Radial ultrasonic roller device for wire structure cleaning

Abstract

The application discloses a radial ultrasonic roller device for wire structure cleaning, which comprises a roller, an ultrasonic generator, a visual processing system, a high-speed camera, a tensioning wheel, a bearing with a seat, a rotating shaft, a connecting wheel, a via conductive slip ring, a rotation-stopping fixer, a support and a column, a wire passing groove is arranged on the circumferential surface of the roller, an ultrasonic transducer is arranged in the roller, the roller is fixedly installed on the rotating shaft, and both ends of the rotating shaft are rotatably installed on the support. Through the cooperation of ultrasonic vibration and the roller structure, the application realizes the rapid atomization and separation of liquid drops, significantly improves the wire surface drying efficiency, avoids the problems of high energy consumption or low efficiency in the traditional method, and avoids the damage to the wire caused by the direct action of the ultrasonic wave on the wire, since the ultrasonic wave acts on the wire through the roller without direct contact with the wire. The wire passing groove is arranged on the roller, the wire moves through the wire passing groove to form clamping on the wire, and the wire offset during movement is avoided.

Description

Technical Field

[0001] This invention relates to the field of materials processing technology, and more specifically to a radial ultrasonic roller device for cleaning wire structures. Background Technology

[0002] In the field of materials processing, wire is widely used in high-precision industries such as electronics, communications, medical, and textiles. During processes such as electroplating, cleaning, and coating, a large number of droplets often adhere to the surface of the wire. If these droplets are not removed in time, it will lead to uneven drying of the wire surface, forming water stains, contaminant deposits, and even affecting the quality of subsequent processing. Traditional droplet removal methods mainly include hot air drying and natural drying, but these methods have significant drawbacks. First, although hot air drying can quickly evaporate droplets, the droplet adhesion layer on the wire surface is thin and subject to surface tension, which is not conducive to droplet removal. At the same time, because the droplet adhesion layer is streamlined, the energy consumption of the hot air drying device (air cutter) is very high, and the prolonged high-temperature environment can easily lead to oxidation of the wire surface or thermal deformation of the coating material. Second, although the natural drying method is simple and easy to implement, the drying efficiency is extremely low, which cannot meet the needs of industrial production, and droplet residue may lead to corrosion or contamination 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 removal. Ultrasonic vibration can break droplets into micron-sized particles through tension waves and cavitation effects, thereby achieving efficient atomization and detachment. However, existing ultrasonic atomization technologies directly act on the workpiece, which can lead to problems such as wire damage, complex clamping and fixing equipment, and positional misalignment in continuous wire processing. Currently, there is no systematic solution specifically for removing droplets from wire surfaces. Summary of the Invention

[0004] The purpose of this invention is to provide a radial ultrasonic roller device for cleaning wire structures, which overcomes the shortcomings of the prior art. It achieves rapid atomization and detachment of droplets through the synergistic effect of ultrasonic vibration and roller structure, significantly improving the drying efficiency of wire surface, while avoiding the problems of high energy consumption or low efficiency in traditional methods. The ultrasonic waves act on the wire through the roller without direct contact with the wire, avoiding damage caused by direct ultrasonic action. The roller is provided with a wire groove, which forms a clamping effect on the wire as it moves through the groove, preventing the wire from deviating during the movement process.

[0005] This invention provides a radial ultrasonic roller device for cleaning wire structures, comprising a roller, an ultrasonic generator, a vision processing system, a high-speed camera, a tensioning wheel, a seated bearing, a rotating shaft, a connecting wheel, a through-hole conductive slip ring, an anti-rotation fixing device, a bracket, and a column. The roller is composed of multiple sets of support modules evenly distributed along the circumferential direction of the connecting wheel. A wire-passing groove is provided on the circumferential surface of the roller. An ultrasonic transducer is installed inside the roller, transmitting ultrasonic waves radially to the wire-passing groove on the circumferential surface of the roller, applying vibration to the wire passing through the groove, causing liquid on the wire to atomize and fall off. The connecting wheel is fixedly mounted on the rotating shaft, and both ends of the rotating shaft are rotatably mounted on the bracket via the seated bearing. The anti-rotation fixing device is disposed on the bracket. The through-hole conductive slip ring is mounted on the rotating shaft. The outer ring of the through-hole conductive slip ring is a fixed ring, and the inner ring is a rotating ring. The ultrasonic generator is connected to the fixed ring of the through-hole conductive slip ring via a cable, and the rotating ring of the through-hole conductive slip ring is connected to the ultrasonic transducer via a cable. The anti-rotation retainer is used to fix the fixed ring of the through-hole conductive slip ring. The ultrasonic generator and the high-speed camera are both electrically connected to the vision processing system. There are two tensioning wheels, both mounted on the column and located on one side of the rotating shaft. One tensioning wheel abuts against the wire before it passes the roller, and the other tensioning wheel abuts against the wire after it leaves the roller. The high-speed camera is used to capture dynamic images of the droplets on the surface of the wire.

[0006] This wire cleaning device consists of five functional modules: power transmission, ultrasonic cleaning, wire positioning, visual monitoring, and support structure. These modules are interconnected mechanically and electrically to form a collaborative working system. The power transmission module uses a rotating shaft as its core, with both ends mounted on a bracket via bearings for free rotation. Rollers are rigidly connected to the rotating shaft via keys, ensuring synchronous rotation. The ultrasonic cleaning module includes an integrated ultrasonic transducer and a fan-shaped amplitude transformer module within the rollers. The ultrasonic transducer is electrically connected to the ultrasonic generator via a rotating ring of a through-hole conductive slip ring, while the fan-shaped amplitude transformer module is bolted to the rollers. Its surface has grooves that contact the wire to transmit radial ultrasonic vibrations. The wire positioning module consists of two tensioning rollers, distributed on a vertical... On the column, the height of the tensioning wheel is adjusted to ensure the wire adheres tightly to the roller and passes through the wire groove, forming a stable wire travel path. The visual monitoring module consists of a high-speed camera and a vision processing system. Two high-speed cameras are located at the front and rear of the roller, respectively, and are connected to the vision processing system via data cables. They acquire real-time dynamic images of droplets on the wire surface and feed them back to the ultrasonic generator for cleaning parameter adjustment. The support structure module includes a bracket, a column, and an anti-rotation fixture. The bracket is fixed to the ground by the column to support the rotating shaft and roller assembly. The anti-rotation fixture prevents the rotating shaft from rotating by locking the conductive slip ring in the through hole. Energy and signals are transmitted between the modules via electrical cables and mechanical transmission, ultimately forming a closed-loop cleaning system.

[0007] As described above, a radial ultrasonic roller device for cleaning wire structures is preferably provided, in which each set of support modules consists of a fan-shaped amplitude transformer module and an ultrasonic transducer; the fan-shaped amplitude transformer module is fixedly connected to the connecting wheel via the ultrasonic transducer; the wire guide groove is provided on the arc-shaped surface of the fan-shaped amplitude transformer module. The roller is fixedly connected to a rotating shaft via a key; the wire is rotated by an external energy component, and the wire drives the roller to rotate; or the rotating shaft is rotated by an external energy component, and the rotating shaft drives the roller to rotate, thereby rotating the wire and achieving overall cleaning and drying of the wire.

[0008] As described above, in a radial ultrasonic roller device for cleaning wire structures, preferably, the fan-shaped amplitude transformer module has multiple hollow radiating strips arranged along the radial direction of the fan-shaped amplitude transformer module.

[0009] In the radial ultrasonic roller device for cleaning wire structures as described above, preferably, the thickness of the fan-shaped amplitude module gradually decreases in the direction away from the connecting wheel.

[0010] As described above, a radial ultrasonic roller device for cleaning wire structures is preferably provided, wherein the ultrasonic transducer includes a rear cover plate, a piezoelectric ceramic, and an amplitude transformer; the high-voltage AC 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 generate high-frequency mechanical vibration.

[0011] As described above, a radial ultrasonic roller device for cleaning wire structures preferably includes a fan-shaped amplitude converter to amplify the amplitude of ultrasonic vibration and enhance the transmission efficiency of ultrasonic radial vibration; the number of fan-shaped amplitude converters is greater than or equal to three.

[0012] As described above, a radial ultrasonic roller device for cleaning wire structures, wherein preferably, the ultrasonic generator includes multiple independently controllable output channels, each output channel corresponding to one of the ultrasonic transducers.

[0013] The radial ultrasonic roller device for cleaning wire structures as described above preferably further includes a key, wherein the roller is connected to the rotating shaft via the key; the wire is rotated by an external energy component, and the wire drives the roller to rotate; or the rotating shaft is rotated by an external energy component, and the rotating shaft drives the roller to rotate, thereby driving the wire to rotate, achieving overall cleaning and drying of the wire.

[0014] In this radial ultrasonic roller device, the generation and radial transmission of ultrasonic waves are achieved through the structural synergy of the ultrasonic transducer and the fan-shaped amplitude transformer module. Specifically, the ultrasonic waves are generated by the electromechanical conversion effect of the piezoelectric ceramic, the core component of the ultrasonic transducer: when the high-frequency AC 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, generating mechanical vibration; subsequently, the amplitude transformer rod inside the transducer amplifies the vibration amplitude, and the vibration energy is further enhanced by the fan-shaped amplitude transformer module at its front end. The fan-shaped amplitude transformer 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 on the surface of the module optimize the vibration distribution through the cavity resonance effect, ultimately efficiently transmitting the amplified ultrasonic energy to the surface of the through-groove on the periphery of the roller. Because the roller is rigidly connected to the rotating shaft via a key, the plating on the surface of the wire groove remains in continuous contact with the wire as the connecting wheel rotates with the wire or is driven externally. This allows the radial ultrasonic vibration to act directly on the wire surface, inducing cavitation and atomization stripping of the adhering liquid, thus achieving cleaning and drying functions. Throughout the process, the through-hole conductive slip ring, through the cooperation of the fixed ring and the rotating ring, ensures a continuous and stable supply of power to the transducer during rotation, while the uniform distribution design of the fan-shaped amplitude transformer modules (≥3 sets) ensures the uniformity of ultrasonic vibration in the circumferential direction of the roller.

[0015] As described above, a radial ultrasonic roller device for cleaning wire structures preferably includes two high-speed cameras, one of which is located before the wire passes the roller, and the other is located after the wire leaves the roller.

[0016] In the radial ultrasonic roller device for cleaning wire structures as described above, 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] This invention utilizes the synergistic effect of ultrasonic vibration and a roller structure to achieve rapid atomization and detachment of droplets, significantly improving the surface drying efficiency of wires. It also avoids the problems of high energy consumption or low efficiency in traditional methods. The ultrasonic waves act on the wire through the roller, avoiding direct contact and preventing damage. The roller has a wire-passing groove, which clamps the wire as it moves, preventing deviation during movement. The clamping structure is also simple.

[0019] The present invention uses rollers arranged in a manner that consists of multiple sets of support modules evenly distributed along the circumference of the connecting rollers. Each set of support modules consists of a fan-shaped amplitude transformer module and an ultrasonic transducer. The ultrasonic transducer of each set of support modules is individually controlled, and the vibration output can be flexibly adjusted according to process requirements to adapt to different wire specifications and cleaning requirements.

[0020] This invention filters out unnecessary lateral vibrations and provides radial ultrasonic vibrations by setting hollow radiation strips on the fan-shaped amplitude transformer module. At the same time, the fan-shaped amplitude transformer module adopts a variable thickness design, extending from the bottom to the top (with the thickness gradually decreasing), so as to obtain a high-power ultrasonic effect on the outer surface of the fan-shaped amplitude transformer module and improve the cleaning effect.

[0021] This invention, by equipping a high-speed camera and a vision processing system, monitors and optimizes the cleaning process in real time, dynamically adjusts the ultrasonic frequency and power, and achieves intelligent and precise control of the cleaning process. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a radial ultrasonic roller device for cleaning wire structures proposed in this invention.

[0023] Figure 2 This is a schematic diagram of the structure of an ultrasonic generator;

[0024] Figure 3 This is the left view of the fan-shaped amplitude transformer module;

[0025] Figure 4 This is a three-dimensional structural diagram of the fan-shaped amplitude transformer module;

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

[0027] Figure 6 This is the front view of the scroll wheel;

[0028] Figure 7 This is a schematic diagram showing the working state of the tensioner pulley;

[0029] Figure 8 This is a schematic diagram of the high-speed camera's working state;

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

[0031] Figure 10 This is a flowchart of the process of the present invention.

[0032] Explanation of reference numerals in the attached figures:

[0033] 1-Ultrasonic generator, 2-Vision processing system, 3-High-speed camera, 4-Wire, 5-Tensioning wheel, 6-Bearing with seat, 7-Rotating shaft, 8-Key, 9-Connecting wheel, 10-Ultrasonic transducer, 11-Fan-shaped amplitude transformer module, 12-Through-hole conductive slip ring, 13-Anti-rotation fixing device, 14-Hollow radiating strip, 15-Wire groove, 16-Coating. Detailed Implementation

[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: such as Figures 1-9As shown, a radial ultrasonic roller device for cleaning wire structures mainly includes an ultrasonic generator 1, a vision processing system 2, a high-speed camera 3, a tensioning wheel 5, a bearing 6, a rotating shaft 7, a connecting wheel 9, a through-hole conductive slip ring 12, an anti-rotation fixing device 13, a bracket, and a column. The roller is composed of multiple sets of support modules evenly distributed along the circumference 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 connecting wheel 9. The ultrasonic transducer 10 transmits ultrasonic waves radially to the wire groove 15 on the circumferential side 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 achieving the function of cleaning and drying. The connecting wheel 9 is fixedly installed on the rotating shaft 7, and both ends of the rotating shaft 7 are rotatably installed on the bracket through the bearing 6. The anti-rotation fixing device 13 is set on the bracket, and the through-hole conductive slip ring 12 is set on the rotating shaft 7. The outer ring of component 2 is a fixed ring, and the inner ring is a rotating ring. The ultrasonic generator 1 is connected to the fixed ring of the through-hole conductive slip ring 12 via a cable, and the rotating ring of the through-hole conductive slip ring 12 is connected to the ultrasonic transducer 10 via a cable. This prevents the cable from getting tangled during the rotation of the roller and ensures 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 implemented by those skilled in the art and will not be described in detail here. 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 electrically connected to the vision processing system 2. There are two tensioning wheels 5, both of which are set on the column and located on one side of the rotating shaft 7. One tensioning wheel 5 abuts against the wire 4 before the wire 4 passes 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 the droplets on the surface of the wire 4.

[0036] As one implementation method, the support includes two parallel square steel bars, and two bearings 6 are fixed to the directional steel bars by bolts. The ultrasonic generator 1 rectifies and filters the input 220V power frequency AC power into DC power, and after the high-frequency transformer amplifies the signal into a high-voltage AC signal, it drives the ultrasonic transducer 10. The ultrasonic transducer 10 can convert the high-voltage AC signal into high-frequency mechanical vibration (vibration frequency of 20-100kHz). The frequency and power of the ultrasonic vibration can be adjusted according to the wire size specifications, the characteristics of the attached droplets and the process requirements to achieve the best removal effect.

[0037] In one implementation, each set of support modules consists of a fan-shaped amplitude transformer module 11 and an ultrasonic transducer 10. The fan-shaped amplitude transformer module 11 is fixedly connected to the connecting wheel 9 via the ultrasonic transducer 10. A wire groove 15 is provided on the arc-shaped surface of the fan-shaped amplitude transformer module 11. The fan-shaped amplitude transformer module 11 is used to amplify the amplitude of ultrasonic vibration and enhance the transmission efficiency of ultrasonic radial vibration. The number of fan-shaped amplitude transformer modules 11 can be three, four, five, six, seven, eight, etc.

[0038] As one implementation method, see Figures 5-7 As shown, the connecting wheel 9 is a hollow hexagonal prism structure with a keyway. A keyway is also provided in the middle of the rotating shaft 7. The connecting wheel 9 is fixedly connected to the rotating shaft 7 via a key 8, achieving efficient power transmission and stable rotation. Six connecting holes are evenly distributed on the outer circumference of the connecting wheel 9 for installing six sets of support modules: six ultrasonic transducers 10 and six sector-shaped amplitude transformer modules 11. The ultrasonic transducers 10 and sector-shaped amplitude transformer modules 11 are connected by fully threaded screws. The connecting wheel 9 is bolted to the connecting steps (with through holes) on the side of the ultrasonic transducers 10, thus sequentially fixing the six sets of ultrasonic transducers 10 and sector-shaped amplitude transformer modules 11. The connecting wheel 9 drives the wire 4 to rotate via an external energy component, which in turn drives the roller to rotate; or it drives the rotating shaft 7 to rotate via an external energy component, which in turn drives the roller to rotate, thus driving the wire 4 to rotate. This design ensures the synchronization between the wire 4 and the roller, and also avoids misalignment and friction between the wire 4 and the fan-shaped amplitude transformer module 11, effectively preventing wear on the wire 4 and the fan-shaped amplitude transformer module 11 and extending the service life of the components. The six-group ultrasonic output design further improves the vibration efficiency. Furthermore, depending on different process requirements, under the action of the ultrasonic generator 1 with six independently controllable output channels, individual or multiple amplitude transformer modules can output vibration, optimizing energy consumption. As one implementation method, see [link to implementation details]. Figure 2 As shown, the six sets of ultrasonic transducers 10 and the sector-shaped amplitude transformer module 11 can be individually controlled by the six independent channels of the ultrasonic generator 1. The output ports of the six independent channels of the ultrasonic generator 1 are A, B, C, D, E, and F, respectively, and the input ports of the six sets of ultrasonic transducers 10 are a, b, c, d, e, and f, respectively. Figure 6 As shown.

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

[0040] As one implementation method, see Figure 4As shown, multiple hollow radial strips 14 are formed on the surface of the fan-shaped amplitude transformer module 11, and the hollow radial strips 14 are arranged along the radial direction of the fan-shaped amplitude transformer module 11. The width of the hollow radial strip 14 is approximately 1 / 4 of the acoustic wavelength. The purpose of setting the hollow radial strips 14 is to filter out unnecessary lateral vibrations, provide radial ultrasonic vibrations, and concentrate the ultrasonic vibrations to the radial surface of the wire 4, thereby realizing the atomization and detachment of droplets. The thickness of the fan-shaped amplitude transformer module 11 gradually decreases along the direction away from the connecting wheel 9. Figure 3 As shown, this design aims to achieve a high-power ultrasonic effect on the outer surface of the fan-shaped amplitude transformer module 11, effectively amplifying the amplitude of the ultrasonic waves and improving the efficiency of droplet removal. Furthermore, after determining the appropriate operating frequency according to different processing requirements, the geometric dimensions of the designed variable-thickness fan-shaped amplitude transformer module 11 also vary (considering the Poisson effect). By adjusting the geometric dimensions of the fan-shaped amplitude transformer module 11, the vibration effect can be optimized according to different wire specifications and droplet adhesion characteristics.

[0041] As one implementation method, see Figure 4 As shown, the surface of the wire groove 15 is provided with a plating layer 16, that is, a protective film is plated on the surface of the wire groove 15 to form a plating layer 16. The material of the plating layer 16 is consistent with the surface material of the wire 4 to avoid contact damage due to the different material properties of the two. It is used to contact the wire 4 to ensure that the wire 4 is stably stressed and fixed in the working position. The plating layer 16 contacts and compacts with the wire 4, transmitting the amplified radial ultrasonic vibration to the surface of the wire 4.

[0042] As one implementation method, see Figure 1 As shown, it also includes tensioning rollers 5, two in number, both located on one side of the rotating shaft 7. One tensioning roller 5 abuts against the wire 4 before it passes the roller, and the other tensioning roller 5 abuts against the wire 4 after it leaves the roller. The contact force between the wire 4 and the wire groove 15 on the fan-shaped amplitude transformer module 11 is adjusted according to the cleaning process of the wire 4 to ensure that the ultrasonic vibration can act evenly and effectively on the surface of the wire 4. To avoid contact damage caused by differences in material properties, the surface of the tensioning roller 5 and the surface of the wire 4 should be made of the same material. By adjusting the working position of the tensioning rollers 5, the contact pressure can be precisely controlled according to the diameter, surface characteristics, and cleaning requirements of the wire 4, thereby optimizing the cleaning effect. The installation of the tensioning rollers 5 is existing technology, which can be implemented by those skilled in the art and will not be described in detail here.

[0043] During the cleaning process, the high-frequency vibration emitted by the ultrasonic transducer 10 generates tension waves and cavitation effects in the liquid (cavitation effect refers to the formation and rapid collapse of tiny bubbles in the liquid under the action of ultrasonic high-frequency vibration, generating strong impacts and high pressure). The cavitation effect generates strong shock waves by forming and rapidly collapsing tiny bubbles. These shock waves effectively break up droplets adhering to the wire surface, causing them to detach from the wire 4 surface and atomize into particles. The tension waves and cavitation effect rapidly atomize the droplets adhering to the wire, thus completing the removal of droplets from the wire surface. Since the vibration frequency and power can be adjusted according to different wire materials and droplet characteristics, this invention can achieve efficient cleaning results in a short time, reducing droplet residue and avoiding the inefficiency and high energy consumption problems of traditional drying methods. By adjusting the ultrasonic frequency, power, and the geometry of the fan-shaped amplitude transformer module, it can adapt to different wire sizes, adhering droplet characteristics, and various process requirements, making it widely applicable.

[0044] To monitor the cleaning effect on the wire surface in real time, a vision processing system 2 and a high-speed camera 3 are also included. The vision processing system 2 is electrically connected to the high-speed camera 3 and to the ultrasonic generator 1. The high-speed camera 3 is used to capture the dynamic behavior of droplets on the wire surface, accurately capturing key parameters such as droplet morphology changes, movement trajectories, and removal effects before and after cleaning, providing visual data support for evaluating the effectiveness of the cleaning process. Two high-speed cameras 3 are used; one is located before the wire 4 passes the roller, and the other is located after the wire 4 leaves the roller. Figure 8 As shown. The vision processing system 2 has two sets of connection ports, namely I and II (see figure). Figure 9 As shown, 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, enabling real-time analysis of the microscopic morphology of wire surfaces captured by a high-speed camera. Through feature extraction and pattern recognition technologies, the system accurately quantifies key indicators such as droplet removal rate and surface cleanliness, and feeds the analysis results back to the ultrasonic generator 1 via a closed-loop control system. Based on a preset process parameter optimization algorithm, the system can dynamically adjust key parameters such as ultrasonic frequency, power, and action time, thereby achieving intelligent control and optimization of the cleaning process and ensuring stable and consistent surface treatment results.

[0046] Detailed operation steps:

[0047] Equipment installation (see) Figure 1Assemble the connecting wheel 9, rotating shaft 7, seated bearing 6, anti-rotation retainer 13, through-hole conductive slip ring 12, and other components according to design requirements to ensure the coaxiality and stability of the rotating shaft 7. Install six sets of ultrasonic transducers 10 and sector-shaped amplitude transformer modules 11, and secure them with fully threaded screws. Install tensioning wheels 5 at both ends of the wire 4 through the sector-shaped amplitude transformer modules 11 to adjust the contact force (see...). Figure 7 ).

[0048] Parameter settings: Based on the wire 4 dimensions, droplet characteristics, and process requirements, set the frequency (20-100kHz) and power of the ultrasonic generator 1. Start the vision processing system 2 and set target values ​​for key indicators such as droplet removal rate and surface cleanliness.

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

[0050] Cleaning effectiveness evaluation: High-speed camera 3 and vision processing system 2 were used to evaluate indicators such as droplet removal rate and surface cleanliness. Based on the evaluation results, the ultrasonic frequency, power, and action time were further optimized.

[0051] In another operational step, before cleaning begins, the equipment is installed, and the parameters of the ultrasonic generator and the preload of the tension wheel are set. The device is then started, and a high-speed camera dynamically captures images and transmits the image information to the vision processing system. The vision processing system analyzes the images, performs preprocessing to extract features and set standards, and then performs feature judgment. If the standards are met, the equipment continues to work until cleaning is complete. If the standards are not met, the ultrasonic generator parameters and the preload of the tension wheel are dynamically adjusted, and the above steps are repeated until the standards are met. Whether the standards are met can be determined by whether the droplet removal rate or the surface cleanliness meets the set standards. See [link to relevant documentation]. Figure 10 As shown.

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

[0053] Parameter settings: Ultrasonic frequency: 40kHz, Power: 200W, Cable length 4, Speed: 10m / min.

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

[0055] Performance evaluation: Droplet removal rate reached 98%, and surface cleanliness was significantly improved. Wire 4 showed no surface damage, meeting high-precision processing requirements.

[0056] It is particularly important to note 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 feedback from a high-speed camera and vision processing system, closed-loop control is achieved to ensure optimal removal results. Simultaneously, this device achieves efficient, energy-saving, and widely adaptable wire surface cleaning, significantly improving cleaning efficiency and avoiding the high energy consumption and low efficiency problems of traditional methods. Its superior cleaning effect makes it particularly suitable for different wire sizes, adhering droplet characteristics, and various process requirements, meeting the demands for efficient, environmentally friendly, and high-quality processing in industrial production, and has broad application prospects.

[0057] The above description, based on the embodiments shown in the figures, details the structure, features, and effects of the present invention. The above description is only a preferred embodiment of the present invention, but the present invention is not limited to the scope of implementation shown in the figures. Any changes made in accordance with the concept of the present invention, or equivalent embodiments modified to have equivalent changes, that do not exceed the spirit covered by the specification and figures, should be within the protection scope of the present invention.

Claims

1. A radial ultrasonic roller device for cleaning wire structures, characterized in that: The system includes rollers, an ultrasonic generator (1), a vision processing system (2), a high-speed camera (3), a tensioning wheel (5), a seated bearing (6), a rotating shaft (7), a connecting wheel (9), a through-hole conductive slip ring (12), an anti-rotation fixing device (13), a bracket, and a column. The rollers are composed of multiple sets of support modules evenly distributed along the circumferential direction of the connecting wheel (9). A wire groove (15) is provided on the circumferential side of the rollers, and an ultrasonic transducer (10) is provided inside the rollers. The ultrasonic transducer (10) transmits ultrasonic waves radially to the wire groove (15) on the circumferential side of the rollers, applying vibration to the wire (4) passing through the wire groove (15), causing the liquid on the wire (4) to atomize and fall off. The connecting wheel (9) is fixedly installed on the rotating shaft (7), and both ends of the rotating shaft (7) are rotatably installed on the bracket through the seated bearing (6). The anti-rotation fixing device (13) is set on the bracket, and the through-hole conductive slip ring (12) is set on the bracket. On the rotating shaft (7), the outer part of the through-hole conductive slip ring (12) is a fixed ring, and the inner part is a rotating ring. The ultrasonic generator (1) is connected to the fixed ring of the through-hole conductive slip ring (12) via a cable, and the rotating ring of the through-hole conductive slip ring (12) is connected to the ultrasonic transducer (10) via a cable. The anti-rotation fixing device (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 vision processing system (2) is electrically connected; there are two tensioning wheels (5), both of which are set on the column and located on one side of the rotating shaft (7). One tensioning wheel (5) abuts against the wire (4) before the wire (4) passes 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); Each set of support modules consists of a fan-shaped amplitude transformer module (11) and an ultrasonic transducer (10); the fan-shaped amplitude transformer module (11) is fixedly connected to the connecting wheel (9) through the ultrasonic transducer (10); the wire groove (15) is provided on the arc surface of the fan-shaped amplitude transformer module (11); The thickness of the fan-shaped amplitude module (11) gradually decreases in the direction away from the connecting wheel (9).

2. The radial ultrasonic roller device for cleaning wire structures according to claim 1, characterized in that: The fan-shaped amplitude module (11) is provided with a plurality of hollow radial strips (14), which are arranged along the radial direction of the fan-shaped amplitude module (11).

3. The radial ultrasonic roller device for cleaning wire structures according to claim 2, characterized in that: The ultrasonic transducer (10) includes a rear cover plate, a piezoelectric ceramic and an amplitude transformer; the high-voltage AC signal transmitted by the cable on one side of the rotating ring of the through-hole conductive slip ring (12) drives the ultrasonic transducer (10) to work and generate high-frequency mechanical vibration.

4. A radial ultrasonic roller device for cleaning wire structures according to claim 3, characterized in that: The fan-shaped amplitude converter (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 converter (11) is greater than or equal to three.

5. A radial ultrasonic roller device for cleaning wire structures according to claim 4, characterized in that: The ultrasonic generator (1) includes multiple independently controllable output channels, each of which corresponds to one of the ultrasonic transducers (10).

6. A radial ultrasonic roller device for cleaning wire structures according to claim 5, characterized in that: It also includes a key (8), the roller is connected to the rotating shaft (7) via the key (8); the wire (4) is driven to rotate by an external energy component, and the wire (4) drives the roller to rotate; or the rotating shaft (7) is driven to rotate by an external energy component, and the rotating shaft (7) drives the roller to rotate, thereby driving the wire (4) to rotate, so as to achieve overall cleaning and drying of the wire (4).

7. A radial ultrasonic roller device for cleaning wire structures according to claim 6, characterized in that: There are two high-speed cameras (3), one of which is located before the wire (4) passes the roller, and the other is located after the wire (4) leaves the roller.

8. A radial ultrasonic roller device for cleaning wire structures according to claim 1, characterized in that: The surface of the wire groove (15) is provided with a plating layer (16), and the material of the plating layer (16) is the same as the surface material of the wire (4).

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