High-speed production process of low-voltage automobile wire

Abstract

The invention discloses a high-speed production process for a low-voltage automotive wire, and particularly relates to the technical field of automotive wire production, and the high-speed production process specifically comprises the following steps: S1, precise treatment of raw materials; s2, intelligent wire drawing; s3, precise wire twisting; s4, optimizing insulation extrusion; s5, carrying out omnibearing online detection; s6, high-speed and accurate marking is carried out; s7, intelligent self-adaptive rolling is carried out; and S8, environment-friendly and efficient packaging. According to the method, the high-purity oxygen-free copper material is carefully treated, foundation is laid for high-quality products, conductor size and performance are controlled in a high-precision mode, product quality is comprehensively improved, the whole process is optimized, all links are closely connected, high-speed equipment is widely applied, production is greatly accelerated, whole-process management and control of an intelligent system are achieved, production efficiency is remarkably enhanced, and meanwhile cost and environmental protection benefits are achieved; the production efficiency is improved, the spreading cost is improved, packaging materials can be degraded, production energy-saving measures are taken, environmental pollution is reduced, economic and environment-friendly benefits are achieved, sustainable development of enterprises is assisted, and the method adapts to the environment-friendly market trend.

Description

Technical Field

[0001] The invention relates to the technical field of automobile wire production, and in particular to a low-voltage automobile wire high-speed production process. Background Art

[0002] There are many problems in the traditional low-voltage automotive wire production process. In the conductor processing link, mechanical design and parameter setting are adopted, but the precision control of wire drawing dies is poor, the copper wire diameter is uneven, the tension control of stranded wire is imprecise, the insulation layer extrusion process is imperfect, the temperature, pressure and other parameters are roughly controlled, the mold is simple, and the inspection is mostly random inspection, which makes it difficult to find subtle defects. Each production link is relatively independent and lacks optimization and integration. The equipment runs at a low speed and cannot meet the needs of high-speed production, resulting in a slow production cycle. These problems lead to uneven product quality, low production efficiency, and high costs, which cannot meet the automotive industry's demand for rapid and large-scale production of low-voltage automotive wires.

[0003] Chinese patent announcement number CN118278651A2 discloses an automobile wiring harness processing production system and method, including a production management module for receiving externally input product shipment demand information, parsing it into a product production task order and sending it to the automobile wiring harness processing module; the automobile wiring harness processing module is used to use the product information in the production task order to obtain the product's tooling storage location information and confirm the successful tooling replacement; then parse the production program of the product corresponding to the current tooling, obtain the material information required for the current tooling, and replace the material; parse, package and send the tooling and material information of the products that are completed in sequence and meet the successful tooling and material replacement to the production management module to request equipment production; the application is applicable to the production and installation of wiring harnesses, reduces work errors, and improves the replacement accuracy and work efficiency of products and materials;

[0004] However, the processing of automotive wire raw materials is simple, the conductor processing accuracy and performance improvement are limited, the detection methods are not comprehensive enough, and cost control lacks multi-dimensional optimization, resulting in low overall production efficiency and intelligence. Summary of the invention

[0005] The main purpose of the present invention is to provide a high-speed production process for low-voltage automotive wires, which can effectively solve the problems of limited conductor processing accuracy and performance improvement, insufficient detection means and low intelligence level.

[0006] To achieve the above object, the technical solution adopted by the present invention is:

[0007] A low-voltage automotive line high-speed production process comprises the following steps:

[0008] S1. Precision processing of raw materials: Select high-purity oxygen-free copper materials and apply anti-oxidation coatings. Remove the oily oxide layer through chemical cleaning, polishing, and ultrasonic vibration. Select nano-modified insulating materials and use vacuum drying equipment to control the moisture content. Removing moisture can prevent defects such as bubbles in the insulating layer.

[0009] S2, Intelligent Wire Drawing: Pre-treated copper materials enter the wire drawing machine equipped with an intelligent control system, using high-precision wire drawing dies, combined with computer control and algorithms, and laser surface treatment during wire drawing to further improve the surface microstructure of the copper wire and enhance conductivity;

[0010] S3, precision stranding: single wire is fed into the automatic stranding machine, the stranding pitch is adjusted by intelligent algorithm, electromagnetic induction heating annealing is carried out and monitored by optical fiber sensor, the conductor quality is guaranteed by the control system that can compensate for the tension change, and the stranded conductor is guaranteed to be tight, round, high in mechanical strength, and the DC resistance meets the standard;

[0011] S4. Optimize insulation extrusion: The insulation material is fed into the intelligent control extruder, the temperature and speed are set according to the material, the insulation layer is controlled by the prediction model and multi-layer flow channel mold, and ultraviolet pretreatment is performed before extrusion to enhance the bonding force between the insulation material and the conductor;

[0012] S5. All-round online inspection: After insulation extrusion, the wires are sequentially subjected to high-speed visual inspection, 3D image reconstruction technology, intelligent image recognition algorithm, high-frequency and high-voltage inspection, pulse voltage test and laser measurement. Related technologies are then used to accurately inspect and adjust and analyze data in real time, which is then uploaded to the cloud for analysis to ensure that product dimensions meet standards and improve production process stability through real-time adjustments.

[0013] S6. High-speed and accurate printing and labeling: Use a high-speed inkjet printer, with micro-piezoelectric nozzles and add fluorescent anti-counterfeiting ingredients to ensure the printing effect;

[0014] S7, intelligent adaptive winding: The wire enters the high-speed winding machine with intelligent tension adaptive adjustment system, and adopts shaftless winding technology for winding;

[0015] S8. Environmentally friendly and efficient packaging: The wire reels are packaged with biodegradable plastic film and high-strength cardboard, and information is marked with laser engraving technology.

[0016] Preferably, the thickness of the special anti-oxidation coating included in the S1 step is 5 to 10 μm, the nano-modified insulating material is nano-silicon dioxide, the particle size of the nano-modified insulating material is 20 to 50 nm, the frequency of the ultrasonic oscillation also included in the S1 step is between 20 and 50 kHz, and the vacuum degree of the vacuum drying equipment is 0.05 to 0.1 MPa.

[0017] Preferably, the intelligent control system wire drawing machine in step S2 includes a hardness sensor, a stress sensor and a temperature sensor, whose measurement accuracy reaches ±0.5HB, ±0.5MPa and ±1°C respectively, the aperture tolerance of the high-precision wire drawing die is accurately controlled at ±0.0005mm, the material is cemented carbide, and its hardness reaches HRA88~HRA92, and the laser power density of the laser surface treatment is 10^5~10^6W / cm 2 , the laser scanning speed is 5~10mm / s.

[0018] Preferably, the optimal twisting pitch calculated by the intelligent algorithm included in step S3 is in the range of 10 to 50 mm, the frequency of the electromagnetic induction heating is adjustable in the range of 10 to 50 kHz, and the power density is 10^4 to 10^5 W / m 2 .

[0019] Preferably, the intelligent control extruder included in step S4 has a temperature control accuracy of ±1°C, a pressure control accuracy of ±0.05MPa, a screw speed control accuracy of ±1rpm, and a traction speed control accuracy of ±0.5m / min. The inner channel diameter of the multi-layer flow channel mold is 5-10mm, the outer channel diameter is 10-15mm, and the irradiation intensity of the ultraviolet pretreatment is 10-20mW / cm 2 , the irradiation time is 5 to 10 seconds.

[0020] Preferably, the high-speed visual inspection system included in step S5 is equipped with a high-definition camera with a pixel of 6 million to 8 million, a frame rate of 120 to 150 fps / s, and a field of view of 6 to 8 mm. 2 The detection speed is 1200-1800m / min, the high-frequency and high-voltage signal frequency generated by the high-frequency and high-voltage detection equipment is 1-10kHz, the voltage is 1-10kV, the measurement frequency of the laser measurement is 100-200Hz, the data storage capacity of the cloud analysis server is 12-15TB, and the data transmission rate is 120-150Mbps.

[0021] Preferably, the printing speed of the high-speed inkjet printer included in the step S6 is 1000-2000 m / min, the jetting frequency of the nozzle is 5-10 kHz, and the content of the fluorescent anti-counterfeiting component added to the printing ink is 0.5%-2%.

[0022] Preferably, the tension measurement accuracy of the intelligent tension adaptive adjustment system included in the S7 step is ±0.5N, the tension is maintained between 10 and 50N, the winding accuracy of the shaftless winding technology is ±0.5mm, the thickness of the degradable plastic film included in the S8 step is 0.05 to 0.15mm, and the thickness of the high-strength cardboard is 3 to 5mm.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1. Product quality is comprehensively improved. In terms of raw materials, high-purity oxygen-free copper is carefully processed, coated with an anti-oxidation coating and strictly cleaned, and nano-modified insulating materials are used with precise moisture control to lay the foundation for high-quality products. When processing conductors, advanced technology is used for intelligent wire drawing and precision stranding to accurately control conductor size and performance. Intelligent operation and optimized processing of the insulation extrusion link ensure the reliability of the insulation layer. Finally, after all-round testing, it is ensured that the product is flawless and the overall excellent performance meets the high standards of automotive lines.

[0025] 2. Production efficiency has been significantly enhanced, the overall process has been optimized, all links have been closely connected, high-speed equipment has been widely used, production has been greatly accelerated, and the intelligent system has been used for full control, from equipment parameter optimization to intelligent process adjustment, and then to big data analysis to achieve precise and intelligent production. The production efficiency is significantly higher than that of traditional processes, and it can respond to the market flexibly, which has greatly enhanced the competitiveness of the enterprise.

[0026] 3. Cost and environmental benefits are achieved at the same time. The production efficiency is improved to dilute the cost, the defective rate is reduced to reduce waste, the packaging is optimized to reduce costs, and the overall cost is significantly reduced. At the same time, degradable packaging materials and production energy-saving measures can reduce environmental pollution, achieve both economic and environmental benefits, help enterprises to achieve sustainable development, and adapt to the trend of the environmental protection market. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 The overall process of the present invention Figure 1 ;

[0028] Figure 2 The process of the present invention Figure 2 ;

[0029] Figure 3 The process of the present invention Figure 3 ;

[0030] Figure 4 The process of the present invention Figure 4 ;

[0031] Figure 5 The process of the present invention Figure 5 ;

[0032] Figure 6 The process of the present invention Figure 6 ;

[0033] Figure 7 The process of the present invention Figure 7 ;

[0034] Figure 8 The process of the present invention Figure 8 . DETAILED DESCRIPTION

[0035] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0036] like Figure 1 As shown, a low-voltage automotive line high-speed production process includes the following steps:

[0037] S1. Precision processing of raw materials: Select high-purity oxygen-free copper materials and apply anti-oxidation coatings. Remove the oily oxide layer through chemical cleaning, polishing, and ultrasonic vibration. Select nano-modified insulating materials and use vacuum drying equipment to control the moisture content. Removing moisture can prevent defects such as bubbles in the insulating layer.

[0038] S2, Intelligent Wire Drawing: Pre-treated copper materials enter the wire drawing machine equipped with an intelligent control system, using high-precision wire drawing dies, combined with computer control and algorithms, and laser surface treatment during wire drawing to further improve the surface microstructure of the copper wire and enhance conductivity;

[0039] S3, precision stranding: single wire is fed into the automatic stranding machine, the stranding pitch is adjusted by intelligent algorithm, electromagnetic induction heating annealing is carried out and monitored by optical fiber sensor, the conductor quality is guaranteed by the control system that can compensate for the tension change, and the stranded conductor is guaranteed to be tight, round, high in mechanical strength, and the DC resistance meets the standard;

[0040] S4. Optimize insulation extrusion: The insulation material is fed into the intelligent control extruder, the temperature and speed are set according to the material, the insulation layer is controlled by the prediction model and multi-layer flow channel mold, and ultraviolet pretreatment is performed before extrusion to enhance the bonding force between the insulation material and the conductor;

[0041] S5. All-round online inspection: After insulation extrusion, the wires are sequentially subjected to high-speed visual inspection, 3D image reconstruction technology, intelligent image recognition algorithm, high-frequency and high-voltage inspection, pulse voltage test and laser measurement. Related technologies are then used to accurately inspect and adjust and analyze data in real time, which is then uploaded to the cloud for analysis to ensure that product dimensions meet standards and improve production process stability through real-time adjustments.

[0042] S6. High-speed and accurate printing and labeling: Use a high-speed inkjet printer, with micro-piezoelectric nozzles and add fluorescent anti-counterfeiting ingredients to ensure the printing effect;

[0043] S7, intelligent adaptive winding: The wire enters the high-speed winding machine with intelligent tension adaptive adjustment system, and adopts shaftless winding technology for winding;

[0044] S8. Environmentally friendly and efficient packaging: The wire reels are packaged with biodegradable plastic film and high-strength cardboard, and information is marked with laser engraving technology.

[0045] See also Figures 1-2 The thickness of the special anti-oxidation coating included in step S1 is 5 to 10 μm, the nano-modified insulating material is nano-silicon dioxide, the particle size of the nano-modified insulating material is 20 to 50 nm, the frequency of the ultrasonic oscillation included in step S1 is between 20 and 50 kHz, and the vacuum degree of the vacuum drying equipment is 0.05 to 0.1 MPa.

[0046] Specifically, the special anti-oxidation coating on the surface of the anti-oxidation coated copper material can prevent oxygen from further corroding the copper material during wire drawing, thereby preventing the performance of the copper wire from deteriorating due to oxidation. The coating will fall off naturally during subsequent processing without leaving any residue, thus ensuring the purity of the product.

[0047] Furthermore, cleaning utilizes specific chemical reagents to react chemically with the oil stains on the surface of the copper material to dissolve and remove the oil stains, while polishing uses mechanical force to remove the oxide layer, impurities, etc. on the surface of the copper material, making the surface of the copper material smoother and flatter, which is conducive to subsequent processing.

[0048] Ultrasonic vibration creates a cavitation effect through high-frequency vibration, which removes oil, impurities, etc. from tiny gaps and depressions on the surface of the copper material, further improving the cleaning effect.

[0049] Furthermore, nano-modification can change the molecular structure and properties of insulating materials by adding nanoparticles to them, making their molecular chains more regular and orderly during the extrusion process, with better fluidity and the ability to more evenly coat the conductor, thereby significantly improving the insulation performance and reducing the probability of defects in the insulation layer.

[0050] Furthermore, the vacuum drying equipment uses a vacuum environment to lower the boiling point of water, allowing the moisture in the insulating material to evaporate quickly at a lower temperature, accurately controlling the moisture content below 0.05%, and avoiding problems such as reduced insulation performance due to residual moisture and the generation of bubbles during extrusion.

[0051] The working process is as follows: after inspecting the high-purity oxygen-free copper material, an anti-oxidation coating is applied, the material is placed in a chemical cleaning tank and degreased with a special cleaning agent, then the material is polished until the roughness meets the standard, and then the material is placed in an ultrasonic vibration device for cleaning, and then the nano-modified insulating material is placed in a vacuum drying device to reduce the moisture content to less than 0.05%.

[0052] See also Figure 3The intelligent control system wire drawing machine in step S2 includes a hardness sensor, a stress sensor and a temperature sensor, whose measurement accuracy reaches ±0.5HB, ±0.5MPa and ±1℃ respectively. The aperture tolerance of the high-precision wire drawing die is precisely controlled at ±0.0005mm. The material is cemented carbide, and its hardness reaches HRA88~HRA92. The laser power density of the laser surface treatment is 10^5~10^6W / cm 2 , the laser scanning speed is 5~10mm / s.

[0053] Specifically, the intelligent control system wire drawing machine system has a variety of built-in sensors to monitor copper material hardness, tensile stress, temperature and other parameters in real time. According to preset algorithms and models, it quickly adjusts the motor speed of the wire drawing machine, the working status of the wire drawing die, etc., so that the wire drawing speed is always maintained in the efficient range of 500 to 1000 m / min.

[0054] Furthermore, the mold material has good wear resistance and self-compensating wear function.

[0055] The computer control system is the core control unit, which receives various sensor data from the intelligent control system wire drawing machine, uses complex control algorithms to process data, calculates in real time and issues instructions to adjust the working parameters of various components of the wire drawing machine, ensuring that the entire wire drawing process runs accurately according to the predetermined process parameters.

[0056] The high-energy laser beam micro-melts and rapidly cools the surface of the copper wire, forming a dense microstructure on the surface of the copper wire, refining the grains, and eliminating surface defects, thereby significantly improving the conductivity of the copper wire.

[0057] The working process is as follows: the processed copper material is fed into the hopper of the wire drawing machine of the intelligent control system, the sensor measures the characteristics of the copper material, the system adjusts the wire drawing machine data based on the data, the copper material enters the high-precision wire drawing die, and the computer system controls the wire drawing. During wire drawing, the laser treatment of the surface can enhance its conductivity.

[0058] See also Figure 4 The optimal twist pitch calculated by the intelligent algorithm included in step S3 is between 10 and 50 mm, the frequency of electromagnetic induction heating is adjustable within the range of 10 to 50 kHz, and the power density is 10^4 to 10^5 W / m 2 .

[0059] Specifically, the automatic twisting machine has a high-precision mechanical transmission structure and an automatic control system, which can accurately control the twisting process of the single wires to ensure the accuracy and stability of the twisting pitch.

[0060] The intelligent algorithm calculates the optimal twisting pitch based on the specific specifications and performance requirements of the wires and real-time data feedback during the production process. It also dynamically adjusts parameters such as tension and speed during the twisting process according to the actual state of the single wire to ensure that the conductor twisting structure is tight and uniform and meets the electrical performance and mechanical strength requirements.

[0061] Furthermore, electromagnetic induction heating uses the principle of electromagnetic induction to generate a high-frequency alternating magnetic field around the single wire, generate an induced current inside the single wire, and use the thermal effect of the current to achieve rapid heating annealing, which can accurately control the annealing temperature and time of the single wire.

[0062] Furthermore, the optical fiber sensor monitors the temperature changes of the single wire during the annealing process in real time. It has high measurement accuracy and fast response speed, and can feed back temperature data to the control system in a timely manner to ensure that the annealing temperature always remains within the process requirements.

[0063] The tension control system can not only apply uniform tension to each single yarn with an error of no more than ±3%, but also monitor the changes in ambient humidity in real time through the built-in humidity sensor, automatically adjust the tension output, and compensate for the fluctuations in single yarn tension caused by changes in ambient humidity.

[0064] The working process is as follows: the single wire enters the high-speed automatic twisting machine, the intelligent algorithm determines the twisting pitch according to the wire specifications, electromagnetic induction heats it during twisting, the optical fiber sensor monitors the temperature and provides feedback and makes fine adjustments, and the tension control system adjusts the initial tension and automatically adjusts it according to the humidity.

[0065] See also Figure 5 The intelligent control extruder included in step S4 has a temperature control accuracy of ±1°C, a pressure control accuracy of ±0.05MPa, a screw speed control accuracy of ±1rpm, and a traction speed control accuracy of ±0.5m / min. The inner channel diameter of the multi-layer channel mold is 5-10mm, the outer channel diameter is 10-15mm, and the irradiation intensity of the ultraviolet pretreatment is 10-20mW / cm 2 , the irradiation time is 5 to 10 seconds.

[0066] Specifically, the intelligent control extruder can monitor and accurately control the temperature of each section of the extruder in real time, 150-180°C for PVC insulating material and 180-220°C for XLPE insulating material, as well as the screw speed and traction speed, to ensure that the insulating material is in the best rheological state during the extrusion process, so that the insulating layer is evenly and densely coated on the conductor surface.

[0067] Furthermore, the intelligent prediction model can predict the changes in the thickness of the insulation layer based on the current working parameters of the extruder, the characteristics of the insulation material, the ambient temperature and other factors, adjust the extrusion parameters in advance, and strictly control the thickness error of the insulation layer within ±0.02mm, effectively reducing insulation performance problems caused by uneven thickness.

[0068] Furthermore, the multi-layer runner mold adopts a unique multi-layer co-extrusion runner design. Different layers of runners can respectively transport insulating materials or additives with different performances. During the extrusion process, the insulating layer forms a multi-layer structure. The layers are closely combined and work synergistically to enhance the overall reliability of the wire.

[0069] Furthermore, ultraviolet rays are used to pre-treat the insulating material, thereby significantly enhancing the bonding force between the insulating material and the conductor, and preventing the insulating layer from peeling off, cracking, and other problems due to weak bonding during use.

[0070] The working process is as follows: the insulating material enters the hopper of the intelligent control extruder, the system sets the temperature, pressure and flow rate according to the material, the prediction model predicts the thickness change trend of the insulation layer in real time and makes timely adjustments, then the insulating material is pre-treated with ultraviolet rays and finally extruded from the multi-layer runner mold.

[0071] See also Figure 6 The high-speed visual inspection system included in step S5 is equipped with a high-definition camera with 6 million to 8 million pixels, a frame rate of 120 to 150 fps / s, and a field of view of 6 to 8 mm. 2 The detection speed is 1200-1800m / min, the high-frequency and high-voltage signal frequency generated by the high-frequency and high-voltage detection equipment is 1-10kHz, the voltage is 1-10kV, the measurement frequency of the laser measurement is 100-200Hz, the data storage capacity of the cloud analysis server is 12-15TB, and the data transmission rate is 120-150Mbps.

[0072] Specifically, the high-speed visual inspection system is equipped with a high-resolution HD camera and a high-speed image processing unit, which can quickly capture image information on the surface of the insulation layer during the high-speed production process of wires.

[0073] Furthermore, the high-definition camera has the characteristics of high pixel, high frame rate and low noise, which can capture the tiny details and defect characteristics on the surface of the insulation layer and obtain rich image data, providing key information support for accurately judging whether there are defects such as bubbles, impurities, scratches, etc. on the surface of the insulation layer.

[0074] Furthermore, the 3D image reconstruction algorithm can process the two-dimensional images collected by the high-definition camera to construct a three-dimensional model of the surface of the insulation layer, presenting the surface morphology of the insulation layer more intuitively and comprehensively.

[0075] Furthermore, the intelligent image recognition algorithm can automatically learn and identify the characteristic patterns of surface defects of the insulation layer, and the recognition accuracy of defects such as bubbles, impurities, scratches, etc. can reach more than 98%, effectively avoiding missed detections and false detections, and timely and accurately screening out products with unqualified appearance.

[0076] The high-frequency and high-voltage detection equipment can generate high-frequency and high-voltage signals to perform insulation resistance tests (required to be no less than 1000MΩ·km) and withstand voltage tests on wires to ensure that the wires will not have electrical safety problems such as insulation breakdown under normal use conditions.

[0077] Furthermore, the pulse voltage testing technology can simulate the instantaneous high-voltage pulse conditions that wires may encounter during actual use, more accurately detect the insulation layer's ability to withstand pulse voltage, and further improve the accuracy and reliability of the insulation layer's withstand voltage performance testing.

[0078] Furthermore, the laser measuring device uses the principle of laser interference to measure the outer diameter of the wire and the thickness of the insulation layer in real time with an ultra-high precision of 0.005mm. It can quickly and accurately obtain the wire size data to ensure that the wire size meets the standard requirements.

[0079] Upload various data obtained during the detection process to the cloud server in real time, use big data analysis technology to deeply mine and analyze massive production data, establish a product quality prediction model, and provide data support and decision-making basis for improving product quality.

[0080] The working process is as follows: the wire enters the high-speed visual inspection area, the high-definition camera transmits the image to the processing unit, and the deep learning algorithm analyzes it after 3D modeling. If there is a defect, an alarm will be recorded. Then the wire enters the high-frequency and high-voltage detection equipment, first measuring the insulation resistance, then using pulse voltage to measure the withstand voltage, and at the same time using laser to measure the wire size. The detection data is uploaded to the cloud in real time for analysis.

[0081] See also Figure 7 The printing speed of the high-speed inkjet printer included in step S6 is 1000-2000 m / min, the jet frequency of the nozzle is 5-10 kHz, and the content of the fluorescent anti-counterfeiting component added to the printing ink is 0.5%-2%.

[0082] Specifically, in inkjet printing technology, the nozzle is able to quickly spray tiny ink droplets, perfectly matching the speed of the production line.

[0083] The micro-piezoelectric nozzle adjusts the ejection volume and ejection speed of ink droplets by precisely controlling the deformation of the piezoelectric element. It can achieve high-precision ejection with a minimum droplet diameter of 10μm, ensuring the clarity of the printed content and the sharpness of the edges, so that the printing quality meets high standards.

[0084] Furthermore, special fluorescent anti-counterfeiting ingredients are added to the printing ink. These ingredients are invisible under normal light, but emit bright fluorescence under ultraviolet light of a specific wavelength, making it easier to quickly and accurately identify authenticity during product quality tracing.

[0085] The working process is as follows: the wires enter the high-speed inkjet printer, and the micro-piezoelectric nozzle sprays ink according to the instructions. The ink contains fluorescent anti-counterfeiting ingredients, and the characters are fixed naturally or at low temperature after printing.

[0086] See also Figure 8 , the S7 step includes biodegradable plastic film, high-strength cardboard and laser engraving technology.

[0087] Specifically, the tension measurement accuracy of the intelligent tension adaptive adjustment system included in step S7 is ±0.5N, the tension is maintained between 10 and 50N, the winding accuracy of the shaftless winding technology is ±0.5mm, the thickness of the degradable plastic film included in step S8 is 0.05 to 0.15mm, and the thickness of the high-strength cardboard is 3 to 5mm.

[0088] The internal packaging uses high-strength corrugated cardboard, and its unique structural design gives it good cushioning performance, which can withstand a certain amount of external force impact and prevent the wire reel from being damaged during handling and transportation.

[0089] Furthermore, by using a laser beam to engrave on packaging materials, important information such as product name, specifications, quantity, production date, quality certification mark, etc. can be clearly and permanently marked, thereby improving the efficiency of logistics and sales.

[0090] The working process is as follows: the wire enters the intelligent adaptive winder, the tension sensor measures the tension and adjusts it according to the result, it is rolled up in an axisless manner and then transferred for packaging. When packaging, the wire reel is wrapped with a degradable film and then placed in a cardboard box for fixing, and finally the information is engraved with a laser.

[0091] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A low-voltage automotive line high-speed production process, comprising the following steps: S1. Precision processing of raw materials: Select high-purity oxygen-free copper materials and apply anti-oxidation coatings. Remove the oily oxide layer through chemical cleaning, polishing, and ultrasonic vibration. Select nano-modified insulating materials and use vacuum drying equipment to control the moisture content. Removing moisture can prevent defects such as bubbles in the insulating layer. S2, Intelligent Wire Drawing: Pre-treated copper materials enter the wire drawing machine equipped with an intelligent control system, using high-precision wire drawing dies, combined with computer control and algorithms, and laser surface treatment during wire drawing to further improve the surface microstructure of the copper wire and enhance conductivity; S3, precision stranding: single wire is fed into the automatic stranding machine, the stranding pitch is adjusted by intelligent algorithm, electromagnetic induction heating annealing is carried out and monitored by optical fiber sensor, the conductor quality is guaranteed by the control system that can compensate for the tension change, and the stranded conductor is guaranteed to be tight, round, high in mechanical strength, and the DC resistance meets the standard; S4. Optimize insulation extrusion: The insulation material is fed into the intelligent control extruder, the temperature and speed are set according to the material, the insulation layer is controlled by the prediction model and multi-layer flow channel mold, and ultraviolet pretreatment is performed before extrusion to enhance the bonding force between the insulation material and the conductor; S5. All-round online inspection: After insulation extrusion, the wires are sequentially subjected to high-speed visual inspection, 3D image reconstruction technology, intelligent image recognition algorithm, high-frequency and high-voltage inspection, pulse voltage test and laser measurement. Related technologies are then used to accurately inspect and adjust and analyze data in real time, which is then uploaded to the cloud for analysis to ensure that product dimensions meet standards and improve production process stability through real-time adjustments. S6. High-speed and accurate printing and labeling: Use a high-speed inkjet printer, with micro-piezoelectric nozzles and add fluorescent anti-counterfeiting ingredients to ensure the printing effect; S7, intelligent adaptive winding: The wire enters the high-speed winding machine with intelligent tension adaptive adjustment system, and adopts shaftless winding technology for winding; S8. Environmentally friendly and efficient packaging: The wire reels are packaged with biodegradable plastic film and high-strength cardboard, and information is marked with laser engraving technology.

2. A low-voltage automotive wire high-speed production process according to claim 1, characterized in that: The thickness of the special anti-oxidation coating included in the S1 step is 5 to 10 μm, the nano-modified insulating material is nano-silicon dioxide, the particle size of the nano-modified insulating material is 20 to 50 nm, the frequency of the ultrasonic oscillation also included in the S1 step is between 20 and 50 kHz, and the vacuum degree of the vacuum drying equipment is 0.05 to 0.1 MPa.

3. A low-voltage automotive wire high-speed production process according to claim 1, characterized in that: The intelligent control system wire drawing machine in step S2 includes a hardness sensor, a stress sensor and a temperature sensor, whose measurement accuracy reaches ±0.5HB, ±0.5MPa and ±1°C respectively. The aperture tolerance of the high-precision wire drawing die is precisely controlled at ±0.0005mm. The material is cemented carbide with a hardness of HRA88-HRA92. The laser power density of the laser surface treatment is 10^5-10^6W / cm 2 , the laser scanning speed is 5~10mm / s.

4. A low-voltage automotive wire high-speed production process according to claim 1, characterized in that: The optimal twisting pitch calculated by the intelligent algorithm included in step S3 is between 10 and 50 mm, the frequency of the electromagnetic induction heating is adjustable within the range of 10 to 50 kHz, and the power density is 10^4 to 10^5 W / m 2 .

5. The high-speed production process for low-voltage automotive wires according to claim 1, characterized in that: The intelligent control extruder included in step S4 has a temperature control accuracy of ±1°C, a pressure control accuracy of ±0.05MPa, a screw speed control accuracy of ±1rpm, and a traction speed control accuracy of ±0.5m / min. The inner channel diameter of the multi-layer channel mold is 5-10mm, the outer channel diameter is 10-15mm, and the irradiation intensity of the ultraviolet pretreatment is 10-20mW / cm 2 , the irradiation time is 5 to 10 seconds.

6. A low-voltage automotive wire high-speed production process according to claim 1, characterized in that: The high-speed visual inspection system included in step S5 is equipped with a high-definition camera with a pixel of 6 million to 8 million, a frame rate of 120 to 150 fps / s, and a field of view of 6 to 8 mm. 2 The detection speed is 1200-1800m / min, the high-frequency and high-voltage signal frequency generated by the high-frequency and high-voltage detection equipment is 1-10kHz, the voltage is 1-10kV, the measurement frequency of the laser measurement is 100-200Hz, the data storage capacity of the cloud analysis server is 12-15TB, and the data transmission rate is 120-150Mbps.

7. The high-speed production process for low-voltage automotive wires according to claim 1, characterized in that: The printing speed of the high-speed inkjet printer included in the step S6 is 1000-2000 m / min, the jet frequency of the nozzle is 5-10 kHz, and the content of the fluorescent anti-counterfeiting component added to the printing ink is 0.5%-2%.

8. The high-speed production process for low-voltage automotive wires according to claim 1, characterized in that: The tension measurement accuracy of the intelligent tension adaptive adjustment system included in step S7 is ±0.5N, and the tension is maintained between 10 and 50N. The winding accuracy of the shaftless winding technology is ±0.5mm. The thickness of the degradable plastic film included in step S8 is 0.05 to 0.15mm, and the thickness of the high-strength paperboard is 3 to 5mm.

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