Radial ultrasonic roller device for cleaning wire rod structure

Abstract

The invention discloses a radial ultrasonic roller device for cleaning a wire structure, which comprises a roller, an ultrasonic generator, a visual processing system, a high-speed camera, a tensioning wheel, a mounted bearing, a rotating shaft, a connecting wheel, a via hole conductive slip ring, a rotation stopping fixer, a bracket and a stand column, the roller is fixedly installed on a rotating shaft, and the two ends of the rotating shaft are rotationally installed on a support. Through the synergistic effect of ultrasonic vibration and a roller structure, rapid atomization and separation of liquid drops are achieved, the wire surface drying efficiency is remarkably improved, and meanwhile the problems of high energy consumption or low efficiency in a traditional method are solved; ultrasonic acts on the wire rod through the roller and does not make direct contact with the wire rod, the wire rod is prevented from being damaged due to the direct action of the ultrasonic, the wire passing groove is formed in the roller, the wire rod moves through the wire passing groove to be clamped, and deviation of the wire rod in the moving process is avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of material processing, and particularly relates to a radial ultrasonic roller device for cleaning wire structures. Background Art

[0002] In the field of material processing, wires are widely used in high-precision industries such as electronics, communication, medical, and textile. During processes such as electroplating, cleaning, and coating, a large number of droplets often adhere to the wire surface. If these droplets cannot be removed in time, it will cause uneven drying on the wire surface, forming water stains and pollutant deposits, and even affecting the quality of subsequent processing. Traditional droplet removal methods mainly include hot air drying and natural drying, but these methods all have significant defects. First of all, although hot air drying can quickly evaporate droplets, because the droplet adhesion layer on the wire surface is thin and is restricted by surface tension and the like, it is not conducive to droplet removal. At the same time, because the droplet adhesion layer presents a wrapped streamline shape, the energy consumption of the acting device (wind cut) using hot air drying will be very high, and the long-term high-temperature environment is likely to cause oxidation of the wire surface or thermal deformation of the coating material. Secondly, although the natural drying method is simple and easy to implement, the drying efficiency is extremely low, which cannot meet the requirements of industrial production, and droplet residues may cause corrosion or pollution of the wire surface.

[0003] In recent years, with the development of ultrasonic technology, ultrasonic-assisted atomization technology has shown unique advantages in the field of droplet treatment. Ultrasonic vibration can break droplets into micron-sized particles through tensile waves and cavitation effects, thereby achieving efficient atomization and detachment. However, the existing ultrasonic atomization technology directly acts on the workpiece to be processed, but for continuous processing processes of wires, problems such as wire damage, complex clamping and fixing equipment, and position deviation will occur. Currently, there is no systematic solution specifically for removing droplets on the wire surface. Summary of the Invention

[0004] The purpose of the present invention is to provide a radial ultrasonic roller device for cleaning wire structures to solve the deficiencies in the prior art. Through the synergistic effect of ultrasonic vibration and the roller structure, it realizes the rapid atomization and detachment of droplets, significantly improves the drying efficiency of the wire surface, and at the same time avoids problems such as high energy consumption or low efficiency in traditional methods. The ultrasonic acts on the wire through the roller without directly contacting the wire, avoiding damage to the wire caused by the direct action of the ultrasonic on the wire. The roller is provided with a wire groove, and the wire moves through the wire groove to form clamping of the wire, avoiding deviation during the movement of the wire.

[0005] The present invention provides a radial ultrasonic roller device for cleaning wire structures, which includes a roller, an ultrasonic generator, a vision processing system, a high-speed camera, a tension pulley, a pedestal bearing, a rotating shaft, a connecting wheel, a through-hole conductive slip ring, a rotation stopper, a bracket, and a column. The roller is composed of multiple groups of support modules evenly distributed along the circumferential direction of the connecting wheel. A wire groove is provided on the circumferential surface of the roller. An ultrasonic transducer is arranged inside the roller. The ultrasonic transducer radially transmits ultrasonic waves into the wire groove on the circumferential surface of the roller to apply vibration to the wire passing through the wire groove, causing the liquid on the wire to atomize and fall off. The connecting wheel is fixedly installed on the rotating shaft. Both ends of the rotating shaft are rotatably installed on the bracket through the pedestal bearings. The rotation stopper is arranged on the bracket. The through-hole conductive slip ring is arranged on the rotating shaft. The outside of the through-hole conductive slip ring is a fixed ring, and the inside is a rotating ring. The ultrasonic generator is connected to the fixed ring of the through-hole conductive slip ring through a cable. The rotating ring of the through-hole conductive slip ring is connected to the ultrasonic transducer through a cable. The rotation stopper is used to fix the fixed ring of the through-hole conductive slip ring. Both the ultrasonic generator and the high-speed camera are electrically connected to the vision processing system. There are two tension pulleys. Both tension pulleys are arranged on the column and located on one side of the rotating shaft. One of the tension pulleys abuts against the wire before the wire passes through the roller, and the other tension pulley abuts against the wire after the wire leaves the roller. The high-speed camera is used to capture the dynamic images of the liquid droplets on the surface of the wire.

[0006] In this wire cleaning device, the system consists of five functional modules: power transmission, ultrasonic cleaning, wire positioning, visual monitoring, and support structure. Each module forms a collaborative working system through mechanical and electrical dual connections. The power transmission module takes the rotating shaft as the core. Its two ends are installed on the bracket through pedestal bearings to achieve free rotation. The roller is rigidly connected to the rotating shaft through a key to ensure synchronous rotation of the roller and the rotating shaft. The ultrasonic cleaning module includes an ultrasonic transducer integrated inside the roller and a sector horn module. Among them, the ultrasonic transducer forms an electrical connection with the ultrasonic generator through the rotating ring of the through-hole conductive slip ring, while the sector horn module is fixed to the roller by bolting. The wire groove opened on its surface contacts the wire to transmit radial ultrasonic vibration. The wire positioning module consists of two tension wheels, which are distributed on the column. By adjusting the height of the tension wheels, the wire is closely attached to the wire groove of the roller to form a stable wire running path. The visual monitoring module consists of a high-speed camera and a visual processing system. Two high-speed cameras are respectively located in front of and behind the roller and are connected to the visual processing system through data lines to collect dynamic images of the liquid droplets on the wire surface in real time and feedback them to the ultrasonic generator for cleaning parameter adjustment. The support structure module includes a bracket, a column, and a rotation prevention fixator. The bracket is fixed to the ground through the column to carry the rotating shaft and the roller assembly. The rotation prevention fixator prevents the fixed ring of the through-hole conductive slip ring from rotating with the rotating shaft by locking it. Energy and signals are transmitted across components between modules through electrical cables and mechanical transmissions, ultimately forming a closed-loop cleaning system.

[0007] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, each group of the support modules consists of a sector horn module and one of the ultrasonic transducers; the sector horn module is fixedly connected to the connecting wheel through the ultrasonic transducer; the wire groove is arranged on the arc surface of the sector horn module. The roller is fixedly connected to the rotating shaft through a key; the wire is driven to rotate by an external energy component, and the wire drives the roller to rotate; or the rotating shaft is driven to rotate by an external energy component, and the rotating shaft drives the roller to rotate, thereby driving the wire to rotate, realizing the overall cleaning and drying of the wire.

[0008] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, a plurality of hollow radiation strips are opened on the sector horn module, and the hollow radiation strips are arranged along the radial direction of the sector horn module.

[0009] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, the thickness of the sector horn module gradually decreases in the direction away from the connecting wheel.

[0010] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, the ultrasonic transducer includes a rear cover plate, a piezoelectric ceramic, and a horn; the high-voltage alternating current signal transmitted through the cable on one side of the rotating ring of the through-hole conductive slip ring drives the ultrasonic transducer to work and generates high-frequency mechanical vibrations.

[0011] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, the sector-shaped amplitude conversion module is used to amplify the amplitude of the ultrasonic vibration and enhance the transmission efficiency of the radial ultrasonic vibration; the number of the sector-shaped amplitude conversion modules is greater than or equal to three.

[0012] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, the ultrasonic generator includes a plurality of independently controllable output channels, and each output channel corresponds to an ultrasonic transducer.

[0013] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, it further includes a key, and the roller is connected to the rotating shaft through the key; the wire is driven to rotate by an external energy component, and the wire drives the roller to rotate; or the rotating shaft is driven to rotate by an external energy component, and the rotating shaft drives the roller to rotate, thereby driving the wire to rotate, so as to realize the cleaning and drying of the whole wire.

[0014] In this radial ultrasonic roller device, the generation and radial transmission process of ultrasonic waves are realized through the structural cooperation of the ultrasonic transducer and the sector-shaped amplitude conversion module. Specifically, ultrasonic waves are generated by the electro-mechanical conversion effect of the piezoelectric ceramic, the core component of the ultrasonic transducer: when the high-frequency alternating current signal generated by the ultrasonic generator is transmitted to the transducer through the rotating ring of the through-hole conductive slip ring, the piezoelectric ceramic undergoes periodic deformation under the excitation of the high-frequency electrical signal and forms mechanical vibrations; subsequently, the horn inside the transducer amplifies the vibration amplitude, and the vibration energy is further strengthened through the sector-shaped amplitude conversion module at its front end. The sector-shaped amplitude conversion module adopts a unique structural design - its thickness gradually decreases along the radial direction away from the connecting wheel, forming an amplitude amplification gradient. At the same time, multiple radial hollow radiation strips opened on the surface of the module optimize the vibration distribution through the cavity resonance effect, and finally transmit the amplified ultrasonic energy efficiently to the surface of the wire groove on the periphery of the roller. Since the roller is rigidly connected to the rotating shaft through a key, during the rotation of the connecting wheel with the wire or external drive, the coating on the surface of the wire groove is in continuous contact with the wire, enabling the radial ultrasonic vibration to directly act on the surface of the wire, triggering the cavitation effect and atomization peeling of the attached liquid, thereby realizing the cleaning and drying functions. During the whole process, the through-hole conductive slip ring ensures the continuous and stable supply of electrical energy to the transducer under the rotating state through the cooperation of the fixed ring and the rotating ring, and the uniform distribution design (number ≥ 3 groups) of the sector-shaped amplitude conversion module ensures the vibration uniformity of ultrasonic waves in the circumferential direction of the roller.

[0015] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, there are two high-speed cameras, one of the high-speed cameras is located before the wire passes through the roller, and the other high-speed camera is located after the wire leaves the roller.

[0016] A radial ultrasonic roller device for wire structure cleaning as described above, wherein, preferably, the surface of the wire groove is provided with a coating, and the material of the coating is the same as the material of the wire surface.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] The present invention adopts the synergistic effect of ultrasonic vibration and roller structure to realize the rapid atomization and detachment of droplets, significantly improve the drying efficiency of the wire surface, and at the same time avoid problems such as high energy consumption or low efficiency in the traditional method. The ultrasonic acts on the wire through the roller without directly contacting the wire, avoiding damage to the wire caused by the direct action of the ultrasonic on the wire. The roller is provided with a wire groove, and the wire moves through the wire groove to form a clamping force on the wire, avoiding the offset of the wire during the movement process, and the clamping structure is simple.

[0019] In the present invention, the roller is arranged to be composed of multiple groups of support modules evenly distributed along the circumferential direction of the connecting wheel. Each group of support modules is composed of a sector horn module and an ultrasonic transducer. The ultrasonic transducers of each group of support modules are controlled separately, and the vibration output can be flexibly adjusted according to process requirements to adapt to different wire specifications and cleaning requirements.

[0020] In the present invention, by setting hollow radiation strips on the sector horn module, unnecessary lateral vibrations can be filtered out to provide radial ultrasonic vibrations. At the same time, the sector horn module adopts a variable thickness design, extending from the bottom to the top (the thickness gradually decreases) so as to obtain a high-power ultrasonic effect on the outer surface of the sector horn module and improve the cleaning effect.

[0021] In the present invention, by equipping with high-speed cameras and a vision processing system, the cleaning process is monitored and optimized in real time, and the ultrasonic frequency and power are dynamically adjusted to realize intelligent and precise cleaning process control. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 is a schematic structural diagram of a radial ultrasonic roller device for wire structure cleaning proposed by the present invention;

[0023] Figure 2 is a schematic structural diagram of an ultrasonic generator;

[0024] Figure 3 is a left view of the sector horn module;

[0025] Figure 4 It is a schematic three-dimensional structure diagram of the fan-shaped amplitude-changing module;

[0026] Figure 5 It is a schematic structure diagram of the roller;

[0027] Figure 6 It is the front view of the roller;

[0028] Figure 7 It is a schematic diagram of the state when the tensioning wheel is working;

[0029] Figure 8 It is a schematic diagram of the state when the high-speed camera is working;

[0030] Figure 9 It is a schematic structure diagram of the vision processing system;

[0031] Figure 10 It is the working flow chart of the present invention.

[0032] Explanation of reference numerals:

[0033] 1 - Ultrasonic generator, 2 - Vision processing system, 3 - High-speed camera, 4 - Wire, 5 - Tensioning wheel, 6 - Pillow block bearing, 7 - Rotating shaft, 8 - Key, 9 - Connecting wheel, 10 - Ultrasonic transducer, 11 - Fan-shaped amplitude-changing module, 12 - Through-hole conductive slip ring, 13 - Anti-rotation fixator, 14 - Hollow radiation bar, 15 - Wire groove, 16 - Coating. Specific embodiments

[0034] The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0035] Embodiments of the present invention: As Figures 1-9As shown in the figure, a radial ultrasonic roller device for wire structure cleaning mainly includes an ultrasonic generator 1, a vision processing system 2, a high-speed camera 3, a tension pulley 5, a pedestal bearing 6, a rotating shaft 7, a connecting wheel 9, a through-hole conductive slip ring 12, a rotation stopper 13, a bracket, a column, etc. The roller is composed of multiple groups of support modules evenly distributed along the circumferential direction of the connecting wheel 9. A wire groove 15 is provided on the circumferential side surface of the roller. An ultrasonic transducer 10 is provided inside the connecting wheel 9. The ultrasonic transducer 10 radially transmits ultrasonic waves into the wire groove 15 on the circumferential side surface of the roller, applying vibration to the wire 4 passing through the wire groove 15, causing the liquid on the wire 4 to atomize and fall off, thereby playing a role in cleaning and drying. The connecting wheel 9 is fixedly installed on the rotating shaft 7. Both ends of the rotating shaft 7 are rotatably installed on the bracket through the pedestal bearings 6. The rotation stopper 13 is provided on the bracket, and the through-hole conductive slip ring 12 is provided on the rotating shaft 7. The outside of the through-hole conductive slip ring 12 is a fixed ring, and the inside is a rotating ring. The ultrasonic generator 1 is connected to the fixed ring of the through-hole conductive slip ring 12 through a cable, and the rotating ring of the through-hole conductive slip ring 12 is connected to the ultrasonic transducer 10 through a cable. In this way, it can prevent the cable from being wound during the rotation of the roller and ensure stable signal transmission between the fixed structure and the rotating structure. The fixing method between the through-hole conductive slip ring 12 and the rotating shaft 7 is a prior art that can be realized by those skilled in the art and will not be elaborated here. The rotation stopper 13 is used to fix the fixed ring of the through-hole conductive slip ring 12. Both the ultrasonic generator 1 and the high-speed camera 3 are electrically connected to the vision processing system 2. There are two tension pulleys 5, both of which are arranged on the column and are located on one side of the rotating shaft 7. One of the tension pulleys 5 abuts against the wire 4 before the wire 4 passes through the roller, and the other tension pulley 5 abuts against the wire 4 after the wire 4 leaves the roller. The high-speed camera 3 is used to capture the dynamic images of the liquid droplets on the surface of the wire 4.

[0036] As an implementation method, the bracket includes two parallel square steels. The two pedestal bearings 6 are respectively fixed on the square steels by bolts. The ultrasonic generator 1 rectifies, filters, and converts the input 220V industrial frequency alternating current into direct current, and amplifies the signal into a high-voltage alternating current signal through a high-frequency transformer to drive the ultrasonic transducer 10. The ultrasonic transducer 10 can convert the high-voltage alternating current signal into high-frequency mechanical vibration (vibration frequency is 20 - 100kHz). The frequency and power of the ultrasonic vibration can be adjusted according to the wire size specifications, the characteristics of the attached liquid droplets, and the process requirements to achieve the best removal effect.

[0037] As an implementation, each group of the support modules is composed of a sector amplitude conversion module 11 and an ultrasonic transducer 10. The sector amplitude conversion module 11 is fixedly connected to the connecting wheel 9 through the ultrasonic transducer 10. The wire groove 15 is arranged on the arc surface of the sector amplitude conversion module 11. The sector amplitude conversion module 11 is used to amplify the amplitude of the ultrasonic vibration and enhance the transmission efficiency of the radial vibration of the ultrasonic wave. The number of the sector amplitude conversion modules 11 can be three, four, five, six, seven, eight, etc.

[0038] As an implementation, refer to Figures 5-7 As shown, the connecting wheel 9 is a hollow hexagonal prism structure. A key groove is arranged in the hollow structure. A key groove is arranged in the middle of the rotating shaft 7. The connecting wheel 9 is fixedly connected to the rotating shaft 7 through a key 8 to achieve efficient transmission of power and stable rotation. Six connecting holes are evenly arranged on the outer periphery of the connecting wheel 9 for installing six groups of support modules, that is, six ultrasonic transducers 10 and six sector amplitude conversion modules 11. The ultrasonic transducer 10 and the sector amplitude conversion module 11 are connected by a full-thread screw. The connecting wheel 9 is bolted to the connecting step (with a through hole) arranged on the side of the ultrasonic transducer 10 to complete the fixation of six groups of ultrasonic transducers 10 and sector amplitude conversion modules 11 in sequence. The connecting wheel 9 drives the wire 4 to rotate through an external energy component, and the wire 4 drives the roller to rotate; or the external energy component drives the rotating shaft 7 to rotate, and the rotating shaft 7 drives the roller to rotate, thereby driving the wire 4 to rotate. This design ensures the synchronism between the wire 4 and the roller, and also avoids the misalignment friction between the wire 4 and the sector amplitude conversion module 11, effectively preventing the wear of the wire 4 and the sector amplitude conversion module 11 and prolonging the service life of the components. The six-group ultrasonic output design further improves the vibration efficiency. At the same time, according to different process requirements, under the action of the ultrasonic generator 1 provided with six independently controllable output channels, the vibration action of a single or multiple amplitude conversion modules can be realized, optimizing the energy consumption in use. As an implementation, refer to Figure 2 As shown, the six groups of ultrasonic transducers 10 and sector amplitude conversion modules 11 can be separately controlled and output by six independent channels of the ultrasonic generator 1. The output ports of the six independent channels of the ultrasonic generator 1 are respectively A, B, C, D, E, and F, and the input ends of the six groups of ultrasonic transducers 10 are respectively a, b, c, d, e, and f. Refer to Figure 6 As shown.

[0039] In actual use, the connecting wheel 9 can also be a hollow cylinder, a hollow quadrangular prism, a hollow octagonal prism, etc. The ultrasonic generator 1 includes multiple independently controllable output channels, and each output channel corresponds to an ultrasonic transducer 10.

[0040] As an implementation, refer to Figure 4As shown, a plurality of hollow radiation strips 14 are provided on the surface of the sector amplitude conversion module 11, and the hollow radiation strips 14 are arranged in the radial direction of the sector amplitude conversion module 11. The width of the hollow radiation strip 14 is about 1 / 4 of the sound wavelength. The purpose of setting the hollow radiation strip 14 is to filter out unnecessary transverse vibrations, provide radial ultrasonic vibrations, and concentrate the ultrasonic vibrations on the radial surface of the wire 4, thereby realizing the atomization and detachment of droplets. The thickness of the sector amplitude conversion module 11 gradually decreases in the direction away from the connecting wheel 9. See Figure 3 As shown, so as to obtain a high-power ultrasonic effect on the outer surface of the sector amplitude conversion module 11, effectively amplify the amplitude of the ultrasonic wave, and improve the efficiency of removing droplets. In addition, after determining the appropriate operating frequency according to different processing technology requirements, the geometric dimensions of the designed variable-thickness sector amplitude conversion module 11 are also different (considering the Poisson effect). By adjusting the geometric dimensions of the sector amplitude conversion module 11, the vibration effect can be optimized according to different wire specifications and droplet adhesion characteristics.

[0041] As an implementation method, see Figure 4 As shown, a coating 16 is provided on the surface of the wire groove 15, that is, a protective film is plated on the surface of the wire groove 15 to form the coating 16. The material of the coating 16 is the same as that of the surface of the wire 4, avoiding contact damage due to different material properties between the two, and is used to contact the wire 4 to ensure that the wire 4 is stressed stably and fixed in the working position. The coating 16 is in contact and compacted with the wire 4 to transfer the amplified radial ultrasonic vibration to the surface of the wire 4.

[0042] As an implementation method, see Figure 1 As shown, it further includes two tension wheels 5. Both tension wheels 5 are located on one side of the rotating shaft 7. One tension wheel 5 abuts against the wire 4 before the wire 4 passes through the roller, and the other tension wheel 5 abuts against the wire 4 after the wire 4 leaves the roller. According to the need of the wire 4 cleaning process, adjust the contact force between the wire 4 and the wire groove 15 on the sector amplitude conversion module 11 to ensure that the ultrasonic vibration can act on the surface of the wire 4 evenly and effectively. To avoid contact damage caused by material property differences, the surfaces of the tension wheels 5 and the wire 4 should be made of the same material. By adjusting the working position of the tension wheels 5, the contact pressure can be accurately controlled according to the diameter, surface characteristics and cleaning requirements of the wire 4, thereby optimizing the cleaning effect. The installation of the tension wheels 5 is a prior art, and those skilled in the art can achieve it and will not be elaborated here.

[0043] During the cleaning process, the high-frequency vibration emitted by the ultrasonic transducer 10 generates tensile waves and cavitation effects in the liquid (the cavitation effect refers to the formation of tiny bubbles in the liquid under the action of ultrasonic high-frequency vibration and their rapid collapse, generating strong impacts, high pressures, etc.). The cavitation effect forms tiny bubbles and rapidly collapses, generating strong shock waves. These shock waves can effectively break the droplets adhering to the surface of the wire, causing them to detach from the surface of the wire 4 and atomize into fine particles. The tensile waves and cavitation effects will quickly atomize the droplets adhering to the wire, thereby completing the removal of the droplets on the wire surface. Since the vibration frequency and power can be adjusted according to different wire materials and droplet characteristics, the present invention can achieve an efficient cleaning effect in a short time, reduce droplet residue, and avoid the low efficiency and high energy consumption problems brought by traditional drying methods. By adjusting the ultrasonic frequency, power, and geometric dimensions of the sector horn module, it can adapt to different wire sizes, the characteristics of adhering droplets, and various process requirements, with a wide range of applications.

[0044] To monitor the cleaning effect of the wire surface in real time, it also includes a vision processing system 2 and a high-speed camera 3. The vision processing system 2 is electrically connected to the high-speed camera 3, and the vision processing system 2 is electrically connected to the ultrasonic generator 1; the high-speed camera 3 is used to capture the dynamic behavior of the droplets on the wire surface, and can accurately capture key parameters such as the morphological changes, movement trajectories, and removal effects of the droplets before and after cleaning, providing visual data support for evaluating the effectiveness of the cleaning process. There are two high-speed cameras 3, one of which is located before the wire 4 passes through the roller, and the other high-speed camera 3 is located after the wire 4 leaves the roller. See Figure 8 as shown. There are two sets of connection ports on the vision processing system 2, namely I and II. See Figure 9 as shown, and the two sets of connection ports are electrically connected to the two high-speed cameras 3 respectively.

[0045] The vision processing system 2 integrates advanced image recognition algorithms and data processing modules, and can perform real-time analysis on the microscopic morphology of the wire surface collected by the high-speed camera. The system uses feature extraction and pattern recognition technologies to accurately quantify key indicators such as droplet removal rate and surface cleanliness, and feeds the analysis results back to the ultrasonic generator 1 through a closed-loop control system. Based on the preset process parameter optimization algorithm, the system can dynamically adjust key parameters such as ultrasonic frequency, power, and action time, thereby realizing the intelligent control and optimization of the cleaning process and ensuring a stable and consistent surface treatment effect.

[0046] Specific operation steps:

[0047] Equipment installation (see Figure 1):Assemble components such as the connecting wheel 9, rotating shaft 7, pedestal bearing 6, anti-rotation retainer 13, and through-hole conductive slip ring 12 according to the design requirements to ensure the coaxiality and stability of the rotating shaft 7. Install six groups of ultrasonic transducers 10 and sector horn modules 11 and fix them with full-thread screws. Install tension wheels 5 at the front and rear ends of the wire 4 passing through the sector horn module 11 to adjust the contact force (see Figure 7 ).

[0048] Parameter setting: Set the frequency (20 - 100 kHz) and power of the ultrasonic generator 1 according to the size of the wire 4, droplet characteristics, and process requirements. Start the vision processing system 2 and set the target values of key indicators such as droplet removal rate and surface cleanliness.

[0049] Start operation: Start the ultrasonic generator 1 to drive the ultrasonic transducers 10 to generate high-frequency vibrations. The wire 4 passes through the sector horn module 11 at a set speed, driving the connecting wheel 9 to rotate (see Figure 1 ). The high-speed camera 3 captures the dynamic behavior of the droplets in real time, and the vision processing system 2 analyzes the cleaning effect and feeds back to the ultrasonic generator 1 to dynamically adjust the parameters.

[0050] Cleaning effect evaluation: Evaluate indicators such as droplet removal rate and surface cleanliness through the high-speed camera 3 and the vision processing system 2. Further optimize the ultrasonic frequency, power, and action time according to the evaluation results.

[0051] In another operating procedure, before cleaning starts, install the equipment, set the parameters of the ultrasonic generator and the pre-tightening force of the tension wheel. Then start the device to run. The high-speed camera dynamically captures images and transmits the image information to the vision processing system. The vision processing system analyzes the images, preprocesses the images for feature extraction and sets standards, and then makes feature judgments. If the standards are met, the equipment continues to work until cleaning is completed. If not, dynamically adjust the parameters of the ultrasonic generator and the pre-tightening force of the tension wheel and repeat the above steps until the standards are met. Whether the standards are met can be whether the droplet removal rate reaches the set standard or whether the surface cleanliness reaches the set standard, see Figure 10 .

[0052] A specific application scenario: Used for removing droplets on the surface of a copper wire 4 with a diameter of 0.5 mm.

[0053] Parameter setting: Ultrasonic frequency: 40 kHz, Power: 200 W, Wire 4 speed: 10 m / min.

[0054] Operation process: Start the ultrasonic generator 1 to drive six groups of ultrasonic transducers 10 to generate high-frequency vibrations of 40 kHz. The copper wire 4 passes through the sector horn module 11 at a speed of 10 m / min, driving the connecting wheel 9 to rotate (see Figure 1)。The high-speed camera 3 captures the dynamic behavior of the droplets in real time, and the vision processing system 2 analyzes the cleaning effect and feeds it back to the ultrasonic generator 1 (see Figure 10 ).

[0055] Effect evaluation: The droplet removal rate reaches 98%, and the surface cleanliness is significantly improved. There is no damage on the surface of the wire 4, meeting the requirements of high-precision processing.

[0056] It should be particularly noted that the frequency and power of the ultrasonic vibration can be flexibly adjusted according to different wire diameters, droplet characteristics, and actual process requirements. With the feedback of the high-speed camera and the vision processing system, closed-loop control adjustment is achieved to ensure the best removal effect. At the same time, this device realizes efficient, energy-saving, and wide-adaptability wire surface cleaning, significantly improving the cleaning efficiency and avoiding the problems of high energy consumption and low efficiency in traditional methods. Its excellent cleaning effect makes it particularly suitable for different wire sizes, attached droplet characteristics, and various process requirements, meeting the requirements of high efficiency, environmental protection, and high-quality processing in industrial production and having a wide application prospect.

[0057] The structure, features, and function effects of the present invention have been described in detail based on the embodiments shown in the drawings above. The above is only the preferred embodiment of the present invention, but the present invention is not limited to the scope shown in the drawings. Any changes made according to the concept of the present invention, or modified into equivalent embodiments with equivalent changes, still within the spirit covered by the specification and the drawings, shall be within the protection scope of the present invention.

Claims

1. A radial ultrasonic roller device for cleaning a wire structure, characterized in that: The invention comprises a roller, an ultrasonic generator (1), a visual processing system (2), a high-speed camera (3), a tensioning wheel (5), a seat bearing (6), a rotating shaft (7), a connecting wheel (9), a through-hole conductive slip ring (12), a rotation stop fixture (13), a bracket and a column. The roller is composed of a plurality of support modules evenly distributed along the circumferential side of the connecting wheel (9); a wire groove (15) is provided on the circumferential side of the roller; an ultrasonic transducer (10) is provided inside the roller; and the ultrasonic transducer (10) is provided inside the roller. 0) radially transmits ultrasonic waves to the wire groove (15) on the peripheral side of the roller, applies vibration to the wire (4) passing through the wire groove (15), so that the liquid on the wire (4) is atomized and falls off; the connecting wheel (9) is fixedly mounted on the rotating shaft (7), and the two ends of the rotating shaft (7) are rotatably mounted on the bracket through the seat bearing (6); the anti-rotation fixture (13) is arranged on the bracket, the through-hole conductive slip ring (12) is arranged on the rotating shaft (7), the outside of the through-hole conductive slip ring (12) is a fixed ring, and the inside is a rotating ring, the ultrasonic generator (1) is connected to the fixed ring of the through-hole conductive slip ring (12) through a cable, and the rotating ring of the through-hole conductive slip ring (12) is connected to the ultrasonic transducer (10) through a cable; the anti-rotation fixture (13) is used to fix the fixed ring of the through-hole conductive slip ring (12); the ultrasonic generator (1) and the high-speed camera (3) are both connected to the The visual processing system (2) is electrically connected; there are two tensioning wheels (5), both of which are arranged on the column and located on one side of the rotating shaft (7), one of the tensioning wheels (5) abuts against the wire (4) before the wire (4) passes through the roller, and the other tensioning wheel (5) abuts against the wire (4) after the wire (4) leaves the roller; the high-speed camera (3) is used to capture dynamic images of droplets on the surface of the wire (4).

2. A radial ultrasonic roller device for cleaning a wire structure according to claim 1, characterized in that: Each group of the support modules is composed of a fan-shaped amplitude variation module (11) and an ultrasonic transducer (10); the fan-shaped amplitude variation module (11) is fixedly connected to the connecting wheel (9) via the ultrasonic transducer (10); and the wire groove (15) is arranged on the arc surface of the fan-shaped amplitude variation module (11).

3. A radial ultrasonic roller device for cleaning a wire structure according to claim 2, characterized in that: The sector-shaped amplitude variation module (11) is provided with a plurality of hollow radiation strips (14), and the hollow radiation strips (14) are arranged along the radial direction of the sector-shaped amplitude variation module (11).

4. A radial ultrasonic roller device for cleaning a wire structure according to claim 3, characterized in that: The thickness of the fan-shaped amplitude variation module (11) gradually decreases in a direction away from the connecting wheel (9).

5. A radial ultrasonic roller device for cleaning a wire structure according to claim 2, characterized in that: The ultrasonic transducer (10) comprises a rear cover plate, piezoelectric ceramics and a horn; a high-voltage AC signal transmitted through a cable on one side of a rotating ring of the through-hole conductive slip ring (12) drives the ultrasonic transducer (10) to operate, thereby generating high-frequency mechanical vibration.

6. A radial ultrasonic roller device for cleaning a wire structure according to claim 5, characterized in that: The fan-shaped amplitude variation module (11) is used to amplify the amplitude of ultrasonic vibration and enhance the transmission efficiency of ultrasonic radial vibration; the number of the fan-shaped amplitude variation modules (11) is greater than or equal to three.

7. A radial ultrasonic roller device for cleaning a wire structure according to claim 6, characterized in that: The ultrasonic generator (1) comprises a plurality of independently controllable output channels, each of the output channels corresponding to one of the ultrasonic transducers (10).

8. A radial ultrasonic roller device for cleaning a wire structure according to claim 7, characterized in that: The invention also comprises a key (8), and the roller is connected to the rotating shaft (7) via the key (8); the wire (4) is driven to rotate via an external energy component, and the wire (4) drives the roller to rotate; or the rotating shaft (7) is driven to rotate via an external energy component, and the rotating shaft (7) drives the roller to rotate, thereby driving the wire (4) to rotate, thereby achieving cleaning and drying of the entire wire (4).

9. A radial ultrasonic roller device for cleaning a wire structure according to claim 8, characterized in that: There are two high-speed cameras (3), one of which is located before the wire (4) passes through the roller, and the other of which is located after the wire (4) leaves the roller.

10. A radial ultrasonic roller device for cleaning a wire structure according to claim 1, characterized in that: The surface of the wire groove (15) is provided with a coating (16), and the material of the coating (16) is consistent with the material of the surface of the wire (4).

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