Low-voltage type stranded conductor and method for manufacturing the same

Abstract

The application provides a low-voltage type wire-stranded conductor manufacturing method and system, and belongs to the technical field of electric wires and cables. The manufacturing method comprises the following steps: providing a central core and a plurality of peripheral cores, and performing preliminary stranding on the cores by using a stranding machine to form a preliminary-stranded formed conductor; subsequently, the conductor is drawn and formed by one or more forming units in stages to achieve the expected conductor size. The forming unit comprises a heating module and a drawing die, wherein the heating module adopts electromagnetic induction heating to quickly heat the drawing die, so that the peripheral cores are softened when passing through the drawing die, thereby improving the drawing and forming efficiency and the conductor quality. Meanwhile, a manufacturing system is provided, which comprises a wire feeding unit, a stranding unit, a forming unit, a winding unit and a control unit.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of electric wire and cable, and particularly relates to a low-voltage special-shaped conductor and a production method thereof. BACKGROUND

[0002] With the rapid development of power transmission and communication technology, low-voltage cables, as an important energy transmission carrier, are widely used in industries, buildings, transportation and other fields. As the core component of the cable, the structure and performance of the conductor directly affect the transmission efficiency and service life of the cable. The traditional round stranded conductor has low space utilization, uneven current distribution and low efficiency in the forming process in some specific application scenarios. To solve these technical bottlenecks, special-shaped stranded conductors have gradually attracted attention. Special-shaped conductors can effectively improve the filling factor of the conductor, reduce voids, and improve the electrical conductivity and mechanical strength of the conductor by optimizing the cross-sectional shape of the conductor. However, in the production process of special-shaped conductors, the twisting process of multiple wires is complex, the material is easily damaged during drawing, and the temperature control precision is not high, which makes it difficult to guarantee the forming quality. Therefore, it is of great practical significance and broad market prospect to develop an efficient and controllable low-voltage wire stranded conductor manufacturing method and system.

[0003] After consulting relevant public technologies, the technical solution with publication number CN110743930A proposes a square wire conductor forming method, which uses a pressure roller and a matching mold to produce a square cable conductor; the technical solution with publication number WO2022120905A1 proposes a manufacturing method of a cable including multiple small-diameter special-shaped conductors, which uses nanoscale semiconductive glue to make the multiple conductors tightly fit to form a tight whole; and the technical solution with publication number KR1020140004030A proposes a cable with a special-shaped filler to realize effective interaction between the twisted pair and the shielding layer.

[0004] The above technical solutions all propose optimization technical solutions to improve the performance of cables using special-shaped conductors, but further improvement of related technologies is still needed for application conditions with higher requirements.

[0005] The foregoing discussion of the background art is intended only to facilitate an understanding of the present application. It is not admitted that any of the materials referred to is part of the common general knowledge of those working in the field. SUMMARY

[0006] The application aims to provide a low-voltage type wire-stranded conductor manufacturing method and system, which comprises the following steps: providing a central wire core and a plurality of peripheral wire cores, and using a stranding machine to preliminarily strand them to form a preliminary-stranded profile conductor; then, the conductor is drawn and formed step by step through one or more forming units to reach the expected conductor size. The forming unit comprises a heating module and a drawing die, wherein the heating module adopts electromagnetic induction heating to quickly heat the drawing die, so that the peripheral wire cores are softened when passing through the drawing die, thereby improving the drawing and forming efficiency and the conductor quality. Meanwhile, a manufacturing system is provided, which comprises a wire feeding unit, a stranding unit, a forming unit, a winding unit and a control unit.

[0007] The application adopts the following technical scheme: a low-voltage type wire-stranded conductor manufacturing method, which is applied to prepare a stranded profile conductor with a special cross-sectional shape; the manufacturing method comprises the following steps:

[0008] S100: providing a central wire core and a plurality of profile wire filaments;

[0009] S200: using a stranding machine to strand the central wire core and the profile wire filaments to prepare a preliminary-stranded profile conductor, wherein the stranding tightness of the profile wire filaments of the preliminary-stranded profile conductor is in a general tight state;

[0010] S300: drawing the preliminary-stranded profile conductor through one or more forming units to form the preliminary-stranded profile conductor to reach the expected conductor size;

[0011] The forming unit comprises a heating module and a drawing die; the heating module adopts electromagnetic induction to quickly heat the drawing die, so that the profile wire filaments are softened when passing through the drawing die, thereby improving the drawing and forming efficiency.

[0012] Preferably, in step S300, the one or more forming units draw and form the preliminary-stranded profile conductor step by step to process the preliminary-stranded profile conductor to the finished product conductor specification.

[0013] Preferably, in step S200, a tension control unit is used to keep the uniform tension of the profile wire filaments during the stranding process.

[0014] Preferably, in step S300, the heating temperature of the drawing die is monitored to control the heating efficiency of the heating module.

[0015] Meanwhile, a low-voltage type wire-stranded conductor manufacturing system is provided, which is applied to the manufacturing method; the manufacturing system comprises a wire feeding unit, a stranding unit, a forming unit, a winding unit and a control unit.

[0016] The wire feeding unit is used for storing and feeding the single type wire monofilament;

[0017] The twisting unit is used for twisting and forming the multiple type wire monofilaments on the periphery of the core wire;

[0018] The forming unit is used for heating and further twisting the preliminary twisted conductor to achieve the expected conductor specification;

[0019] The winding unit is used for winding the completed twisted conductor into a disc;

[0020] The control unit is used for coordinating the above working units to work cooperatively.

[0021] Preferably, the forming unit comprises a heating module and a drawing die; the heating module adopts electromagnetic induction to quickly heat the drawing die, so that the type wire monofilament is softened when passing through the drawing die, thereby improving the drawing forming efficiency.

[0022] Preferably, the heating module comprises a rotating body and a driving component; the working surface of the rotating body is provided with multiple magnets; the driving component is used for driving the rotating motion of the rotating body, so that the multiple magnets rotate around one of the normal lines of the working surface as the rotation axis to generate an induced current in the drawing die and finally heat the drawing die.

[0023] The present application has the following beneficial effects:

[0024] 1. The electromagnetic induction heating module is used to quickly heat the drawing die, so that the peripheral wire core maintains a softened state when passing through the drawing die, effectively reducing the friction resistance and deformation resistance of the wire in the drawing process, thereby improving the efficiency and stability of the drawing forming. At the same time, the heating temperature is monitored and dynamically adjusted in real time through the temperature control program, so as to ensure the accurate control of the heating temperature and avoid the performance degradation or drawing forming defects caused by overheating or insufficient temperature.

[0025] 2. In the drawing forming process, the step-by-step drawing forming process is adopted, the preliminary twisted conductor is drawn and accurately formed step by step through multiple forming units, so as to ensure the uniform transition of the size control of each drawing die and avoid the structure cracking or stress concentration caused by sudden material deformation. In addition, the multi-stage drawing process can effectively reduce the surface defects of the conductor and significantly improve the cross-sectional size accuracy and product quality of the conductor.

[0026] 3. The production system of the present application can be used for producing type wire twisted conductors with various specifications and sizes, thereby improving the production efficiency and reducing the overall production cost. BRIEF DESCRIPTION OF DRAWINGS

[0027] The present application can be further understood from the following description in conjunction with the accompanying drawings. In the drawings, the components are not necessarily drawn to scale, emphasis instead being placed upon illustrating the principles of the embodiments. In different views, like reference numerals designate corresponding parts throughout the figures.

[0028] BRIEF DESCRIPTION OF DRAWINGS 10 - core; 12 - profile strand; 100 - manufacturing system; 110 - wire feeding unit; 120 - stranding unit; 122 - tension control unit; 150 - forming unit; 152 - heating module; 154 - drawing die; 156 - die cavity; 161 - rotating body; 163 - driving member; 165 - temperature sensor; 169 - magnet; 171 - working surface; 500 - computer system; 502 - bus; 504 - processor; 506 - main memory; 508 - read only memory; 510 - storage device; 512 - display; 514 - input device; 516 - cursor control device; 518 - network device;

[0029] Figure 1 is a schematic view of the manufacturing system described in the embodiments of the present application;

[0030] Figure 2 is a schematic view of the profile strand stranding conductor described in the embodiments of the present application;

[0031] Figure 3 is a schematic view of the forming unit described in the embodiments of the present application;

[0032] Figure 4 is a schematic view of the heating module described in the embodiments of the present application;

[0033] Figure 5 is a schematic view of the computer system employed by the control unit in the embodiments of the present application. DETAILED DESCRIPTION

[0034] In order to make the technical solutions and advantages of the present application more clear, the present application is further described in detail below in conjunction with the embodiments thereof; it should be understood that the specific embodiments described herein are only used to explain the present application, and are not used to limit the present application. For those skilled in the art, other systems, methods and / or features of the embodiments will become apparent after reading the following detailed description. All such additional systems, methods, features and advantages are intended to be included within the scope of the present application. They are included in the scope of the present application, and are protected by the appended claims. Additional features of the disclosed embodiments are described in the following detailed description, and will be apparent to one of ordinary skill in the art upon reading the following detailed description.

[0035] The same or similar reference numerals in the drawings of the embodiments of the present application correspond to the same or similar components; in the description of the present application, it is understood that if the orientations or positional relationships indicated by the terms "upper", "lower", "left", "right" and the like are based on the orientations or positional relationships shown in the drawings, they are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or components referred to must have a particular orientation. The orientation and operation are constructed in a particular orientation, so the positional relationship described in the drawings is only used for exemplary illustration, and cannot be understood as a limitation on the present patent. For those skilled in the art, the specific meanings of the above terms can be understood according to the specific circumstances.

[0036] Embodiment one: exemplarily, a low-voltage type wire stranded conductor manufacturing method is proposed, which is applied to prepare a stranded special-shaped conductor with a special cross-sectional shape; the manufacturing method comprises the following steps:

[0037] S100: providing a central core and a plurality of type wire filaments;

[0038] S200: using a stranding machine to strand the central core and the type wire filaments to prepare a primary stranded and shaped conductor, at this time the stranding tightness of the type wire filaments of the primary stranded and shaped conductor is in a general tight state;

[0039] S300: pulling the primary stranded and shaped conductor through one or more shaping units to shape the primary stranded and shaped conductor to the expected conductor size;

[0040] Wherein, the shaping unit comprises a heating module and a drawing die; the heating module adopts electromagnetic induction to quickly heat the drawing die, so that the type wire filaments are softened when passing through the drawing die, thereby improving the drawing and shaping efficiency.

[0041] Preferably, in step S300, the one or more shaping units are in a step-by-step drawing and shaping manner, so that the primary stranded and shaped conductor is processed to the finished product conductor specification step by step.

[0042] Preferably, in step S200, a tension control unit is included to maintain uniform tension of the type wire filaments during the stranding process.

[0043] Preferably, in step S300, the heating temperature of the drawing die is monitored to control the heating efficiency of the heating module.

[0044] Meanwhile, a low-voltage type wire stranded conductor manufacturing system is proposed, which is applied to the manufacturing method; the manufacturing system comprises a wire feeding unit, a stranding unit, a shaping unit, a winding unit and a control unit;

[0045] The wire feeding unit is used to store and transport a single filament of the profiled wire;

[0046] The stranding unit is used to strand multiple single wires around the core wire to form a shape.

[0047] The forming unit is used to heat the initially stranded conductor and further strand it to achieve the desired conductor specifications.

[0048] The winding unit is used to wind the stranded conductor into a coil;

[0049] The control unit is used to coordinate the collaborative work of the above working units.

[0050] Preferably, the forming unit includes a heating module and a drawing die; the heating module uses electromagnetic induction to rapidly heat the drawing die, so that the profile filament is softened when it passes through the drawing die, thereby improving the drawing forming efficiency.

[0051] Preferably, the heating module includes a rotating body and a driving component; the working surface of the rotating body is provided with a plurality of magnets; the driving component is used to drive the rotating body to rotate, so that the plurality of magnets rotate about one of the normals of the working surface as the axis of rotation, thereby generating an induced current in the drawing die and ultimately heating the drawing die.

[0052] For the sake of simplicity, see attached. Figure 2 Taking a type of wire conductor as an example, this paper illustrates an exemplary implementation of the manufacturing method and the manufacturing system used in this technical solution.

[0053] The conductor structure of the shaped conductor shown includes a core wire 10, which can be a circular wire or other required structure, such as a regular hexagon or a regular octagon. Multiple shaped wire monofilaments 12 are annularly twisted around the outer side of the core wire 10. The cross-sectional shape of the shaped wire monofilaments 12 can be trapezoidal or other required shapes, such as a fan shape, an approximate trapezoid, or other approximate polygons. (See attached diagram.) Figure 2 The conductor structure shown is merely an example for convenience of description and is not intended to be a limiting conductor structure of this technical solution.

[0054] Now return to the attached Figure 1 , attached Figure 1 In the illustrated manufacturing system, in an exemplary embodiment, the manufacturing system includes a wire feeding unit 110, a stranding unit 120, a forming unit 150, a winding unit, and a control unit (not shown in the figure). The control unit is communicatively connected to the other units in the manufacturing system 100 to coordinate their collaborative operation.

[0055] The wire feeding unit 110 is used to store and transport a single wire monofilament 12 of the aforementioned wire; the wire feeding unit 110 is equipped with a tension control device to ensure that the tension of the wire is uniform during the wire feeding process and to prevent the wire from getting tangled or broken.

[0056] The stranding unit 120 is used to strand multiple profiled monofilaments 12 around the core wire 10; the stranding unit 120 can be configured to be installed on a cage stranding machine, a tubular stranding machine, or a frame stranding machine, and can strand the profiled monofilaments 12 according to a set stranding pitch and angle. (The attached text is incomplete and requires further context.) Figure 1 The stranding unit 120 shown is only for a portion of a single filament 12 of the profile wire. Multiple stranding units 120 can be provided in the stranding machine to correspond to the stranding of each single filament 12 of the profile wire.

[0057] Preferably, the stranding unit 120 can work in conjunction with the tension control unit 122; the tension control unit 122 is communicatively connected to the control unit and is used to monitor and adjust the tension of each filament 12 in real time during the stranding process to prevent the filament 12 from becoming loose or overstretched, and to ensure that the stranding is tight and uniform.

[0058] Preferably, the manufacturing system 100 may further include a winding unit for winding the stranded conductor into a reel for subsequent processing or transportation.

[0059] As exemplarily shown in FIG. 3, the forming unit 150 includes a heating module 152 and a drawing die 154. The heating module 152 employs electromagnetic induction heating, which uses a rotating magnet to generate a periodically changing magnetic field relative to the conductive component, thereby generating an induced current and heating the conductive component.

[0060] For example, in conjunction with the appendix Figure 3 and attached Figure 4 As shown, the heating module 152 includes a rotating body 161 and a driving component 163; a plurality of magnets 169 are provided on the working surface 171 of the rotating body 161. On one side of the working surface 171, a plurality of magnets 169 are arranged with two or more concentric circles as their trajectories.

[0061] The driving component 163 drives the rotating body 161 to rotate about its center O. Preferably, the driving component 163 includes a drive motor and a related transmission device to provide rotational power to the rotating body 161. The drive motor and the rotating body 161 can be arranged non-coaxially, and a transmission device such as a chain or belt is used to connect the drive motor and the rotating body 161.

[0062] In one embodiment, as shown in the drawings, concentric circles C1 and C2 with radii R1 and R2 respectively are set with the center O of the rotating body 161 as the center. In each circle, a plurality of magnets 169 are arranged along a circular track. Exemplarily, the number and arrangement of the magnets 169 on each circle are only for illustration and not as a limitation of the present technical solution.

[0063] Preferably, the center of the rotating body 161 is provided with a through hole to allow the conductor to be twisted to pass through the through hole and continue to enter the cavity 156 of the drawing die 154 at the rear end.

[0064] Further, the magnet 169 is preferably cylindrical and at least partially embedded in the rotating body 161 to ensure that the magnet 169 is completely fixed on the rotating body 161.

[0065] Preferably, the magnet 169 can be a ferrite magnet, a samarium-cobalt magnet, a neodymium magnet, etc.

[0066] Preferably, all the magnets 169 on the rotating body 161 are arranged with the same polarity pointing, for example, all the magnets 169 are arranged as N-pole or S-pole at the end close to the drawing die 154.

[0067] In one embodiment, the magnets 169 on each concentric circular track (for example, the circles C1 and C2 in the present embodiment) can be cylindrical magnets of the same size. In some embodiments, the magnets 169 on the same circular track can have the same specifications, but different sizes of magnets 169 can be used on different circular tracks.

[0068] Preferably, the radius of the cylindrical magnet 169 can be 3mm to 12mm, or more preferably, 5mm to 10mm.

[0069] Preferably, the height of the cylindrical magnet 169 is between 1 to 4 times the radius, and more preferably, between 5mm to 30mm.

[0070] Further, as shown in the drawings, Figure 4 The centers of any two magnets 169 are set as p1 and p2, and the radii are r1 and r2, then the distance D between the two adjacent magnets 169 is defined as the distance between the two centers minus the radii of the two circles, i.e. D=(p1,p2)-r1-r2. Preferably, for any two adjacent magnets 169, the minimum value of the distance D is 2 times r1 or r2 (taking the larger one of the two). And the maximum value of the distance D is preferably 4 times r1 or r2 (taking the larger one of the two).

[0071] The optimal design of the magnet spacing is crucial for maximizing the effect of electromagnetic induction heating. Firstly, the distance between magnets directly affects the distribution of the magnetic field on the heated object and the uniformity of the magnetic flux density. When the magnets are too close, the magnetic fields of adjacent magnets interfere with each other, resulting in uneven magnetic flux density, reduced efficiency in generating the induced current, and compromised heating performance. Conversely, when the magnets are too far apart, the magnetic field coverage on the heated object becomes sparse, weakening the eddy current effect and also reducing heating efficiency. Therefore, a balance needs to be found to ensure uniform magnetic field distribution and optimal induced current generation.

[0072] In practical applications, measurements showed that the heating effect was optimal when the distance D between adjacent magnets 169 was set between 20mm and 45mm, resulting in a more uniform magnetic flux density and efficient distribution of induced current on the surface of the heated object. Furthermore, within this range, ineffective magnetic field diffusion was effectively suppressed, significantly improving energy utilization. Specifically, the magnetic flux density peaked when the distance D between adjacent magnets was between 30mm and 35mm, exhibiting the best heating efficiency. This optimized design not only reduces magnetic field interference but also effectively improves the uniformity of eddy current distribution, reduces energy loss, and allows more energy to be effectively transferred to the heated object, ensuring a more efficient and stable heating process.

[0073] Furthermore, attached Figure 4 The diagram also schematically illustrates one structure of the drawing die 154. Preferably, the drawing die is generally disc-shaped and has a cavity 156 in the center for shape constraint of the conductor after preliminary stranding and further drawing. The cavity 156 has the same or similar shape as the finished wire conductor. Multi-stage drawing can be achieved by providing two or more forming units 150.

[0074] Each forming unit 150 can be equipped with the same heating module 152, but with different drawing dies 154. The forming cavity design of each stage of the drawing die 154 follows the principles of gradual transition and precise forming. Preferably, the first-stage drawing die is mainly responsible for preliminary forming, making significant dimensional adjustments to the stranded conductor while ensuring uniform material flow and internal structural integrity. The die cross-sectional shape is close to the target shape, but retains a certain margin to lay the foundation for subsequent drawing. The second drawing die further refines the conductor cross-sectional shape, making it closer to the design standard, focusing on dimensional accuracy and material uniformity, while reducing surface defects. For conductors requiring higher precision, the third and subsequent drawing dies will be fine-tuned to ensure that the conductor cross-sectional dimensions achieve micron-level precision, smooth edges, and surface quality that meets design requirements.

[0075] The whole drawing process adopts step-by-step transition and compression ratio control, and multiple forming units 150 are reasonably arranged to make the deformation area between the cavities 156 of each drawing die 154 smoothly transition and avoid sudden deformation leading to material cracking. Key design parameters include entry angle, compression angle, working zone length, and lubrication channel to ensure uniform deformation and stable flow of the conductor during drawing. By reasonably designing and precisely controlling the shape and process parameters of each drawing die, high-precision, uniform cross-section, and smooth-surface profiled conductors can be produced.

[0076] Preferably, the drawing dies 154 and cavities 156 can be modularly arranged, that is, the drawing dies 154 can be uniformly designed in size, and different cavities 156 are used in combination to reduce production cost. To achieve better heating efficiency, the drawing dies 154 can be made of aluminum or aluminum alloy. Aluminum and aluminum alloy are both good conductive materials, and can generate induced current (eddy current) in the drawing dies 154 by electromagnetic induction, thereby quickly releasing heat and achieving uniform heating. Preferably, the drawing dies 154 can be wrapped with heat insulation materials such as asbestos and heat insulation yarn on the outside to reduce heat conduction with air and improve the heat retention effect of the drawing dies 154.

[0077] Preferably, the material of the cavities 156 can be different from that of the drawing dies 154. The cavities 156 can be made of hard alloy, such as hard die steel, which has high hardness and strength, and is heat treated to improve its hardness and wear resistance, so as to maintain the size during long-term drawing to meet the forming requirements of the conductor.

[0078] Embodiment Two: This embodiment should be understood as at least containing all the features of any one of the preceding embodiments, and further improving on the basis thereof:

[0079] In the preferred exemplary embodiment, the forming unit 150 further comprises one or more temperature sensors 165. The control unit is in communication connection with the temperature sensors 165 and the driving components 163. Based on the temperature feedback from the one or more temperature sensors 165, the control unit calculates the required rotation speed of the driving motor by the control program to adjust the heating effect of the heating module 152 on the drawing die 154.

[0080] In the preferred exemplary embodiment, temperature sensors 165 are arranged at one or more positions of the drawing die 154, such as at the inlet, middle, or outlet of the cavity 156, to comprehensively monitor the temperature distribution of the conductor at different stages. Optionally, the temperature sensors 165 can be thermocouples or infrared temperature sensors to achieve high-precision and rapid-response temperature monitoring.

[0081] Further, the temperature sensor transmits the detected real-time temperature data to the control unit; the control unit compares the temperature data with the preset target temperature range to determine whether the current heating temperature meets the process requirements.

[0082] When the temperature is lower than the target temperature, the control unit increases the rotation speed of the driving motor to increase the rotation speed of the rotating body 161, thereby increasing the magnetic field change frequency and the rate of electromagnetic induction heating. When the temperature is higher than the target temperature, the control system reduces the rotation speed of the rotating body 161 to reduce the magnetic field change frequency, thereby slowing down the heating rate to avoid overheating. The rotation speed of the rotating body 161 directly affects the magnetic field change frequency and the heating intensity. Based on the feedback data of the temperature sensor, the control system precisely controls the rotation speed of the rotating body by adjusting the rotation speed of the driving motor 163.

[0083] Preferably, the control program run by the control unit further includes setting a segmented temperature control strategy for the plurality of forming units 150 according to the drawing requirements of different stages, for example, setting a higher temperature for the drawing die of the forming unit located in the initial stage of drawing to accelerate the softening of the profile wire single filament 12; and setting a corresponding lower temperature for the drawing die located in the later stage to prevent over-softening.

[0084] Preferably, the following calculation formula can be used to calculate and set the rotation angular velocity ω of the rotating body 161:

[0085]

[0086] In formula 1, ω0 is the initial rotation angular velocity, which can be zero or set to an initial non-zero value.

[0087] e(t) represents the deviation value of the real-time temperature T means from the target temperature T set , that is:

[0088] e(t) = |T set -T means |; and

[0089] t is a time variable, that is, the rotation angular velocity ω(t) controlled based on the error value e(t) at each time t.

[0090] wherein K p is a proportional gain weight to control the fast response of the rotation angular velocity ω based on the real-time temperature. K i is an integral gain weight to eliminate steady-state error, wherein ∫e(t)·dt is the cumulative value of temperature error over time. K d is a differential gain to suppress the rate of error change, A rate of change of the temperature error.

[0091] And, K p , K i and K d may be obtained by experiment and the control needs of temperature, and the following calculation formula is obtained by referring to the following calculation formula:

[0092]

[0093] In formula 2, T is the target temperature, T0 is the initial temperature of the drawing die 154, η is the thermal conductivity of the drawing die 154 measured in the laboratory; B is the magnetic field strength under the working distance of the current drawing die 154 and the rotating body 161; σ is the electrical conductivity of the drawing die 154; V is the volume of the drawing die 154; t is the heating time; ρ is the average density of the drawing die 154 or the drawing die 154 and the die cavity 156; C is the specific heat capacity of the drawing die 154 or the drawing die 154 and the die cavity 156.

[0094] Through the above rotation speed control algorithm, the dynamic adjustment of the heating temperature of the drawing die can be realized, and the specific values of the parameters can be changed by the technician according to the different material requirements of the produced core wire and profile monofilament, so as to quickly set the control algorithm to simplify the use of the production system.

[0095] Embodiment three: this embodiment should be understood as at least containing all the features of any one of the preceding embodiments, and further improving on the basis thereof:

[0096] Exemplarily, the drawings Figure 5 The schematic diagram of the computer system 500 adopted by the control unit in the production system implemented in the present embodiment is depicted; the computer system 500 can realize the working control of each working unit, module and component in the system according to the current control program; and further, the working data, detection data generated in the system working are collected, stored and processed to finally realize the expected effect of the fluorescent marking system.

[0097] Among them, the computer system 500 includes a bus 502 or other communication mechanism for transmitting information, one or more processors 504 coupled with the bus 502 for processing information; the processor 504 can be, for example, one or more general-purpose microprocessors;

[0098] The computer system 500 also includes a main memory 506, such as a random access memory (RAM), cache and / or other dynamic storage devices, coupled to bus 502 for storing information and instructions to be executed by processor 504; main memory 506 also can be used for storing temporary variables or other intermediate information during execution of instructions to be executed by processor 504; such instructions, when stored in storage media accessible to processor 504, render the computer system 500 into a special-purpose machine that operates to perform the operations specified in the instructions;

[0099] The computer system 500 further can include a read only memory (ROM) 508 or other static storage device coupled to the bus 502 for storing static information and instructions for the processor 504; a storage device 510, such as a magnetic disk, optical disk, or USB drive (flash drive), etc., can be provided and coupled to bus 502 for storing information and instructions;

[0100] Still further, a display 512, such as a flat panel LCD, can be coupled to bus 502 for displaying various information, data, media, etc.; input devices 514, such as a keyboard, mouse, touchpad, etc., can be coupled to bus 502 for allowing a user to control, manipulate, and / or interact with the computer system 500;

[0101] One preferred manner of interacting with the management system can be through a cursor control device 516, such as a computer mouse or similar control / navigational mechanism;

[0102] Further, the computer system 500 can also include a network device 518 coupled to bus 502; the network device 518 can include components such as a wired network card, a wireless network card, a switch chip, a router, a switch, etc.;

[0103] In general, the terms "engine," "component," "system," "database," etc., as used herein can refer to logic embodied in hardware or firmware, or to a collection of software instructions, possibly having entry and exit points, written in a programming language, such as, for example, Java, C or C++; a software component can be compiled and linked into an executable program, installed in a dynamic link library, or can be written in an interpreted programming language such as, for example, BASIC, Perl, or Python; software components can be invoked to execute by other components or by an operating system thread or process manager;

[0104] Software components configured to execute on a computing device can be provided on a computer- readable medium, such as an optical disc, a digital video disc, a flash drive, a magnetic disc or any other tangible medium, or as a digital download (and can initially be stored) in a compressed or installable format, requiring installation, decompression or decryption, before execution); such software code can be stored, in whole or in part, on a memory device of the executing computing device, for execution by the computing device; software instructions can be embedded in firmware, such as an EPROM. It will also be appreciated that hardware components can be comprised of connected logic units, such as gates and flip-flops, and / or can be comprised of programmable units, such as programmable gate arrays or processors;

[0105] The computer system 500 includes a custom hard-wired logic, one or more ASICs or FPGAs, firmware and / or program logic that when in operation, in combination with the computer system, makes the computer system 500 a special purpose computing device to perform the techniques described herein;

[0106] In accordance with one or more embodiments, the techniques herein are performed by the computer system 500 in response to the processor 504 executing one or more sequences of instructions contained in the main memory 506; such instructions can be read into the main memory 506 from another storage medium, such as the storage device 510; execution of the sequences of instructions contained in the main memory 506 causes the processor 504 to perform the process steps described herein; in alternative embodiments, hard-wired circuitry can be used in place of or in combination with software instructions;

[0107] The term "non-transitory medium" and similar terms as used herein refers to any medium that stores the data and / or instructions that cause a machine to operate in a specific manner; such a non-transitory medium can include non-volatile media and / or volatile media; non-volatile media includes, for example, optical or magnetic disks, such as the storage device 510; volatile media includes dynamic memory, such as the main memory 506;

[0108] Common forms of non-transitory media include, for example, a floppy disk, a flexible disk, a hard disk, a solid-state drive, a magnetic tape, or any other magnetic data storage medium, a CD-ROM, any other optical data storage medium, any physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, NVRAM, any other memory chip or cartridge, and a networked version of any of the above;

[0109] A non-transitory medium is distinct from a transmission medium, but can be used in combination with a transmission medium; a transmission medium participates in communicating information between non-transitory media; for example, a transmission medium includes a coaxial cable, a copper wire, and a fiber optic cable, including the wires that make up the bus 502; a transmission medium can also take the form of a sound or light wave, such as a radio or infrared data communication;

Claims

1. A method for manufacturing a low-voltage stranded conductor, characterized in that, The fabrication method is applied to the preparation of stranded irregular conductors; the fabrication method includes the following steps: S100: Provides one central core and multiple profiled monofilaments; S200: The central core and the shaped wire monofilament are stranded together using a stranding machine to obtain a preliminary stranded shaped conductor. At this time, the stranding tightness of the shaped wire monofilament of the preliminary stranded shaped conductor is in a generally tight state. S300: The initial stranded composite conductor is pulled through one or more forming units so that the initial stranded composite conductor is formed to the expected conductor size; The forming unit includes a heating module and a drawing die; the heating module uses electromagnetic induction to rapidly heat the drawing die, so that the profile filament is softened when it passes through the drawing die, thereby improving the drawing forming efficiency. In step S300, one or more forming units process the initial stranded conductor to the finished conductor specification by a step-by-step drawing forming method. In step S200, a tension control unit is used to maintain uniform tension on the profiled wire monofilaments during the stranding process; in step S300, the heating temperature of the drawing die is monitored to control the heating efficiency of the heating module. The manufacturing method further includes using a low-voltage stranded conductor manufacturing system; the manufacturing system includes a wire feeding unit, a stranding unit, a forming unit, a winding unit, and a control unit. The wire feeding unit is used to store and transport a single filament of the profiled wire; The stranding unit is used to strand multiple single wires around the core wire to form a shape. The molding unit is used to process the initial... step Stranding of The conductor is heated and further stranded to achieve the desired conductor specifications; The winding unit is used to wind the stranded conductor into a coil; The control unit is used to coordinate the wire feeding unit, stranding unit, forming unit and winding unit to work together. The heating module includes a rotating body and a driving component; the working surface of the rotating body is provided with multiple magnets; the driving component is used to drive the rotating body to rotate, so that the multiple magnets rotate about one of the normals of the working surface as the axis of rotation, thereby generating an induced current in the drawing die and ultimately heating the drawing die. Among them, concentric circles C1 and C2 with radii R1 and R2 respectively are set with the center of the rotating body as the center. In each circle, multiple magnets are set along the trajectory line of the circle. The center of the rotating body is provided with a through hole to allow the conductor to be stranded to pass through the through hole and continue into the drawing die cavity at the rear end; the magnet is cylindrical and is at least partially embedded in the rotating body; all magnets on the rotating body are arranged with the same polarity orientation. The forming unit also includes one or more temperature sensors; the control unit is communicatively connected to the temperature sensors and the drive components; based on the temperature feedback from one or more temperature sensors, the control unit calculates the required rotational speed of the drive motor by the control program to adjust the heating effect of the heating module on the drawing die; temperature sensors are set at one or more locations on the drawing die, and the temperature sensors transmit the detected real-time temperature data to the control unit; the control unit compares the temperature data with the preset target temperature range to determine whether the current heating temperature meets the process requirements; When the temperature is below the target temperature, the control unit increases the speed of the drive motor to increase the rotational speed of the rotating body, thereby increasing the frequency of magnetic field changes and increasing the rate of electromagnetic induction heating. When the temperature is above the target temperature, the control system reduces the rotational speed of the rotating body and decreases the frequency of magnetic field changes, thereby slowing down the heating rate and preventing overheating. The control system controls the rotational speed of the rotating body based on feedback data from the temperature sensor. The control program running by the control unit also includes setting segmented temperature control strategies for multiple forming units according to the drawing requirements at different stages, and using the following formula to calculate and set the rotational angular velocity ω of the rotating body: Equation 1; In Equation 1, ω0 is the initial rotational angular velocity; e(t) represents the real-time temperature T means With target temperature T set The deviation value, i.e.: e(t)=│T set -T means │; t is a time variable, that is, the controlled rotational angular velocity ω(t) is output based on the error value e(t) at each time t; Among them, K p K is a proportional gain weight used to control the rapid response of the rotational angular velocity ω based on real-time temperature; i The integral gain weight is used to eliminate steady-state error, where K represents the cumulative value of the temperature error over time. d The differential gain is used to suppress the rate of error variation. This indicates the rate of change of temperature error.

2. A low-voltage stranded conductor, characterized in that, The stranded conductor is manufactured using the method described in claim 1.

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