, and the flat wire is correspondingly detected through the coating thickness detection device and the insulation performance detection device; the detection and post-processing preparation stage also includes a post-processing part, which includes a cutting device; the lower end of the cutting device is provided with a collecting hood, and the waste and dust generated during the cutting process are collected centrally through the collecting hood; the outer end of the collecting hood is also provided with a cartridge dust removal device, and the collected waste and dust are filtered and processed through the cartridge dust removal device; the post-processing part also includes a bending device, and the flat wire is bent through the bending device.

[0011] As a further improvement of the present invention, in order to improve product quality and stability, ensure that the shape and size of the product meet the requirements, and facilitate subsequent delivery and use; the finished product delivery preparation stage includes a pressing and shaping device, which is used to press and shape the flat wire before delivery; the rear end of the pressing and shaping device is provided with a drying and shaping device, and the drying and shaping device is equipped with a plurality of electromagnetic heaters and heated by the electromagnetic heater; the finished product delivery preparation stage also includes a finished product winding delivery device, which is connected to the drying and shaping device, and is used to collect and organize the finished flat wire after all processing steps.

[0012] One of the beneficial effects of the present invention is that: through multiple preparation stages, a continuous and automated production process is realized, which significantly improves production efficiency and product quality; by optimizing the temperature control, power and control systems, refined control of the alumina copper rod rolling preparation stage is achieved; through a perfect nickel plating preparation stage, the nickel plating effect is ensured, and the corrosion resistance of the flat wire surface is comprehensively improved; in addition, multiple spraying and drying treatments ensure the uniformity and adhesion of the coating, and comprehensive testing and post-processing operations further ensure product quality and stability, providing strong support for the manufacture and application of motors.

[0013] The present invention also provides a process for preparing a high-performance ceramic fiber insulating coated flat wire, the process comprising the following steps: Step 1: Place and convey the alumina copper rod raw material through the raw material unwinding device; use the upper adjusting roller, the lower adjusting roller, and the straightness measurement detection device arranged between the upper adjusting roller and the lower adjusting roller to detect the straightness of the rod material and straighten the rod material; Step 2: Rolling is performed by a front roller assembly and a rear roller assembly, and the front roller assembly and the rear roller assembly are both provided with multiple groups; and the straightened alumina copper rod is multi-pass rolled and extruded by using a correspondingly provided front extrusion die device and a rear extrusion die device; Step 3: During the rolling process, the cooling temperature of the bar during and after rolling is precisely controlled by a cooling box and a zoned temperature control device; a smoke hood is provided outside the rolling mechanism, and the exhaust gas generated during the preparation process is treated by connecting to the WESP system; the roll drive device and hydraulic system are used to power the rolls and control their rotation speed and direction; Step 4: Connect with each actuator through the DCS system to adjust the working status of each component to ensure the stability and accuracy of the preparation process; Step 5: Send the rolled alumina copper flat wire to the heat treatment and shaping unit, and achieve accurate temperature measurement and control through the heating control device and thermocouple to complete annealing and shaping; Step 6: The shaped flat wire is sent to the pickling and polishing treatment unit, and the pickling treatment is carried out through the connected pickling tank and solution tank and the first solution storage tank arranged outside. The waste water after pickling is sequentially treated through the turbid ring water tank, the sedimentation water tank and the waste liquid tank. The process water tank downstream of the sedimentation water tank stores reusable water, and at the same time, it is rinsed by the spray flushing device provided with the first cleaning agent storage tank; Step 7: Send the polished flat wire to the passivation cleaning treatment unit, and passivate it through the passivation tank, the second cleaning agent storage tank, and the second solution storage tank; Step 8: Send the passivated flat wire to the neutralization and cleaning processing unit, and neutralize and clean it through the neutralization tank, the third cleaning agent storage tank, and the third solution storage tank; Step nine: Send the cleaned flat wire to the drying and nickel plating treatment unit, heat and dry it with an air heater, then perform surface nickel plating with a nickel plating device, and finally reel it with a flat wire reeling device; Step 10: Send the nickel-plated alumina copper flat wire into the spraying equipment, and provide the ceramic fiber insulation coating through the coating storage tank for spraying; dry the sprayed flat wire through the drying equipment; repeat the spraying and drying steps several times until the required coating thickness is reached; recycle the hazardous waste in the spraying process through the hazardous goods recovery device; Step 11: The flat wire with ceramic fiber insulation coating is tested by a coating thickness testing device and an insulation performance testing device; the flat wire is cut by a cutting device, a collecting hood provided at the lower end of the cutting device collects waste and dust in a centralized manner, a cartridge dust removal device provided at the outer end of the collecting hood filters and processes waste and dust, and a bending device is used to bend the flat wire; Step 12: First, the bent flat wire is sent to the compacting and shaping device for compacting and shaping, and then heated by several electromagnetic heaters set in the drying and shaping device. Finally, the finished flat wire after all processing steps is collected and sorted by the finished winding delivery device, ready for delivery and use.

[0014] Another beneficial effect of the present invention is that through the orderly connection and precise operation of each step, continuous and automated production from alumina copper rod raw materials to finished flat wires is achieved; during the rolling process, the straightness of the rods is detected and straightened, and multiple rolling and extrusion molding are carried out, combined with precise temperature control, exhaust gas treatment, power and control system adjustment, to ensure product quality and performance, and to ensure the cleanliness and safety of the production environment; subsequent heat treatment, pickling and polishing, passivation cleaning, neutralization cleaning, and drying and nickel plating steps further improve the physical properties and surface quality of the flat wires; the spraying and drying process of the ceramic fiber insulation coating provides the flat wires with good insulation performance; the final detection and post-processing stage ensures that the product's dimensional accuracy and insulation performance meet the standards, while realizing the centralized collection and treatment of waste materials, in line with environmental protection requirements.

[0015] When the present invention is working, firstly, the raw material of alumina copper rod is placed and conveyed through the raw material unwinding device, and after being straightened by the upper adjusting roller, the lower adjusting roller and the straightness measurement detection device, it enters the front roller assembly and the rear roller assembly for multi-pass rolling, and is extruded and formed by the front extrusion die device and the rear extrusion die device at the same time; during the rolling process, the cooling temperature is controlled by the cooling box and the partition temperature control device, the smoke hood is connected to the WESP system to treat the exhaust gas, and the roller drive device and the hydraulic system provide power and control the rotation direction; the DCS system adjusts the working state of each component to ensure stable and accurate preparation; then, the rolled flat wire is sent to the heat treatment and shaping treatment unit, and annealing and shaping are performed by the heating control device and the thermocouple; then the shaped flat wire is sent to the pickling and polishing treatment unit in turn, and pickled by the pickling tank, the waste water is treated by the turbid ring water tank, the sedimentation water tank and the waste liquid tank, the process water tank stores reusable water, and is rinsed by the spray flushing device; then, it is sent to the passivation cleaning treatment unit, and the heat treatment unit is used to heat the flat wire. The passivation tank, the second cleaning agent storage tank and the second solution storage tank are passivated, and then sent to the neutralization cleaning treatment unit, and neutralized by the neutralization tank, the third cleaning agent storage tank and the third solution storage tank; then, the cleaned flat wire is sent to the drying and nickel plating treatment unit, heated and dried by the air heater, nickel-plated by the nickel plating equipment, and then wound by the flat wire winding device; then, the nickel-plated flat wire is sent to the spraying equipment, sprayed with ceramic fiber insulation coating by the coating storage tank, dried by the drying equipment, sprayed and dried multiple times to the required coating thickness, and the waste can be recycled by the hazardous goods recovery device; the flat wire is tested by the coating thickness detection device and the insulation performance detection device, cut by the cutting device, the collection hood and the cartridge dust removal device collect and process the waste dust, and the bending device bends the flat wire; finally, the bent flat wire is pressed and shaped by the pressing and shaping device, heated by the electromagnetic heater in the drying and shaping device, and then the finished flat wire is collected and sorted by the finished winding delivery device for delivery and use. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to facilitate the understanding of those skilled in the art, the present invention is further described below with reference to the accompanying drawings: Figure 1 It is a schematic diagram of the process of the rolling preparation stage of alumina copper flat wire in the present invention.

[0017] Figure 2 It is a schematic flow diagram of the heat treatment and shaping treatment unit in the preparation stage of nickel plating on the surface of aluminum oxide copper flat wire in the present invention.

[0018] Figure 3 It is a schematic flow chart of the pickling and polishing treatment units in the preparation stage of nickel plating on the surface of alumina copper flat wire in the present invention.

[0019] Figure 4 It is a schematic flow chart of the passivation cleaning treatment unit in the preparation stage of nickel plating on the surface of aluminum oxide copper flat wire in the present invention.

[0020] Figure 5 It is a schematic flow chart of the neutralization and cleaning treatment unit in the preparation stage of nickel plating on the surface of alumina copper flat wire in the present invention.

[0021] Figure 6 It is a schematic flow chart of the drying and nickel plating processing units in the preparation stage of nickel plating on the surface of alumina copper flat wire in the present invention.

[0022] Figure 7 It is a schematic diagram of the process of preparing the insulating coating of alumina copper flat wire ceramic fiber in the present invention.

[0023] Figure 8 It is a schematic diagram of the process of the detection and post-processing preparation stage in the present invention.

[0024] Fig. 9 It is a schematic diagram of the process of the finished product delivery preparation stage in the present invention.

[0025] Among them, 1 alumina copper rod rolling preparation stage, 101 raw material unwinding device, 102 DCS system, 103 upper adjustment roller, 104 straightness measurement detection device, 105 WESP system, 106 smoke hood, 107 zone temperature control device, 108 rear extrusion die device, 109 rear roller assembly, 110 cooling box, 111 front extrusion die device, 112 front roller assembly, 113 roller drive device, 114 lower adjustment roller, 115 hydraulic system, 2 preparation stage of surface nickel plating of alumina copper flat wire, 201 heating control device, 202 thermocouple, 203 solution tank, 204 first solution storage tank, 205 pickling tank, 206 turbid ring water tank, 207 sedimentation water tank, 208 waste liquid tank, 209 process water tank, 210 dust collection bin, 211 dust hood, 212 first cleaning agent storage tank, 213 spray flushing device, 214 second cleaning agent storage tank, 215 passivation tank, 216 The second solution storage tank, 217 the third cleaning agent storage tank, 218 the neutralization tank, 219 the third solution storage tank, 220 the air heater, 221 the nickel plating equipment, 222 the flat wire winding device, 3 the alumina copper flat wire ceramic fiber insulation coating preparation stage, 301 the coating storage tank, 302 the spraying equipment, 303 the drying equipment, 304 the hazardous materials recovery device, 4 the detection and post-processing preparation stage, 401 the coating thickness detection device, 402 the insulation performance detection device, 403 the cutting device, 404 the collecting hood, 405 the cartridge dust removal device, 406 the bending device, 5 the finished product delivery preparation stage, 501 the pressing and shaping device, 502 the drying and shaping device, 503 the electromagnetic heater, 504 the finished product winding delivery device. DETAILED DESCRIPTION

[0026] In order to enable those skilled in the art to better understand the technical solution in this application, Figure 1-9The present invention is further described. The following examples are only used to more clearly illustrate the technical solution of the present invention, and are not intended to limit the protection scope of the present invention.

[0027] As shown in the figure, a high-performance ceramic fiber insulation coating flat wire preparation system is described, the preparation system includes an alumina copper rod rolling preparation stage 1, an alumina copper flat wire surface nickel plating preparation stage 2, an alumina copper flat wire ceramic fiber insulation coating preparation stage 3, a detection and post-processing preparation stage 4, and a finished product delivery preparation stage 5; the various stages of the preparation system are connected through corresponding transmission and collaborative work to achieve a continuous and automated production process to prepare composite flat wires for motors; the alumina copper rod rolling preparation stage 1 includes a raw material unwinding device 101, and the alumina copper rod raw material is placed and transported through the raw material unwinding device 101; the downstream of the raw material unwinding device 101 is equipped with a bar straightening mechanism and a rolling mechanism. The mechanism prepares alumina copper flat wire through a bar straightening mechanism and a rolling mechanism; the bar straightening mechanism includes an upper adjusting roller 103 and a lower adjusting roller 114, a straightness measurement detection device 104 is arranged between the upper adjusting roller 103 and the lower adjusting roller 114, and the straightness of the bar is detected by the straightness measurement detection device 104; the rolling mechanism includes a front roller assembly 112 and a rear roller assembly 109, and the front roller assembly 112 and the rear roller assembly 109 are both provided with multiple groups; the rolling mechanism also includes a front extrusion die device 111 and a rear extrusion die device 108 arranged corresponding to the front roller assembly 112 and the rear roller assembly 109, and extrusion is performed through the front extrusion die device 111 and the rear extrusion die device 108 forming; a cooling box 110 is arranged between the front roller assembly 112 and the rear roller assembly 109, and the rolled bar is cooled by the cooling box 110; a zone temperature control device 107 is arranged in the cooling box 110, and the cooling temperature of the bar during and after rolling is accurately controlled by the zone temperature control device 107 to ensure the quality and performance of the product; a smoke hood 106 is arranged on the outside of the rolling mechanism, and the smoke hood 106 is connected to the WESP system 105 for treating the waste gas generated during the preparation process; the bar straightening mechanism and the rolling mechanism are also provided with a roller drive device 113 and a hydraulic system 115, which provide power for the rollers , and control its rotation speed and direction; the alumina copper rod rolling preparation stage 1 also includes a DCS system 102, which can adjust the working state of each component by connecting with each actuator to ensure the stability and accuracy of the preparation process; the alumina copper flat wire surface nickel plating preparation stage 2 includes a pickling and polishing treatment unit, a passivation cleaning treatment unit and a neutralization cleaning treatment unit; the pickling and polishing treatment unit includes a pickling tank 205 and a solution tank 203, and the pickling (205 and the solution tank 203 are connected; the outside of the pickling tank 205 and the solution tank 203 are provided with a first solution storage tank 204, and the first solution storage tank 204 is connected to the solution tank 203;Downstream of the pickling tank 205, a turbid water tank 206, a sedimentation water tank 207 and a waste liquid tank 208 are provided, and the turbid water tank 206, the sedimentation water tank 207 and the waste liquid tank 208 are connected and controlled by pipelines and valves; downstream of the sedimentation water tank 207, a process water tank 209 is also provided, and the water treated to meet the reuse standard is stored in the process water tank 209; the pickling and polishing treatment unit also includes a spray flushing device 213, and the spray flushing device 213 is provided with a first cleaning agent storage tank 212; the passivation cleaning treatment unit includes a passivation tank 215 and a second cleaning agent storage tank 214, and the outer side of the passivation tank 215 is also provided with a second solution storage tank 216; The neutralization and cleaning treatment unit includes a neutralization tank 218 and a third cleaning agent storage tank 217, and a third solution storage tank 219 is also provided outside the neutralization tank 218; the surface nickel plating preparation stage 2 of the aluminum oxide copper flat wire also includes a heat treatment and shaping treatment unit and a drying and nickel plating treatment unit; the heat treatment and shaping treatment unit includes a heating zone, and a thermocouple 202 is correspondingly provided in the heating zone, and the thermocouple 202 is provided with a plurality of thermocouples; the thermocouple 202 is also connected to a heating control device 201, and accurate temperature measurement and control are achieved through the heating control device 201; the drying and nickel plating treatment unit includes an air heater 220, and the treated aluminum oxide copper flat wire is heated by the air heater 220 Heating and drying; the drying and nickel plating treatment unit also includes a nickel plating device 221 and a flat wire winding device 222, and the surface of the alumina copper flat wire is nickel plated and wound through the nickel plating device 221 and the flat wire winding device 222; the alumina copper flat wire ceramic fiber insulation coating preparation stage 3 includes a spraying device 302 and a drying device 303, and the spraying device 302 and the drying device 303 are correspondingly provided with a plurality of spraying and drying devices 302 and 303. The spraying device 302 and the drying device 303 can perform multiple spraying and drying treatments; the outer side of the spraying device 302 is also provided with a paint storage tank 301 and a hazardous material recovery device 304; the detection and post-processing preparation stage 4 includes a detection part, which includes a coating thickness detection The device 401 and the insulation performance detection device 402 perform corresponding detection on the flat wire through the coating thickness detection device 401 and the insulation performance detection device 402; the detection and post-processing preparation stage 4 also includes a post-processing part, which includes a cutting device 403; the lower end of the cutting device 403 is provided with a collecting hood 404, and the waste and dust generated during the cutting process are collected through the collecting hood 404; the outer end of the collecting hood 404 is also provided with a cartridge dust removal device 405, and the collected waste and dust are filtered and processed through the cartridge dust removal device 405; the post-processing part also includes a bending device 406, and the flat wire is bent through the bending device 406;The finished product delivery preparation stage 5 includes a pressing and shaping device 501, which is used to press and shape the flat wire before delivery; the rear end of the pressing and shaping device 501 is provided with a drying and shaping device 502, and the drying and shaping device 502 is provided with a plurality of electromagnetic heaters 503 and heated by the electromagnetic heaters 503; the finished product delivery preparation stage 5 also includes a finished winding delivery device 504, which is connected to the drying and shaping device (502) and is used to collect and organize the finished flat wire after all processing steps. ;

[0028] As shown in the figure, a high-performance ceramic fiber insulation coated flat wire preparation process is provided, and the preparation process comprises the following steps: Step 1: Place and convey the alumina copper rod raw material through the raw material unwinding device 101; use the upper adjusting roller 103, the lower adjusting roller 114, and the straightness measurement detection device 104 arranged between the upper adjusting roller 103 and the lower adjusting roller 114 to detect the straightness of the rod material and straighten the rod material; Step 2: Rolling is performed by the front roller assembly 112 and the rear roller assembly 109, and the front roller assembly 112 and the rear roller assembly 109 are both provided in multiple groups; and the straightened alumina copper rod is multi-pass rolled and extruded by using the correspondingly provided front extrusion die device 111 and the rear extrusion die device 108; Step 3: During the rolling process, the cooling temperature of the bar during and after the rolling process is precisely controlled by the cooling box 110 and the zone temperature control device 107; a smoke hood 106 is provided outside the rolling mechanism, and the exhaust gas generated during the preparation process is treated by connecting to the WESP system 105; the roller drive device 113 and the hydraulic system 115 are used to provide power to the rollers and control their rotation speed and direction; Step 4: Connect with each actuator through the DCS system 102 to adjust the working state of each component to ensure the stability and accuracy of the preparation process; Step 5: Send the rolled alumina copper flat wire to the heat treatment and shaping treatment unit, and achieve accurate temperature measurement and control through the heating control device 201 and the thermocouple 202 to complete annealing and shaping; Step 6: The shaped flat wire is sent to the pickling and polishing treatment unit, and the pickling treatment is carried out through the connected pickling tank 205 and the solution tank 203 and the first solution storage tank 204 arranged outside. The waste water after pickling is processed in turn through the turbid water tank 206, the sedimentation water tank 207 and the waste liquid tank 208. The process water tank 209 downstream of the sedimentation water tank 207 stores reusable water, and at the same time, it is rinsed by the spray flushing device 213 provided with the first cleaning agent storage tank 212; Step 7: Send the polished flat wire to the passivation cleaning treatment unit, and passivate it through the passivation tank 215, the second cleaning agent storage tank 214 and the second solution storage tank 216; Step 8: Send the passivated flat wire to the neutralization and cleaning processing unit, and neutralize and clean it through the neutralization tank 218, the third cleaning agent storage tank 217 and the third solution storage tank 219; Step nine: sending the cleaned flat wire to the drying and nickel plating processing unit, heating and drying it through the air heater 220, then performing surface nickel plating treatment through the nickel plating device 221, and finally winding it through the flat wire winding device 222; Step 10: Send the nickel-plated alumina copper flat wire to the spraying equipment 302, and provide ceramic fiber insulation coating through the coating storage tank 301 for spraying; dry the sprayed flat wire through the drying equipment 303; repeat the spraying and drying steps several times until the required coating thickness is reached; and recycle the hazardous waste in the spraying process through the hazardous material recovery device 304; Step 11: The flat wire with ceramic fiber insulation coating is tested by the coating thickness detection device 401 and the insulation performance detection device 402; the flat wire is cut by the cutting device 403, and the collecting hood 404 arranged at the lower end of the cutting device 403 collects waste and dust in a centralized manner, and the cartridge dust removal device 405 arranged at the outer end of the collecting hood 404 filters and processes the waste and dust, and the flat wire is bent by the bending device 406; Step 12: First, the bent flat wire is sent to the pressing and shaping device 501 for pressing and shaping, and then heated by a plurality of electromagnetic heaters 503 provided in the drying and shaping device 502. Finally, the finished flat wire after all the processing steps is collected and sorted by the finished winding delivery device 504, and is ready for delivery and use.

[0029] When the present invention is working, first, the raw material of alumina copper rod is placed and conveyed through the raw material unwinding device 101, and after being straightened by the upper adjusting roller 103, the lower adjusting roller 114 and the straightness measurement detection device 104, it enters the front roller assembly 112 and the rear roller assembly 109 for multi-pass rolling, and is extruded and formed by the front extrusion die device 111 and the rear extrusion die device 108 at the same time; during the rolling process, the cooling temperature is controlled by the cooling box 110 and the zone temperature control device 107, the smoke hood 106 is connected to the WESP system 105 to treat the exhaust gas, and the roller drive device 113 and the hydraulic system 115 provide power and Control the direction of rotation; DCS system 102 adjusts the working state of each component to ensure stable and accurate preparation; then, the rolled flat wire is sent to the heat treatment and shaping unit, and annealing and shaping are performed using the heating control device 201 and the thermocouple 202; the shaped flat wire is then sent to the pickling and polishing unit in turn, and pickled in the pickling tank 205, and the waste water is treated in the turbid water tank 206, the sedimentation water tank 207 and the waste liquid tank 208, and the process water tank 209 stores reusable water, and is rinsed by the spray flushing device 213; then, it is sent to the passivation cleaning unit, and the The passivation tank 215 and the second cleaning agent storage tank 214 and the second solution storage tank 216 are passivated, and then sent to the neutralization cleaning processing unit, and neutralized by the neutralization tank 218 and the third cleaning agent storage tank 217 and the third solution storage tank 219; then, the cleaned flat wire is sent to the drying and nickel plating processing unit, heated and dried by the air heater 220, nickel-plated by the nickel plating equipment 221, and then wound by the flat wire winding device 222; then, the nickel-plated flat wire is sent to the spraying equipment 302, and the ceramic fiber insulation coating is sprayed by the coating storage tank 301, and the drying equipment 303 is dried, and the spraying and drying are repeated multiple times until the required The coating thickness is measured, and waste can be recycled through the hazardous material recycling device 304; the flat wire is tested by the coating thickness detection device 401 and the insulation performance detection device 402, and cut by the cutting device 403. The collecting hood 404 and the cartridge dust removal device 405 collect and process the waste dust, and the bending device 406 bends the flat wire; finally, the bent flat wire is pressed and shaped by the pressing and shaping device 501, and heated by the electromagnetic heater 503 in the drying and shaping device 502, and then the finished flat wire is collected and sorted by the finished winding delivery device 504 for delivery and use.

[0030] The present invention is not limited to the above-mentioned embodiments. On the basis of the technical solution disclosed in the present invention, technicians in this field can make some substitutions and deformations to some technical features therein according to the disclosed technical content without creative labor, and these substitutions and deformations are all within the protection scope of the present invention.

Claims

1. A high-performance ceramic fiber insulation coated flat wire preparation system, characterized in that: The preparation system comprises an alumina copper rod rolling preparation stage (1), an alumina copper flat wire surface nickel plating preparation stage (2), an alumina copper flat wire ceramic fiber insulation coating preparation stage (3), a detection and post-processing preparation stage (4) and a finished product delivery preparation stage (5); the various stages of the preparation system are connected through corresponding transmission and coordinated work to achieve a continuous and automated production process to prepare a composite flat wire for a motor.

2. A high performance ceramic fiber insulation coated flat wire preparation system according to claim 1, characterized in that: The aluminum oxide copper rod rolling preparation stage (1) comprises a raw material unwinding device (101) and the aluminum oxide copper rod raw material is placed and transported through the raw material unwinding device (101); a rod straightening mechanism and a rolling mechanism are arranged downstream of the raw material unwinding device (101); and the aluminum oxide copper flat wire is prepared through the rod straightening mechanism and the rolling mechanism; the rod straightening mechanism comprises an upper adjusting roller (103) and a lower adjusting roller (114); a straightness measurement detection device is arranged between the upper adjusting roller (103) and the lower adjusting roller (114). The invention relates to a rolling mechanism comprising a front roller assembly (112) and a rear roller assembly (109), wherein the front roller assembly (112) and the rear roller assembly (109) are each provided with a plurality of groups; the rolling mechanism also comprises a front extrusion die device (111) and a rear extrusion die device (108) provided corresponding to the front roller assembly (112) and the rear roller assembly (109), and extrusion molding is performed by the front extrusion die device (111) and the rear extrusion die device (108).

3. A high performance ceramic fiber insulation coated flat wire preparation system according to claims 1 and 2, characterized in that: A cooling box (110) is provided between the front roller assembly (112) and the rear roller assembly (109), and the rolled bar is cooled by the cooling box (110); a zoned temperature control device (107) is provided in the cooling box (110), and the cooling temperature of the bar during and after rolling is accurately controlled by the zoned temperature control device (107), thereby ensuring the quality and performance of the product; a smoke hood (106) is provided outside the rolling mechanism, and the smoke hood (106) is connected to the WESP system (105) for The rod straightening mechanism and the rolling mechanism are also provided with a roller drive device (113) and a hydraulic system (115), which provide power for the rollers and control their rotation speed and direction; the alumina copper rod rolling preparation stage (1) also includes a DCS system (102), which can adjust the working state of each component by connecting with each actuator to ensure the stability and accuracy of the preparation process.

4. A high performance ceramic fiber insulation coated flat wire preparation system according to claim 1, characterized in that: The alumina copper flat wire surface nickel plating preparation stage (2) comprises a pickling and polishing treatment unit, a passivation cleaning treatment unit and a neutralization cleaning treatment unit; the pickling and polishing treatment unit comprises a pickling tank (205) and a solution tank (203), and the pickling tank (205) and the solution tank (203) are connected; the outsides of the pickling tank (205) and the solution tank (203) are provided with a first solution storage tank (204), and the first solution storage tank (204) is connected to the solution tank (203); the downstream of the pickling tank (205) is provided with a turbid circulating water tank (206), a sedimentation water tank (207) and a waste liquid tank (208), and the turbid circulating water tank (206), the sedimentation water tank (207) and the waste liquid tank (208) are connected and controlled by pipelines and valves; the sedimentation water tank (207) A process water pool (209) is also provided downstream, and water that has been treated and reaches the reuse standard is stored in the process water pool (209); the pickling and polishing treatment unit also includes a spray flushing device (213), and a first cleaning agent storage tank (212) is provided on the spray flushing device (213); the passivation cleaning treatment unit includes a passivation tank (215) and a second cleaning agent storage tank (214), and a second solution storage tank (216) is also provided outside the passivation tank (215); the neutralization cleaning treatment unit includes a neutralization tank (218) and a third cleaning agent storage tank (217), and a third solution storage tank (219) is also provided outside the neutralization tank (218); the alumina copper flat wire surface nickel plating preparation stage (2) also includes a heat treatment and shaping treatment unit and a drying and nickel plating treatment unit.

5. A high performance ceramic fiber insulation coated flat wire preparation system according to claims 1 and 4, characterized in that: The heat treatment and shaping treatment unit comprises a heating zone, wherein a thermocouple (202) is correspondingly arranged in the heating zone, and a plurality of the thermocouples (202) are arranged; the thermocouple (202) is also connected to a heating control device (201), and accurate temperature measurement and control are achieved through the heating control device (201); the drying and nickel plating treatment unit comprises an air heater (220), and the treated alumina copper flat wire is heated and dried through the air heater (220); the drying and nickel plating treatment unit also comprises a nickel plating device (221) and a flat wire winding device (222), and the surface of the alumina copper flat wire is nickel plated and wound through the nickel plating device (221) and the flat wire winding device (222).

6. A high performance ceramic fiber insulation coated flat wire preparation system according to claim 1, characterized in that: The alumina copper flat wire ceramic fiber insulation coating preparation stage (3) includes a spraying device (302) and a drying device (303), wherein a plurality of the spraying devices (302) and the drying devices (303) are provided correspondingly, and the spraying devices (302) and the drying devices (303) can perform multiple spraying and drying processes; and a coating storage tank (301) and a hazardous material recovery device (304) are also provided outside the spraying device (302).

7. A high performance ceramic fiber insulation coated flat wire preparation system according to claim 1, characterized in that: The detection and post-processing preparation stage (4) includes a detection part, which includes a coating thickness detection device (401) and an insulation performance detection device (402), and the coating thickness detection device (401) and the insulation performance detection device (402) are used to perform corresponding detection on the flat wire; the detection and post-processing preparation stage (4) also includes a post-processing part, which includes a cutting device (403); a collecting hood (404) is provided at the lower end of the cutting device (403), and the waste and dust generated during the cutting process are collected by the collecting hood (404); the outer end of the collecting hood (404) is also provided with a filter cartridge dust removal device (405), and the collected waste and dust are filtered and processed by the filter cartridge dust removal device (405); the post-processing part also includes a bending device (406), and the flat wire is bent by the bending device (406).

8. The high performance ceramic fiber insulation coated flat wire preparation system according to claim 1, characterized in that: The finished product delivery preparation stage (5) includes a pressing and shaping device (501), which is used to press and shape the flat wire before delivery; a drying and shaping device (502) is provided at the rear end of the pressing and shaping device (501), and a plurality of electromagnetic heaters (503) are provided in the drying and shaping device (502) and are heated by the electromagnetic heaters (503); the finished product delivery preparation stage (5) also includes a finished product winding delivery device (504), which is connected to the drying and shaping device (502) and is used to collect and organize the finished flat wire after all processing steps.

9. A process for preparing high-performance ceramic fiber insulation coated flat wire, characterized in that: The preparation process comprises the following steps: Step 1: placing and conveying the alumina copper rod raw material through the raw material unwinding device (101); using the upper adjusting roller (103), the lower adjusting roller (114), and the straightness measurement detection device (104) arranged between the upper adjusting roller (103) and the lower adjusting roller (114) to detect the straightness of the rod material, and straighten the rod material; Step 2: rolling the aluminum oxide copper rod by using a front roller assembly (112) and a rear roller assembly (109), wherein the front roller assembly (112) and the rear roller assembly (109) are provided in multiple groups; and simultaneously, the aluminum oxide copper rod after being straightened is subjected to multiple rolling and extrusion molding by using a correspondingly provided front extrusion die device (111) and a rear extrusion die device (108); Step 3: During the rolling process, the cooling temperature of the bar during and after the rolling process is precisely controlled by a cooling box (110) and a zoned temperature control device (107); a smoke hood (106) is arranged outside the rolling mechanism, and the exhaust gas generated during the preparation process is treated by connecting to a WESP system (105); a roller drive device (113) and a hydraulic system (115) are used to provide power to the rollers and control their rotation speed and direction; Step 4: Connecting with each actuator through the DCS system (102) to adjust the working state of each component to ensure the stability and accuracy of the preparation process; Step 5: sending the rolled alumina copper flat wire to a heat treatment and shaping treatment unit, achieving accurate temperature measurement and control through a heating control device (201) and a thermocouple (202), and completing annealing and shaping; Step 6: The shaped flat wire is sent to the pickling and polishing treatment unit, and is pickled through the connected pickling tank (205) and the solution tank (203) and the first solution storage tank (204) arranged outside. The waste water after pickling is sequentially treated through the turbid water tank (206), the sedimentation water tank (207) and the waste liquid tank (208). The process water tank (209) downstream of the sedimentation water tank (207) stores reusable water, and is rinsed by the spray flushing device (213) provided with the first cleaning agent storage tank (212); Step 7: sending the polished flat wire into a passivation cleaning treatment unit, and passing through a passivation tank (215), a second cleaning agent storage tank (214), and a second solution storage tank (216) for passivation treatment; Step 8: sending the passivated flat wire to a neutralization and cleaning processing unit, and performing neutralization and cleaning through a neutralization tank (218), a third cleaning agent storage tank (217), and a third solution storage tank (219); Step nine: sending the cleaned flat wire to a drying and nickel plating treatment unit, heating and drying the flat wire through an air heater (220), then performing surface nickel plating treatment through a nickel plating device (221), and finally winding the flat wire through a flat wire winding device (222); Step 10: feeding the nickel-plated alumina copper flat wire into a spraying device (302), providing ceramic fiber insulation coating through a coating storage tank (301) for spraying; drying the sprayed flat wire through a drying device (303); repeating the spraying and drying steps several times until the desired coating thickness is reached; and recycling hazardous wastes from the spraying process through a hazardous material recycling device (304); Step 11: The flat wire with the ceramic fiber insulation coating is inspected by the coating thickness detection device (401) and the insulation performance detection device (402); the flat wire is cut by the cutting device (403); a collecting hood (404) provided at the lower end of the cutting device (403) collects waste and dust in a centralized manner; a cartridge dust removal device (405) provided at the outer end of the collecting hood (404) filters and processes the waste and dust; and the flat wire is bent by the bending device (406); Step 12: First, the bent flat wire is sent to the pressing and shaping device (501) for pressing and shaping, and then heated by a plurality of electromagnetic heaters (503) provided in the drying and shaping device (502). Finally, the finished flat wire after all the processing steps is collected and sorted by the finished winding delivery device (504) and prepared for delivery and use.

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