Flat type flexible energy-saving cable special-shaped copper core coating forming device and method

Abstract

The invention relates to the technical field of cable production, in particular to a flat type flexible energy-saving cable special-shaped copper core cladding forming device and method, and the device comprises a copper core extrusion forming device, a first cladding machine and a second cladding machine which are sequentially arranged in the sheet copper bar conveying direction. The prepared special-shaped copper core is a conductor of a circular arc special-shaped structure, by utilizing the skin effect, the current bearing capacity is improved by about 10% compared with a traditional busbar with the same specification, the current-carrying capacity is improved by more than 15% compared with a cable with the same sectional area, an ultra-large current-carrying capacity product with the current-carrying capacity reaching up to 8000A can be produced, the power transmission efficiency is remarkably improved, and the high-load power transmission requirement is met; under the conditions of the same sectional area and the same current-carrying capacity, about 8% of copper material is consumed by the conductor compared with the traditional busbar and cable in the production process, the production cost is reduced, and the resource utilization efficiency is improved; during installation, the bending radius is small, bending is easy, and the installation difficulty is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of cable production, and particularly relates to a device and method for forming an abnormal-shaped copper core of a flat flexible energy-saving cable by coating. Background Art

[0002] In power transmission and power distribution systems, busbars are mainly important components for carrying and distributing large currents and large cross-sections. Traditional busbars are usually made of relatively thick copper bars, with no insulation or sheath on the conductor surface, resulting in high material costs, high energy consumption, and low safety. At the same time, due to the fixed shape and size of traditional busbars, the installation flexibility and installation efficiency in specific environments are limited. Therefore, a device and method for forming an abnormal-shaped copper core of a flat flexible energy-saving cable by coating are proposed to improve the current-carrying capacity and use safety, reduce energy loss, and be applicable to different installation and use environments. Summary of the Invention

[0003] Aiming at the problems in the prior art, the present invention provides a device and method for forming an abnormal-shaped copper core of a flat flexible energy-saving cable by coating, which can improve the current-carrying capacity and use safety, reduce energy loss, and be applicable to different installation and use environments.

[0004] The technical solution adopted by the present invention to solve its technical problems is a device for forming an abnormal-shaped copper core of a flat flexible energy-saving cable by coating, which includes a copper core extrusion forming device, a first coater, and a second coater arranged in sequence along the conveying direction of the thin copper strip. The copper core extrusion forming device includes a housing with a feeding port and a discharging port respectively arranged on both sides. Inside the housing, several groups of rotating rods distributed along the conveying direction of the thin copper strip are connected in an up-and-down movable manner at the upper and lower parts. The distance between the adjacent rotating rods above and below gradually decreases along the conveying direction of the thin copper strip. A roller cutter assembly is slidably connected to the rotating rods. A driving mechanism for driving the rotating rods to rotate after they move towards the thin copper strip is arranged on the side of the housing. A conveying assembly for conveying the copper core is arranged on one side of the housing close to the feeding port.

[0005] Specifically, the roller cutter assembly includes a sleeve slidably connected to the rotating rod, and a first extrusion roller and a second extrusion roller installed on the sleeve. Vertical chutes corresponding to both ends of the rotating rod are arranged on the side of the housing. One end of the rotating rod close to the driving mechanism passes through the chute and is slidably connected to the chute. Both ends of the rotating rod and the sleeve away from each other are connected to the housing through telescopic mechanisms;

[0006] Several groups of circular arc-shaped annular grooves are arranged on the first extrusion roller, and several groups of trapezoidal annular grooves are arranged on the second extrusion roller.

[0007] Specifically, the driving structure includes a turbine connected to one end of a rotating rod, and a worm horizontally arranged and meshing with the turbine. Both ends of the worm are rotatably connected to support plates fixedly connected to the outside of the housing. One end of the worm is connected to the output end of a driving motor, and the driving motor is installed on the support plate.

[0008] Specifically, an eddy current heating ring is provided between adjacent sleeves, and a thin copper busbar passes through the eddy current heating ring; an air inlet joint for accessing inert gas is connected and communicated at the top of one side of the housing away from the feed port.

[0009] Specifically, the adjusting structure includes a vertically arranged moving plate. One end of the sleeve is slidably connected to one side of the moving plate. A fixed end of an electro-hydraulic telescopic rod is fixedly connected to the side of the moving plate away from the sleeve, and a vertically arranged leg is fixedly connected to the fixed end of the electro-hydraulic telescopic rod;

[0010] One end of the rotating rod is fixedly connected to a first sealing plate. One end of the sleeve is slidably connected to a second sealing plate, and the second sealing plate is slidably connected to the outside of the housing. The first sealing plate and the second sealing plate respectively correspond to the sliding grooves on both sides of the housing.

[0011] Specifically, several groups of horizontally distributed conveying rollers are provided on both the upper and lower sides of the housing near the feed port. Both ends of the conveying rollers are rotatably connected to vertically arranged moving rods. A horizontally arranged mounting plate is fixedly connected to the outside of the housing. An activity groove is provided on the mounting plate. One end of the moving rod passes through the activity groove and is fixedly connected to a pressing plate. A compression spring is provided on the side of the mounting plate close to the pressing plate. A pressing control device for controlling the telescopic mechanism is provided between the mounting plate and the pressing plate.

[0012] Specifically, the telescopic mechanism includes activity cylinders vertically fixed on both sides of the housing. Two horizontally arranged electromagnets are slidably connected in the activity cylinders. The two electromagnets are magnetically adsorbed in the initial state. Activity rods are vertically arranged on the sides of the electromagnets away from each other. A return spring is fixedly connected between the side of the electromagnet close to the activity rod and the inner wall of the piston cylinder. A first sliding ring fixedly connected to the end of the activity rod is slidably connected to the rotating rod. A second sliding ring fixedly connected to the end of the activity rod is slidably connected to the sleeve;

[0013] The pressing control device includes several groups of pressing switches arranged on the upper surface of the mounting plate. The lower surface of the pressing plate is in pressing contact with the pressing switches, and the pressing switches are used to control the electromagnets.

[0014] Specifically, two groups of vertically symmetrically arranged conical air outlet housings are provided on the upper and lower sides of the housing near the feed port. Air outlet openings for blowing air to the thin copper busbar are provided in the contraction sections of the conical air outlet housings, and the conical air outlet housings are communicated with the inside of the housing.

[0015] Specifically, on one side of the shell near the discharge port, there are auxiliary rollers symmetrically arranged up and down; between adjacent sleeves on the left and right, there are vertically arranged positioning rollers. The positioning rollers are in rolling contact with both sides of the thin copper strip. Both ends of the positioning rollers are rotatably connected to connecting rods, and the ends of the connecting rods away from the positioning rollers are fixedly connected to the inner wall of the shell.

[0016] The method for forming an abnormally shaped copper core of a flat flexible energy-saving cable adopts the above-mentioned device for forming an abnormally shaped copper core of a flat flexible energy-saving cable, and specifically includes the following steps:

[0017] Step 1: Place the thin copper strip near the feed port of the copper core extrusion forming device, start the conveying component of the copper core extrusion forming device, and convey the thin copper strip from the feed port to the inside of the shell through the conveying component;

[0018] Step 2: The driving mechanism drives the rotating rod to rotate, driving the roller cutter assembly to extrude and process the thin copper strip, so that the thin copper strip gradually forms an abnormally shaped copper core during the conveying process, and the processed abnormally shaped copper core is sent out from the discharge port;

[0019] Step 3: Convey the abnormally shaped copper core sent out from the discharge port of the copper core extrusion forming device to the first coater, and the first coater performs a coating operation on the abnormally shaped copper core to complete the coating of the inner heat dissipation layer on the surface of the abnormally shaped copper core;

[0020] Step 4: Convey the abnormally shaped copper core after the first coating to the second coater, and the second coater performs a coating operation on the abnormally shaped copper core after the first coating again, and completes the coating of the insulating layer on the basis of the first coating.

[0021] The beneficial effects of the present invention are as follows:

[0022] (1) For the device and method for forming an abnormally shaped copper core of a flat flexible energy-saving cable of the present invention, the prepared abnormally shaped copper core is a conductor with a circular arc abnormally shaped structure. Utilizing the skin effect, compared with the traditional busbar of the same specification, the current-carrying capacity is increased by about 10%. Compared with the cable of the same cross-sectional area, the current-carrying capacity is increased by more than 15%. It can produce super-large current-carrying capacity products with a current-carrying capacity of up to 8000A, significantly improving the power transmission efficiency and meeting the high-load power transmission requirements; under the conditions of the same cross-sectional area and the same current-carrying capacity, during the production process, the conductor consumes about 8% less copper than the traditional busbar and cable, reducing the production cost and improving the resource utilization efficiency; during installation, the bending radius is small and it is easy to bend, reducing the installation difficulty.

[0023] (2) For the device and method for forming an abnormally shaped copper core of a flat flexible energy-saving cable of the present invention, through the linkage of the conveying roller, the extrusion plate, the pressing control device and the telescopic mechanism, the distance between the roller cutter assembly and the copper strip can be automatically adjusted according to the thickness of the copper strip, realizing the adaptive processing of copper strips with different thicknesses. This automatic adjustment mechanism improves the production efficiency, reduces manual intervention, and at the same time ensures the product quality.

[0024] (3) For the special-shaped copper core coating forming device and method of the flat flexible energy-saving cable of the present invention, the inert gas forms multiple functions of protection, heat dissipation and cleaning in the shell. On the one hand, it isolates oxygen to prevent the copper row from oxidizing; on the other hand, the gas discharged from the discharge port dissipates heat from the copper row and preheats it, facilitating subsequent coating. The gas discharged from the conical air outlet shell can also blow off impurities, optimizing the production process.

[0025] (4) For the special-shaped copper core coating forming device and method of the flat flexible energy-saving cable of the present invention, the first extrusion roller and the second extrusion roller in the roller cutter assembly can be slid and switched. With the cooperation of the adjustment structure, it can quickly meet diverse production requirements and improve the flexibility of production; the cooperation of the electric hydraulic telescopic rod, the moving plate and the first sealing plate and the second sealing plate in the adjustment structure can not only adjust the position of the roller cutter assembly, but also maintain the sealing performance in the shell, ensure the environment for the extrusion forming of the copper core, and ensure the forming quality of the copper core. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The present invention will be further described below in conjunction with the drawings and embodiments.

[0027] Figure 1 Is an isometric view of the present invention;

[0028] Figure 2 Is an isometric view of another perspective of the present invention;

[0029] Figure 3 Is a side view of the present invention;

[0030] Figure 4 Is Figure 2 An enlarged view of area A;

[0031] Figure 5 Is Figure 2 An enlarged view of area B;

[0032] Figure 6 Is a schematic diagram of the internal structure of the housing of the present invention;

[0033] Figure 7 Is a schematic top view of the internal structure of the housing of the present invention;

[0034] Figure 8 Is Figure 6 An enlarged view of area C;

[0035] Figure 9 Is Figure 6 An enlarged view of area D;

[0036] Figure 10 Is a schematic diagram of the rotating rod structure of the present invention;

[0037] Figure 11Side view of the arc-shaped special-shaped copper core of the present invention;

[0038] Figure 12 Side view of the trapezoidal special-shaped copper core of the present invention;

[0039] Figure 13 Cross-sectional view of the arc-shaped special-shaped copper core cable of the present invention;

[0040] In the figure: 1. First covering machine; 2. Second covering machine; 3. Feed inlet; 4. Discharge outlet; 5. Shell; 6. Rotating rod; 7. Sleeve; 8. First extrusion roller; 9. Second extrusion roller; 10. Chute; 11. Connecting rod; 12. Moving plate; 13. Electric hydraulic telescopic rod; 14. Leg; 15. First sealing plate; 16. Second sealing plate; 17. Turbine; 18. Worm; 19. Support plate; 20. Driving motor; 21. Eddy current heating ring; 22. Air inlet joint; 23. Conveyor roller; 24. Moving rod; 25. Mounting plate; 26. Activity slot; 27. Extrusion plate; 28. Extrusion spring; 29. Activity cylinder; 30. Electromagnet; 31. Activity rod; 32. Reset spring; 33. First sliding ring; 34. Second sliding ring; 35. Press switch; 36. Conical air outlet shell; 37. Air outlet; 38. Auxiliary roller; 39. Positioning roller. Detailed implementation manners

[0041] In order to make the technical means, creative features, achieved purposes and effects of the present invention easy to understand, the present invention will be further described below in conjunction with specific implementation manners.

[0042] In order to improve the current-carrying capacity and use safety, reduce energy loss, and be applicable to different installation and use environments, as an embodiment of the present invention, as Figure 1 , Figure 2 , Figure 3 , Figure 4 , Figure 6 shown, the special-shaped copper core covering and forming device and method of the flat flexible energy-saving cable of the present invention include a copper core extrusion forming device, a first covering machine 1, and a second covering machine 2 arranged in sequence along the conveying direction of the thin copper strip; the copper core extrusion forming device includes a shell 5 with a feed inlet 3 and a discharge outlet 4 respectively arranged on both sides, and several groups of rotating rods 6 distributed along the conveying direction of the thin copper strip are vertically movably connected to the upper and lower parts inside the shell 5. The distance between the upper and lower adjacent rotating rods 6 gradually decreases along the conveying direction of the thin copper strip. A roller cutter assembly is slidably connected to the rotating rod 6. A driving mechanism for driving the rotating rod 6 to rotate after the rotating rod 6 moves towards the thin copper strip is arranged on the side surface of the shell 5. A conveying component for conveying the copper core is arranged on one side of the shell 5 close to the feed inlet 3.

[0043] During use, in the process of cable production, first place the thin copper strip on the conveying component, and then start the conveying component. At this time, the conveying component smoothly feeds the thin copper strip into the interior of the housing 5 from the feed port 3. When the thin copper strip enters the housing 5, start the driving mechanism to drive the rotating rod 6 to rotate. During the rotation process, the roller cutter assembly applies a uniform extrusion force to the thin copper strip, causing the thin copper strip to gradually deform and finally form the required circular arc-shaped special-shaped structure;

[0044] When the thin copper strip enters the housing 5, it is necessary to adjust the up and down position of the rotating rod 6 according to the thickness of the thin copper strip and the forming requirements. When ensuring that the distance between the roller cutter assembly and the copper strip is appropriate, without adjusting the position of the rotating rod 6, the roller cutter assembly can apply an extrusion force to the copper strip to meet the forming requirements of the copper core; However, if the thickness of the thin copper strip is relatively thick, at this time, if the rotating rod 6 still remains in the initial position, some of the roller cutter assemblies on the side far from the feed port 3 will generate too much extrusion force on the copper strip during operation, which is likely to cause excessive deformation of the copper strip, seriously affecting the forming quality of the copper core, resulting in deviations in the shape, dimensional accuracy, etc. of the copper core, reducing the product quality, and it is difficult to ensure the consistency of the product. Therefore, when the thickness of the thin copper strip is relatively thick, it is necessary to timely adjust the position of some of the rotating rods 6 to keep an appropriate distance between the roller cutter assembly and the copper strip, ensuring that during the processing, the extrusion force applied by the roller cutter assembly to the copper strip is moderate, ensuring that the copper strip is formed according to the predetermined shape and size, and improving the quality and consistency of the product;

[0045] The extruded copper core will enter the subsequent processing equipment in sequence. First, the copper core enters the first coater 1, and the first coater 1 is responsible for the first coating operation on the copper core. During this process, the inner heat dissipation layer is coated to ensure that the copper core has good heat dissipation performance. The copper core that has completed the first coating then enters the second coater 2, and the second coater 2 performs the second coating operation, mainly completing the coating of the insulation layer to provide reliable insulation for the cable. After the insulation layer is coated, according to the specific requirements of the product, the selection can be made to perform the coating of the armor layer to enhance the mechanical strength and protection performance of the cable. After the armor layer is coated, then install the outer sheath layer on the cable, thus completing the entire cable processing process.

[0046] To meet diverse production requirements, for example, such as Figure 6 、 Figure 7 、 Figure 8 、 Figure 9 、 Figure 10 、 Figure 11 、 Figure 12 、 Figure 13As shown, the present invention also includes that the roller cutter assembly includes a sleeve 7 slidably connected to the rotating rod 6, and a first squeezing roller 8 and a second squeezing roller 9 installed on the sleeve 7, and a side of the shell 5 is provided with a vertically arranged slide groove 10 corresponding to the two ends of the rotating rod 6, and the end of the rotating rod 6 close to the driving mechanism passes through the slide groove 10 and is slidably connected to the slide groove 10, and the ends of the rotating rod 6 and the sleeve 7 away from each other are connected to the shell 5 through a telescopic mechanism;

[0047] The first squeezing roller 8 is provided with a plurality of groups of circular arc-shaped annular grooves, and the second squeezing roller 9 is provided with a plurality of groups of trapezoidal annular grooves.

[0048] When in use, the required forming shape is determined according to the product design requirements, the sleeve 7 is driven to slide along the rotating rod 6, and the first extrusion roller 8 with arc-shaped annular grooves installed on the sleeve 7 is moved to a suitable processing position; if a trapezoidal extrusion effect is required, the second extrusion roller 9 is moved to the corresponding working position. In this process, the movement of the sleeve 7 realizes the selection of a suitable roller body and meets the diversified production needs;

[0049] At the same time, the conveying assembly smoothly delivers the thin copper bar from the feed port 3 into the shell 5. During the copper bar conveying process, the telescopic mechanism drives the rotating rod 6 at the corresponding position to move, thereby adjusting the position of the rotating rod 6 to ensure that the roller knife assembly and the thin copper bar maintain a suitable distance;

[0050] The driving mechanism drives the rotating rod 6 to rotate, thereby causing the first extrusion roller 8 or the second extrusion roller 9 installed on the sleeve 7 to start rotating. If the first extrusion roller 8 is involved in the processing, the arc-shaped annular groove will extrude a precise arc shape on the thin copper busbar; if the second extrusion roller 9 is put into operation, the trapezoidal annular groove will extrude a trapezoid that meets the requirements on the thin copper busbar, effectively ensuring the smooth progress of the production process while ensuring the high quality and consistency of the products.

[0051] In order to facilitate the operation of the drive roller cutter assembly, for example, Figure 3 , Figure 6 As shown, the present invention also includes a driving structure including a turbine 17 connected to one end of a rotating rod 6, and a worm 18 horizontally arranged and meshing with the turbine 17, both ends of the worm 18 are rotatably connected to a support plate 19 fixed to the outer side of the housing 5, one end of the worm 18 is connected to the output end of a driving motor 20, and the driving motor 20 is mounted on the support plate 19.

[0052] When in use, the driving motor 20 drives the worm 18 to rotate, the worm 18 drives the turbine 17 to rotate synchronously, the turbine 17 drives the rotating rod 6 and the sleeve 7 sleeved on the rotating rod 6 to rotate together, and the roller cutter assembly installed on the sleeve 7 enters the working state to extrude the thin copper bar;

[0053] During the extrusion process, the roller-knife assembly applies a uniform extrusion force to the thin copper busbar, which causes the thin copper busbar to gradually undergo plastic deformation according to predetermined design requirements, and finally form into the required arc-shaped special-shaped structure or trapezoid.

[0054] In order to improve the overall performance and service life of the cable, for example, Figure 2 , Figure 6 , Figure 7 , Figure 8 As shown, the present invention also includes that an eddy current heating ring 21 is provided between adjacent sleeves 7, and the thin copper bar passes through the eddy current heating ring 21; the top of the side of the shell 5 away from the feed port 3 is connected to an inert gas inlet connector 22.

[0055] When in use, before the thin copper bar starts to be conveyed, the eddy current heating ring 21 is first turned on, and the thin copper bar is conveyed by the conveying assembly and passes through the eddy current heating ring 21. At the same time, the inert gas valve connected to the air inlet connector 22 is opened to allow the inert gas to enter the shell 5 through the air inlet connector 22. The eddy current heating ring 21 heats the thin copper bar, so that the temperature of the thin copper bar is increased, the plasticity of the material is enhanced, and when the roller cutter assembly extrude the thin copper bar, it is more likely to deform, thereby reducing the demand for extrusion force and reducing the wear of the equipment.

[0056] The inert gas introduced from the air inlet connector 22 fills the interior of the housing 5, forming an inert gas protection around the thin copper busbar. This layer of protective gas can effectively isolate oxygen in the air, prevent the thin copper busbar from being oxidized during the heating and extrusion process, ensure that the conductivity and other physical and chemical properties of the thin copper busbar are not affected, and improve the overall performance and service life of the cable;

[0057] When the gas enters the shell 5 through the air inlet connector 22, part of the gas will naturally be discharged from the outlet 4 because the air inlet connector 22 is located close to the outlet 4. The discharged gas forms an airflow at the outlet 4, which plays a role in dissipating air and dissipating heat for the thin copper busbar that has been shaped. On the one hand, it can promptly take away the excess heat generated by the thin copper busbar during the shaping process to prevent the internal structure of the thin copper busbar from changing due to excessive temperature or affecting the subsequent processing quality; on the other hand, this airflow does not reduce the temperature of the thin copper busbar indefinitely, but keeps the thin copper busbar within a certain suitable temperature range, so that the thin copper busbar enters the first coating machine 1 for preheating. The appropriate preheating temperature helps to improve the fit between the coating material and the thin copper busbar, so that the inner heat dissipation layer can be more tightly and evenly attached to the surface of the thin copper busbar during the coating process, thereby enhancing the heat dissipation effect while improving the performance and quality of the entire cable, ensuring the continuity and efficiency of the cable production process.

[0058] In order to ensure the sealing of the housing 5, for example, Figure 2 ,Figure 5 , Figure 6 , Figure 9 , Figure 10 As shown in Figure 9 , Figure 10 , etc., the present invention further includes that the adjusting structure includes a moving plate 12 arranged vertically. One end of the sleeve 7 is slidably connected to one side of the moving plate 12. A side of the moving plate 12 away from the sleeve 7 is fixedly connected with an electro-hydraulic telescopic rod 13. The fixed end of the electro-hydraulic telescopic rod 13 is fixedly connected with a vertically arranged leg 14;

[0059] One end of the rotating rod 6 is fixedly connected with a first sealing plate 15. One end of the sleeve 7 is slidably connected with a second sealing plate 16. The second sealing plate 16 is slidably connected to the outside of the housing 5. The first sealing plate 15 and the second sealing plate 16 respectively correspond to the sliding grooves 10 on both sides of the housing 5.

[0060] During use, to meet different processing requirements, the position of the sleeve 7 in the roller cutter assembly needs to be adjusted. At this time, the electro-hydraulic telescopic rod 13 can be started to drive the movement of the moving plate 12. Driven by the moving plate 12, the sleeve 7 will slide smoothly along the rotating rod 6, so as to accurately move the first pressing roller 8 or the second pressing roller 9 installed on the sleeve 7 to a suitable processing station;

[0061] During the movement of the sleeve 7, it remains slidably connected to the second sealing plate 16. During this period, the first sealing plate 15 and the second sealing plate 16 cooperate with the sliding grooves 10 on both sides of the housing 5 respectively, which can maintain the sealing performance of the inner wall of the housing 5, prevent external pollutants such as dust and impurities from invading the housing 5, ensure the environment for copper core extrusion molding, and ensure the forming quality of the copper core;

[0062] In addition, when the telescopic mechanism drives the rotating rod 6 to adjust the position in the vertical direction, the corresponding relationship between the first sealing plate 15 and the second sealing plate 16 and the sliding groove 10 can continuously ensure the sealing performance of the inner wall of the housing 5, avoid damaging the closed environment inside the housing 5 due to the movement of the rotating rod 6. At the same time, when the rotating rod 6 moves, one end of the sleeve 7 is slidably connected to one side of the moving plate 12, so as to facilitate the adjustment of the position of the rotating rod 6.

[0063] To ensure the forming quality of the copper core, for example, as Figure 2 , Figure 3 , Figure 4 , as shown in the figure, the present invention further includes that several groups of horizontally distributed conveying rollers 23 are arranged up and down on one side of the housing 5 close to the feeding port 3. Both ends of the conveying roller 23 are rotatably connected with vertically arranged moving rods 24. A horizontally arranged mounting plate 25 is fixedly connected to the outside of the housing 5. An activity groove 26 is provided on the mounting plate 25. One end of the moving rod 24 passes through the activity groove 26 and is fixedly connected with a pressing plate 27. A pressing spring 28 is provided on one side of the mounting plate 25 close to the pressing plate 27. A pressing control device for controlling the telescopic mechanism is provided between the mounting plate 25 and the pressing plate 27.

[0064] When in use, the thin copper bar is transported by the conveying roller 23, and the thin copper bar to be processed is transported into the housing 5 for shaping processing;

[0065] If the thickness of the thin copper bar is thin, the telescopic mechanism does not adjust the position of the rotating rod 6, and the roller-knife assembly can apply an extrusion force to the thin copper bar to meet the forming requirements of the copper core; however, if the thickness of the thin copper bar is thick, the surface of the thin copper bar squeezes the conveying roller 23 and drives the conveying roller 23 to move. When the conveying roller 23 moves, it relies on the moving rod 24 to drive the extrusion plate 27 to move up synchronously. At the same time, when the extrusion plate 27 moves up, it drives the extrusion spring 28 to store force. When the extrusion plate 27 moves up to different heights, the pressing control device drives the corresponding telescopic mechanism to work, and relies on the corresponding telescopic mechanism to drive the corresponding rotating rod 6 to move, so that the rotating rod 6 with a smaller upper and lower spacing is separated, so that the corresponding roller-knife assembly does not contact the thin copper bar, avoids the thin copper bar from being damaged by excessive extrusion, and ensures that the thicker thin copper bar is gradually shaped according to the preset shape and size, thereby ensuring the forming quality of the copper core.

[0066] In order to ensure that the thin copper bar can be processed and formed under the appropriate number of roller cutter assemblies, for example, Figure 2 , Figure 3 , Figure 5 , Figure 10 As shown, the present invention also includes that the telescopic mechanism includes a movable cylinder 29 vertically fixed on both sides of the shell 5, and two groups of horizontally arranged electromagnets 30 are slidably connected in the movable cylinder 29. The two groups of electromagnets 30 are magnetically adsorbed in the initial state, and the sides of the electromagnets 30 that are far away from each other are each provided with a vertically arranged movable rod 31, and a return spring 32 is fixedly connected between the side of the electromagnet 30 close to the movable rod 31 and the inner wall of the piston cylinder, and a first sliding ring 33 fixedly connected to the end of the movable rod 31 is slidably connected to the rotating rod 6, and a second sliding ring 34 fixedly connected to the end of the movable rod 31 is slidably connected to the sleeve 7;

[0067] The pressing control device includes a plurality of pressing switches 35 arranged on the upper surface of the mounting plate 25 . The lower surface of the pressing plate 27 is in pressing contact with the pressing switches 35 . The pressing switches 35 are used to control the electromagnet 30 .

[0068] When in use, when the thin copper bar is conveyed to the housing 5 for processing by the conveying roller 23, if the thickness of the thin copper bar is relatively thin, the extrusion plate 27 will not exert sufficient extrusion on the press switch 35, the electromagnet 30 is in the initial state, the first sliding ring 33 and the second sliding ring 34 on the rotating rod 6 and the sleeve 7 remain in the same position, and the roller cutter assembly normally applies extrusion force to the copper bar for shaping processing;

[0069] If the thickness of the thin copper strip is relatively thick, the thin copper strip contacts the conveying roller 23 and drives the conveying roller 23 to move. The conveying roller 23 drives the pressing plate 27 to move through the movable rod 31. During the movement of the pressing plate 27, the extrusion on the corresponding pressing switch 35 will gradually decrease. When the pressing plate 27 moves to a certain position, it no longer extrudes the corresponding pressing switch 35, and the pressing switch 35 is triggered to turn off the electromagnet 30 in the corresponding movable cylinder 29. After turning off the magnetic suction force of the electromagnet 30, the two electromagnets 30 no longer magnetically adsorb. At the same time, under the elastic force of the return spring 32, the electromagnet 30 drives the movable rod 31 connected to it to move. The movement of the movable rod 31 will cause the first sliding ring 33 on the rotating rod 6 and the second sliding ring 34 on the sleeve 7 to generate displacements, thereby driving the rotating rod 6 and the sleeve 7 to adjust their positions, increasing the distance between the roller cutter assembly and the thick copper strip, avoiding the roller cutter assembly with a relatively small original distance from generating extrusion force on the thin copper strip, and ensuring that the thin copper strip can be processed and formed under the appropriate number of roller cutter assemblies;

[0070] When the processed thin copper strip disengages from the conveying roller 23, the extrusion force on the conveying roller 23 from the copper strip is eliminated. At this time, the elastic potential energy of the extrusion spring 28 is released, driving the pressing plate 27 to return to its initial state. After that, the lower surface of the pressing plate 27 presses against the pressing switch 35 again, triggering the pressing switch 35, and then starting the electromagnet 30 in the corresponding movable cylinder 29. After the electromagnet 30 is powered on, it generates magnetism, and the two electromagnets 30 adsorb each other. The adsorption force causes the movable rod 31 to generate a displacement. The movement of the movable rod 31 drives the first sliding ring 33 on the rotating rod 6 and the second sliding ring 34 on the sleeve 7 to move synchronously, thereby causing the rotating rod 6 and the sleeve 7 to return to their initial relative positions, and finally realizing the reset of the roller pressing assembly to its initial working state, preparing for the subsequent new round of thin copper strip processing

[0071] Exemplarily, as Figure 2 、 Figure 4 shown, the present invention further includes that on both the upper and lower sides of the housing 5 near the feed port 3, there are two groups of tapered air outlet housings 36 arranged symmetrically up and down. The contraction sections of the tapered air outlet housings 36 are each provided with an air outlet 37 for blowing air on the thin copper strip, and the tapered air outlet housings 36 are communicated with the inside of the housing 5.

[0072] During use, after the inert gas enters the housing 5 through the air inlet joint 22, part of the inert gas is discharged from the discharge port 4. During the process of escaping from the housing 5, it produces an air outlet and heat dissipation effect on the surface of the already shaped thin copper strip, which can timely take away the heat accumulated by the thin copper strip during the shaping process, effectively control the temperature of the thin copper strip, and avoid the change of the material properties of the thin copper strip due to excessive temperature;

[0073] Another part of the inert gas is discharged from the conical air outlet housing 36. Since the air outlet 37 of the conical air outlet housing 36 faces the thin copper strip, when the gas is discharged, it will directly act on the surface of the thin copper strip. The flowing inert gas generates sufficient impact force, which can effectively blow off various impurities adsorbed by the thin copper strip during the feeding stage, such as dust, debris, etc., effectively preventing impurities from entering the subsequent processing links, avoiding interference of impurities with processes such as extrusion molding and coating of the thin copper strip, optimizing the entire cable production process, and improving the reliability and stability of the product.

[0074] Exemplarily, such as Figure 3 、 Figure 6 、 Figure 7 、 Figure 8 As shown, the present invention further includes that on one side of the housing 5 near the discharge port 4, there are symmetrically arranged auxiliary rollers 38 up and down; between adjacent sleeves 7 left and right, there is a vertically arranged positioning roller 39, and the positioning roller 39 is in rolling contact with both sides of the thin copper strip. Both ends of the positioning roller 39 are rotatably connected to a connecting rod 11, and one end of the connecting rod 11 away from the positioning roller 39 is fixedly connected to the inner wall of the housing 5.

[0075] During use, the positioning roller 39 plays a positioning role for the thin copper strip by rolling contact with both sides of the thin copper strip, preventing the thin copper strip from shifting or misaligning during the extrusion process, and improving the precision of extrusion molding of the thin copper strip;

[0076] The auxiliary roller 38 is located near the discharge port 4 and plays an auxiliary output role for the thin copper strip that is about to complete processing, being able to share part of the frictional force of the thin copper strip during the discharging process, enabling the thin copper strip to be sent out from the discharge port 4 more smoothly, avoiding surface scratches or deformation of the thin copper strip due to excessive resistance during discharging, and improving the surface quality and production efficiency of the product.

[0077] The present invention also provides a method for forming and coating a special-shaped copper core of a flat flexible energy-saving cable, using the above-mentioned device for forming and coating a special-shaped copper core of a flat flexible energy-saving cable, which specifically includes the following steps:

[0078] Step 1: Place the thin copper strip near the feeding port 3 of the copper core extrusion molding device, start the conveying component of the copper core extrusion molding device, and convey the thin copper strip from the feeding port 3 to the inside of the housing 5 through the conveying component;

[0079] Step 2: The driving mechanism drives the rotating rod 6 to rotate, driving the roller cutter assembly to perform extrusion processing on the thin copper strip, so that the thin copper strip gradually forms a special-shaped copper core during the conveying process, and the processed special-shaped copper core is sent out from the discharge port 4;

[0080] Step 3: Convey the shaped copper core sent out from the discharge port 4 of the copper core extrusion forming device to the first coating machine 1. The first coating machine 1 performs a coating operation on the shaped copper core to complete the coating of the inner heat dissipation layer on the surface of the shaped copper core.

[0081] Step 4: Convey the shaped copper core after the first coating to the second coating machine 2. The second coating machine 2 performs a coating operation on the shaped copper core after the first coating again, and on the basis of the first coating, completes the coating of the insulating layer.

[0082] When the present invention is in use, turn on the eddy current heating ring 21, open the inert gas valve connected to the intake joint 22, and let the inert gas fill the inside of the housing 5 to form a protective atmosphere. At the same time, preheat the thin copper busbar that enters subsequently to enhance the plasticity of the material.

[0083] According to the product design requirements, if an arc-shaped extrusion effect is required, start the electro-hydraulic telescopic rod 13 to drive the moving plate 12 to move, so that the sleeve 7 slides along the rotating rod 6, and move the first extrusion roller 8 to a suitable processing position; if a trapezoidal extrusion effect is required, move the second extrusion roller 9 to the working position; during the adjustment process, the first sealing plate 15 cooperates with the second sealing plate 16 and the sliding grooves 10 on both sides of the housing 5 to maintain the sealing performance of the housing 5.

[0084] Place the thin copper busbar on the conveying roller 23, and rely on the rotation of the conveying roller 23 to smoothly convey it into the housing 5; during the conveying process, if the thickness of the thin copper busbar is relatively thin, the telescopic mechanism does not adjust the position of the rotating rod 6, and the roller cutter assembly can apply an extrusion force to the thin copper busbar to meet the forming requirements of the copper core.

[0085] If the thickness of the thin copper busbar is relatively thick, the thin copper busbar contacts the conveying roller 23 and drives the conveying roller 23 to move. The conveying roller 23 drives the pressing plate 27 to move through the movable rod 31. During the movement of the pressing plate 27, the extrusion on the corresponding pressing switch 35 will be gradually reduced. When the pressing plate 27 moves to a certain position, it no longer presses the corresponding pressing switch 35, and the pressing switch 35 is triggered to turn off the electromagnet 30 in the corresponding movable cylinder 29. After turning off the magnetic suction of the electromagnet 30, the two electromagnets 30 no longer magnetically adsorb. At the same time, under the elastic force of the return spring 32, the electromagnet 30 drives the movable rod 31 connected to it to move, and the movement of the movable rod 31 will cause the first sliding ring 33 on the rotating rod 6 and the second sliding ring 34 on the sleeve 7 to generate displacement, thereby driving the rotating rod 6 and the sleeve 7 to adjust the position, so as to increase the distance between the roller cutter assembly and the thick copper busbar, avoid the extrusion force of the roller cutter assembly with a relatively small original distance on the thin copper busbar, and ensure that the thin copper busbar can be processed and formed under a suitable number of roller cutter assemblies.

[0086] Start the drive motor 20. The drive motor 20 drives the worm 18 to rotate. The worm 18 drives the turbine 17 to rotate synchronously, and then drives the rotating rod 6 and the sleeve 7 sleeved on the rotating rod 6 to rotate together, so that the roller cutter assembly performs an extrusion operation on the thin copper strip;

[0087] The inert gas introduced from the air inlet joint 22 fills the inside of the housing 5, forming an inert gas protection around the thin copper strip. This layer of protective gas can effectively isolate the oxygen in the air, prevent the thin copper strip from being oxidized during the heating and extrusion processes, ensure that the electrical conductivity and other physical and chemical properties of the thin copper strip are not affected, and improve the overall performance and service life of the cable;

[0088] After the gas enters the housing 5 through the air inlet joint 22, since the air inlet joint 22 is close to the discharge port 4, part of the gas will naturally discharge from the discharge port 4. These discharged gases form an air flow at the discharge port 4, which plays a role in cooling and dissipating heat from the shaped thin copper strip. On the one hand, it can timely take away the excess heat generated by the thin copper strip during the shaping process, preventing the thin copper strip from undergoing internal structure changes or affecting the subsequent processing quality due to excessive temperature; on the other hand, this air flow does not reduce the temperature of the thin copper strip without limit, but keeps the thin copper strip within a certain suitable temperature range, preheating the thin copper strip before it enters the first coater 1. The appropriate preheating temperature helps to improve the adhesion between the coating material and the thin copper strip, enabling the inner heat dissipation layer to adhere more closely and evenly to the surface of the thin copper strip during the coating process, enhancing the heat dissipation effect while improving the performance and quality of the entire cable, and ensuring the continuity and high efficiency of the cable production process;

[0089] At the same time, another part of the inert gas discharges from the conical air outlet housing 36. Since the air outlet 37 of the conical air outlet housing 36 faces the thin copper strip, when the gas discharges, it will directly act on the surface of the thin copper strip. The flowing inert gas generates sufficient impact force, which can effectively blow off various impurities adsorbed by the thin copper strip during the feeding stage, such as dust and debris, effectively preventing impurities from entering the subsequent processing links and avoiding interference from impurities to the processes such as extrusion forming and coating of the thin copper strip;

[0090] The copper core after extrusion forming will enter the subsequent processing equipment in sequence. First, the copper core enters the first coater 1, and the first coater 1 is responsible for performing the first coating operation on the copper core. During this process, the inner heat dissipation layer is coated to ensure that the copper core has good heat dissipation performance. The copper core that has completed the first coating then enters the second coater 2, and the second coater 2 performs the second coating operation, which mainly completes the coating of the insulation layer to provide reliable insulation for the cable. After the insulation layer coating is completed, according to the specific requirements of the product, the coating of the armor layer can be selected to enhance the mechanical strength and protection performance of the cable. After the armor layer coating is completed, an outer sheath layer is installed on the cable, and thus the entire cable processing process is completed.

[0091] The foregoing has shown and described the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments, and the above-described embodiments and the descriptions in the specification are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements fall within the scope of the present invention claimed. The scope of the present invention claimed is defined by the appended claims and their equivalents.

Claims

1. Flat flexible energy-saving cable special-shaped copper core coating and forming device, characterized in that, It includes a copper core extrusion forming device, a first coater (1), and a second coater (2) arranged in sequence along the conveying direction of the thin copper busbar. The copper core extrusion forming device includes a housing (5) with a feed inlet (3) and a discharge outlet (4) provided on both sides respectively. A plurality of groups of rotating rods (6) distributed along the conveying direction of the thin copper busbar are vertically movably connected to the upper and lower inner sides of the housing (5). The distance between the adjacent upper and lower rotating rods (6) gradually decreases along the conveying direction of the thin copper busbar. A roller cutter assembly is slidably connected to the rotating rod (6). A driving mechanism for driving the rotating rod (6) to rotate after the rotating rod (6) moves towards the thin copper busbar is arranged on the side of the housing (5). A conveying assembly for conveying the copper core is provided on one side of the housing (5) close to the feed inlet (3).

2. The special-shaped copper core coating and forming device for the flat flexible energy-saving cable according to claim 1, characterized in that, The roller cutter assembly includes a sleeve (7) slidably connected to the rotating rod (6), a first extrusion roller (8), and a second extrusion roller (9) installed on the sleeve (7). Vertical chutes (10) corresponding to both ends of the rotating rod (6) are arranged on the side of the housing (5). One end of the rotating rod (6) close to the driving mechanism passes through the chute (10) and is slidably connected to the chute (10). Both ends of the rotating rod (6) and the sleeve (7) away from each other are connected to the housing (5) through a telescopic mechanism. A plurality of groups of circular arc-shaped annular grooves are provided on the first extrusion roller (8), and a plurality of groups of trapezoidal annular grooves are provided on the second extrusion roller (9).

3. The flat flexible energy-saving cable special-shaped copper core coating and forming device according to claim 2, characterized in that, The driving structure includes a turbine (17) connected to one end of the rotating rod (6), and a worm (18) horizontally arranged and meshing with the turbine (17). Both ends of the worm (18) are rotatably connected to a support plate (19) fixedly connected to the outside of the housing (5). One end of the worm (18) is connected to the output end of a driving motor (20), and the driving motor (20) is installed on the support plate (19).

4. The special-shaped copper core coating and forming device for the flat flexible energy-saving cable according to claim 3, wherein, An eddy current heating ring (21) is provided between adjacent sleeves (7), and the thin copper busbar passes through the eddy current heating ring (21). An air inlet joint (22) for introducing inert gas is connected and accessed to the top of one side of the housing (5) away from the feed inlet (3).

5. The special-shaped copper core coating and forming device for the flat flexible energy-saving cable according to claim 4, wherein The adjusting structure includes a vertically arranged moving plate (12). One end of the sleeve (7) is slidably connected to one side of the moving plate (12). A fixed end of an electro-hydraulic telescopic rod (13) is fixedly connected to the side of the moving plate (12) away from the sleeve (7). A vertically arranged support leg (14) is fixedly connected to the fixed end of the electro-hydraulic telescopic rod (13). One end of the rotating rod (6) is fixedly connected to a first sealing plate (15). One end of the sleeve (7) is slidably connected to a second sealing plate (16). The second sealing plate (16) is slidably connected to the outside of the housing (5). The first sealing plate (15) and the second sealing plate (16) respectively correspond to the chutes (10) on both sides of the housing (5).

6. The flat flexible energy-saving cable special-shaped copper core coating and forming device according to claim 5, characterized in that On both the upper and lower sides of the housing (5) near the feed inlet (3), there are several groups of horizontally distributed conveying rollers (23). The two ends of the conveying rollers (23) are rotatably connected to vertically arranged moving rods (24). A horizontally arranged mounting plate (25) is fixedly connected to the outside of the housing (5). An activity slot (26) is provided on the mounting plate (25). One end of the moving rod (24) passes through the activity slot (26) and is fixedly connected to a pressing plate (27). A pressing spring (28) is provided on the side of the mounting plate (25) close to the pressing plate (27). A pressing control device for controlling the telescopic mechanism is provided between the mounting plate (25) and the pressing plate (27).

7. The flat flexible energy-saving cable special-shaped copper core coating and forming device according to claim 6, characterized in that The telescopic mechanism includes activity cylinders (29) vertically fixed on both sides of the housing (5). Two groups of horizontally arranged electromagnets (30) are slidably connected in the activity cylinders (29). The two groups of electromagnets (30) are magnetically adsorbed in the initial state. Activity rods (31) are vertically arranged on the sides of the electromagnets (30) away from each other. A return spring (32) is fixedly connected between the side of the electromagnet (30) close to the activity rod (31) and the inner wall of the piston cylinder. A first sliding ring (33) fixedly connected to the end of the activity rod (31) is slidably connected to the rotating rod (6). A second sliding ring (34) fixedly connected to the end of the activity rod (31) is slidably connected to the sleeve (7). The pressing control device includes several groups of pressing switches (35) arranged on the upper surface of the mounting plate (25). The lower surface of the pressing plate (27) is in pressing contact with the pressing switches (35). The pressing switches (35) are used to control the electromagnets (30).

8. The flat flexible energy-saving cable special-shaped copper core coating and forming device according to claim 7, characterized in that, On both the upper and lower sides of the housing (5) near the feed inlet (3), there are two groups of conical air outlet housings (36) arranged symmetrically up and down. Air outlet openings (37) for blowing air on the thin copper strip are provided in the contraction sections of the conical air outlet housings (36). The conical air outlet housings (36) are communicated with the inside of the housing (5).

9. The flat flexible energy-saving cable special-shaped copper core coating and forming device according to claim 8, characterized in that, On one side of the housing (5) near the discharge outlet (4), auxiliary rollers (38) arranged symmetrically up and down are connected. A positioning roller (39) vertically arranged is provided between adjacent sleeves (7) on the left and right. The positioning roller (39) is in rolling contact with both sides of the thin copper strip. The two ends of the positioning roller (39) are rotatably connected to connecting rods (11). One end of the connecting rod (11) away from the positioning roller (39) is fixedly connected to the inner wall of the housing (5).

10. A method for forming a special-shaped copper core of a flat flexible energy-saving cable, using the flat flexible energy-saving cable special-shaped copper core forming device according to any one of claims 1 to 9, specifically including the following steps: Step 1: Place the thin copper strip near the feed inlet (3) of the copper core extrusion forming device, start the conveying component of the copper core extrusion forming device, and convey the thin copper strip from the feed inlet (3) into the housing (5) through the conveying component; Step 2: The driving mechanism drives the rotating rod (6) to rotate, driving the roller cutter assembly to extrude the thin copper strip, so that the thin copper strip gradually forms a special-shaped copper core during the conveying process, and the processed special-shaped copper core is sent out from the discharge outlet (4); Step 3: Convey the special-shaped copper core sent out from the discharge port (4) of the copper core extrusion forming device to the first coater (1), and the first coater (1) performs a coating operation on the special-shaped copper core to complete the coating of the inner heat dissipation layer on the surface of the special-shaped copper core; Step 4: Convey the special-shaped copper core after the first coating to the second coater (2), and the second coater (2) performs a coating operation on the special-shaped copper core after the first coating again. On the basis of the first coating, the insulation layer is completed.

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