Device for controlling thickness of paint film on surface of enameled aluminum wire

Abstract

A device for controlling the thickness of a paint film on the surface of an enamelled aluminum wire comprises a coating pool, a control device and a control device, and paint liquid is arranged in the coating pool; the plurality of painting molds are arranged above the coating pool, each painting mold only allows one aluminum wire to penetrate through, a coating cavity is formed in each painting mold, and each painting mold is provided with a pressure sensor for monitoring the pressure of the corresponding coating cavity; and the output end of the paint liquid pump is provided with a plurality of conveying pipelines connected to the painting mold. The pressure sensor is arranged in the coating cavity, the pressure of the paint liquid in the cavity can be monitored in real time, it is ensured that the paint liquid completely immerses the guide wire all the time, the preset pressure is formed, closed-loop dynamic adjustment of the liquid supply flow of the coating cavity is achieved through feedback of the pressure sensor, and the constant paint liquid pressure in the cavity is maintained; the constant pressure ensures that the aluminum conductor is always wrapped by the paint liquid, air mixing is reduced, and the bubble residual probability is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of enameled aluminum wire production, and more particularly to a device for controlling the film thickness of the enamel film on the surface of enameled aluminum wire. Background Art

[0002] The painting process of enameled aluminum wire is the core link in the manufacture of enameled aluminum wire. In the existing die coating method, the upper and lower paint pipes are usually used for coating. The first paint pipe (with paint liquid gushing out from the bottom) relies on the upward flow of the paint liquid to cover the aluminum conductor, and the second paint pipe (with paint liquid dripping down from the top) relies on gravity to cover downward. The flow directions of the two are opposite, which easily causes a fluid intersection area of the paint liquid on the surface of the aluminum conductor, resulting in fluctuations in the coating thickness or residual bubbles. The pressure difference between the above-mentioned upper and lower paint pipes may cause uneven distribution of the paint liquid, especially more obvious during high-speed production. The existing process requires multiple coatings (3 - 8 times) to make up for the deficiencies of a single coating. Due to relying on multiple coatings, if the insulation paint coating of multiple aluminum conductors is processed at one time, the difficulty of multi-wire synchronous control is higher. Therefore, it is not conducive to maintaining the consistency of multi-wire simultaneous coating. Summary of the Invention

[0003] In view of the technical problems existing in the painting of enameled aluminum wire in the prior art, the present invention provides a device for controlling the film thickness of the enamel film on the surface of enameled aluminum wire, including:

[0004] A coating pool, in which there is paint liquid;

[0005] A plurality of painting dies, arranged above the coating pool, each painting die is only for one aluminum conductor to pass through, an inner part of the painting die is provided with a coating cavity, and the painting die is provided with a pressure sensor for monitoring the pressure in the coating cavity;

[0006] A paint liquid pump, with a plurality of delivery pipes connected to the painting dies at the output end, and each delivery pipe is provided with a flow valve for controlling the flow rate of the paint liquid entering the painting die;

[0007] A wire feeding device, including a plurality of wire feeding wheel groups, each wire feeding wheel group is used for controlling the aluminum conductor to pass through the painting die at a predetermined speed;

[0008] A controller, electrically connected to the wire feeding wheel groups, the flow valves, and the pressure sensors;

[0009] Wherein, the controller is configured to adjust the opening degree of the flow valve according to the pressure in the coating cavity monitored by the pressure sensor, so that the pressure in each coating cavity is the same, and the controller controls the rotation speed of the wire feeding wheel groups, so that the speed of each aluminum conductor passing through the coating cavity is consistent.

[0010] Preferably, the coating chamber is arranged to surround the path through which the aluminum wire passes, and the pressure sensor is arranged at the uppermost part of the coating chamber, higher than the path through which the aluminum wire passes.

[0011] Preferably, the paint coating die includes a first housing, a second housing, and a third housing;

[0012] The second housing is arranged in the inner cavity of the first housing, and a liquid supply pipe is arranged below the second housing. The liquid supply channel in the liquid supply pipe is communicated with the conveying pipeline;

[0013] An immersion coating chamber is formed inside the second housing, and the liquid supply channel in the liquid supply pipe is communicated with the immersion coating chamber;

[0014] The third housing is arranged above the first housing, and a liquid return chamber is formed inside the third housing. A liquid return hole is arranged on the outer wall of the third housing to communicate the liquid return chamber with the inner cavity of the first housing;

[0015] The coating chamber is composed of the immersion coating chamber and the liquid return chamber. The pressure sensor is connected to the first housing and is located above the liquid return chamber.

[0016] Preferably, first through holes for the aluminum wire to penetrate into and out of are arranged on both side wall surfaces of the first housing, and second through holes for the aluminum wire to penetrate into and out of are arranged on both side wall surfaces of the second housing. The second through holes and the first through holes are coaxially arranged;

[0017] Wherein, a drain pipe is arranged at the bottom of the first housing. The drain channel in the drain pipe is communicated with the inner cavity of the first housing, and the drain pipe is connected to the coating bath.

[0018] Preferably, the diameter of the second through hole is 1.5 to 2.0 times the diameter of the first through hole.

[0019] Preferably, the diameter of the aluminum wire defining the target paint layer thickness is d1, the diameter of the first through hole is d2, and the thickness of the target paint layer is h1. Wherein, d2 - d1 / 2 = 1.5h1 to 2h1.

[0020] Preferably, the cord between the liquid return chamber and the liquid supply channel intersects with the aluminum wire passing through the second through hole.

[0021] Preferably, the cross-sectional dimension of the liquid return hole is smaller than the cross-sectional dimension of the liquid supply channel.

[0022] Preferably, a plurality of the paint coating dies are arranged in the upstream direction of the coating bath for feeding the aluminum wire.

[0023] Preferably, the paint liquid pump is arranged in the downstream direction of the coating bath for feeding the aluminum wire.

[0024] Compared with the prior art, the advantages of the present invention are as follows:

[0025] In this application, by setting a pressure sensor in the coating chamber, the pressure of the paint liquid in the chamber can be monitored in real time to ensure that the paint liquid always completely submerges the wire guide and forms a predetermined pressure. The liquid supply flow rate of the coating chamber is closed-loop dynamically adjusted through the feedback of the pressure sensor to maintain a constant paint liquid pressure in the chamber. The constant pressure ensures that the aluminum wire is always wrapped by the paint liquid, reduces the mixing of air, and reduces the probability of bubble residue.

[0026] For the simultaneous processing of multiple aluminum wires, the above-mentioned closed-loop control system automatically adjusts the liquid supply volume through pressure feedback to ensure that the paint liquid pressure distribution around each wire guide is uniform, avoiding the coating thickness difference caused by uneven flow distribution in the traditional process. Since each wire guide passes through the perforation of the independent inner and outer shells, and the uniform wrapping of the paint liquid brought by the stable superposition pressure is achieved, a double consistency guarantee of physical limit and dynamic compensation is realized.

[0027] In addition, the pressure and flow data generated during the production process can be stored and analyzed to identify the process fluctuation rules, such as the flow attenuation caused by the aging of the paint liquid pump, etc., and early warning maintenance can be achieved. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The drawings are not intended to be drawn to scale. In the drawings, each identical or approximately identical component shown in each figure may be denoted by the same reference numeral. For the sake of clarity, not every component is labeled in each figure. Now, embodiments of various aspects of the present invention will be described by way of example and with reference to the drawings, wherein:

[0029] Figure 1 is a schematic structural diagram of the thickness consistency control system for painting the surface of aluminum enameled wire shown in the present invention;

[0030] Figure 2 is a schematic diagram of a plurality of painting molds arranged in a coating tank shown in the present invention;

[0031] Figure 3 is a schematic structural diagram of the painting mold shown in the present invention;

[0032] Figure 4 is a schematic structural diagram of the coating chamber of the painting mold shown in the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0033] In order to better understand the technical content of the present invention, specific embodiments are hereby given and described in conjunction with the accompanying drawings as follows.

[0034] Combined with Figure 1 and Figure 2As shown in the figure, the present invention provides a device for controlling the film thickness of the paint film on the surface of an enameled aluminum wire, which includes a coating tank 1000, a plurality of paint coating dies, a paint liquid pump 1100, a wire feeding device 3000, and a controller 2000.

[0035] The coating tank 1000 is filled with paint liquid. Optionally, the paint liquid is selected with appropriate materials and viscosities according to requirements.

[0036] A plurality of paint coating dies are arranged above the coating tank 1000, and can simultaneously coat insulating paint liquid on a plurality of aluminum wires.

[0037] Among them, each paint coating die is only for one aluminum wire to pass through. The interior of the paint coating die is provided with a coating cavity, and the paint coating die is provided with a pressure sensor 400 for monitoring the pressure in the coating cavity.

[0038] Preferably, the coating cavity is arranged to surround the path through which the aluminum wire passes. The pressure sensor 400 is arranged at the uppermost part of the coating cavity, higher than the path through which the aluminum wire passes.

[0039] In this way, when the aluminum wire passes through the coating cavity, the paint liquid in the coating cavity completely submerges the path through which the aluminum wire passes and reaches the height where the pressure sensor 400 is arranged. By controlling the liquid inflow in the coating cavity, the paint liquid pressure in the coating cavity reaches a certain pressure value. Therefore, the paint liquid in the coating cavity through which the aluminum wire passes maintains a certain pressure. Under the action of the paint liquid under this predetermined pressure, the outer wall of the aluminum wire is completely wrapped by the paint liquid to achieve better coating quality.

[0040] Furthermore, the output end of the paint liquid pump 1100 is provided with a plurality of conveying pipelines connected to the paint coating dies. Each conveying pipeline is provided with a flow valve 1200, and the flow valve 1200 is used to control the flow rate of the paint liquid entering the paint coating die.

[0041] By controlling the flow rate of the paint liquid in each paint coating die, the pressure of the paint liquid in each coating cavity can be effectively controlled, which is beneficial to making the paint liquid pressures in all paint coating dies consistent and laying a foundation for forming a consistent paint coating process for all aluminum wires.

[0042] Furthermore, the wire feeding device 3000 includes a plurality of wire feeding wheel groups 3100, and each wire feeding wheel group 3100 is used to control the aluminum wire to pass through the paint coating die at a predetermined speed.

[0043] It should be understood that the speed at which the aluminum wire passes through the paint coating die also determines the coating quality of its surface. When controlling all aluminum wires to pass through the paint coating die at a consistent speed and immersion liquid pressure, it helps to ensure that all aluminum wires are painted with consistent process parameters, thereby ensuring the consistency of the paint layer on the surface of the aluminum wire.

[0044] Furthermore, the controller 2000 is electrically connected to the wire feeding wheel group 3100, the flow valve 1200 and the pressure sensor 400; wherein the controller 2000 is configured to adjust the opening of the flow valve 1200 according to the coating chamber pressure monitored by the pressure sensor 400, so that the pressure in each coating chamber is the same, and the controller 2000 controls the rotation speed of the wire feeding wheel group 3100, so that the speed of each aluminum wire passing through the coating chamber is consistent.

[0045] As described above, through the closed-loop control of the pressure sensor 400 and the flow valve 1200, the stability and consistency of the painting process are improved, especially in the multi-wire coating scenario.

[0046] Among them, the pressure sensor 4000 can monitor the paint liquid pressure in the coating cavity in real time to ensure that the paint liquid always completely immerses the guide wire and forms a certain pressure; further, the flow rate of the liquid supply pipe is dynamically adjusted according to the pressure data to compensate for the pressure disturbance caused by changes in wire diameter or fluctuations in production speed, and maintain a constant paint liquid pressure in the cavity. In this way, constant pressure ensures that the aluminum wire is always wrapped in paint liquid, reduces air mixing, and reduces the probability of bubble residue.

[0047] In an optional embodiment, in combination with Figure 3 and Figure 4 As shown, the painting mold includes a first shell 100, a second shell 200 and a third shell 300, and the second shell 200 is arranged in the cavity of the first shell 100. Optionally, the first shell 100 and the second shell 200 are constructed as hollow cylindrical structures.

[0048] The first shell 100 has two side walls with first through holes 104 for aluminum wires to pass through and out, and the second shell 200 has two side walls with second through holes 202 for aluminum wires to pass through and out. The second through holes 202 and the first through holes 104 are coaxially arranged.

[0049] In this way, the aluminum wire can enter from the first through hole 104 on the right side of the first shell 100 into the second through hole 202 on the right side of the second shell 200, and thereby enter into the immersion coating chamber 201, and then enter between the second shell 200 and the first shell 100 through the second through hole 202 on the left side of the second shell 200, and finally pass through the first through hole 104 on the left side of the first shell 100 and pass through the entire painted structure.

[0050] Furthermore, a liquid immersion and coating chamber 201 is formed inside the second shell 200, and a liquid supply channel 211 in the liquid supply tube 210 is connected to the liquid immersion and coating chamber 201; the third shell 300 is arranged above the first shell 100, and a liquid return chamber 301 is formed inside the third shell 300, and a liquid return hole 302 is provided on the outer wall of the third shell 300, so that the liquid return chamber 301 is connected to the cavity inside the first shell 100.

[0051] Among them, the coating chamber is composed of the immersion liquid coating chamber 201 and the liquid return chamber 301. The pressure sensor 400 is connected to the first housing 100 and is located above the liquid return chamber 301.

[0052] Furthermore, a liquid supply pipe 210 is provided below the second housing 200, and the liquid supply channel 211 in the liquid supply pipe 210 is communicated with the conveying pipeline.

[0053] In this way, the paint liquid can be conveyed to the conveying pipeline by the paint liquid pump 1100, and the flow rate of the paint liquid entering the liquid supply channel 211 is controlled by the flow valve 1200.

[0054] In this way, after the paint liquid enters the immersion liquid coating chamber 201, through continuous liquid supply in the liquid supply channel 211, the paint liquid enters the liquid return chamber 301, and further due to the liquid supply pressure, the excess paint liquid in the immersion liquid coating chamber 201 overflows through two channels of the liquid return hole 302 and the second through hole 202, and is discharged through the drain pipe 110. The pressure sensor 400 can detect the paint liquid pressure entering the coating chamber 201 in real time, and the consistency of the paint liquid pressure is ensured by controlling the liquid inlet flow rate.

[0055] In a preferred embodiment, the connection line between the liquid return chamber 301 and the liquid supply channel 211 intersects with the aluminum wire passing through the second through hole 202.

[0056] Furthermore, a drain pipe 110 is provided at the bottom of the first housing 100. The drain channel in the drain pipe 110 is communicated with the cavity in the first housing 100, and the drain pipe 110 is connected to the coating pool 1000. A plurality of painting molds are arranged in the upstream direction of the coating pool 1000 for feeding the aluminum wire, and the paint liquid pump 1100 is arranged in the downstream direction of the coating pool 1000 for feeding the aluminum wire.

[0057] In this way, the drainage position of each painting mold is far from the liquid suction position of the paint liquid pump 1100, and the bubbles formed by drainage will be stably defoamed in the coating pool 1000, avoiding excessive air being sucked into the paint liquid pump 1100 and causing unstable liquid supply.

[0058] In the above embodiment, the flow path of the paint liquid in the painting structure includes two paths. The first path is: liquid supply channel 211 - immersion liquid coating chamber 201 - liquid return chamber 301 - liquid return hole 302 - second reflux area 102 - confluence area 103 - drain channel 111; the second path is: liquid supply channel 211 - immersion liquid coating chamber 201 - second through hole 202 - confluence area 103 - drain channel 111.

[0059] Preferably, the cross-sectional size of the liquid return hole 302 is smaller than the cross-sectional size of the liquid supply channel 211. In this way, the immersion liquid coating chamber 201 can be ensured to be in a slightly positive pressure state.

[0060] Among them, the pressure sensor 400 is arranged in the liquid return cavity 301 and can monitor the pressure in the liquid return cavity 301. When the paint liquid does not reach the liquid return cavity 301, it indicates that the liquid level is not high enough, and the liquid supply flow needs to be increased until the paint liquid fills the liquid return cavity 301 and forms a certain pressure on the pressure sensor 400. In this way, the supply of the paint liquid reaches a stable state.

[0061] As described above, the paint liquid is injected into the immersion coating cavity 201 through the liquid supply channel 211, and the slightly positive pressure in the immersion coating cavity 201 is maintained by controlling the liquid inlet flow rate, so that the paint liquid in the immersion coating cavity 201 completely covers the surface of the aluminum wire entering the immersion coating cavity 201. Since the paint liquid in the immersion coating cavity 201 has always filled up to the liquid return cavity 301, a relatively constant liquid level is maintained in the immersion coating cavity 201, especially higher than the liquid level of the aluminum wire. Even if the flow rate of the paint liquid injected into the liquid supply channel 211 is uneven (containing bubbles), the aluminum wire can still be kept in a soaked state all the time, especially evenly wrapped 360 degrees. This method can avoid the adverse effects on the quality of the paint coating layer caused by the existence of bubbles in the paint liquid.

[0062] In order to optimize the thickness of the paint liquid on the aluminum wire after passing through the immersion coating cavity 201, the diameter of the second through hole 202 can be selected to be 1.5 to 2.0 times the diameter of the first through hole 104.

[0063] In this way, after the aluminum wire passes through the immersion coating cavity 201, the paint liquid adheres to the surface. By passing through the second through hole 202 and the first through hole 104 in sequence, and using the step-by-step scraping of the thickness of the paint liquid on the surface of the aluminum wire, the excess paint liquid can be scraped off first to form a preliminary uniform paint layer, and then the ultra-thick part of the paint liquid can be scraped off again to accurately control the thickness of the final coating.

[0064] When the aluminum wire continuously passes through the first through hole 104 and exits the first housing 100, in order to avoid uncontrollable scraping of the paint liquid on the surface of the aluminum wire after the inner wall of the first through hole 104 adheres to the paint liquid, define the diameter of the aluminum wire with the target paint layer thickness as d1, the diameter of the first through hole 104 as d2, and the thickness of the target paint layer as h1. Among them, d2 - d1 / 2 = 1.5h1 to 2h1.

[0065] In this way, the thickness of the paint layer on the surface of the final aluminum wire is limited by the first through hole 104 slightly larger than the diameter of the target paint layer, and the diameter of the first through hole 104 can be selected according to the speed of the aluminum wire, the viscosity of the paint liquid, etc.

[0066] Combined with the above embodiments, in the present application, by setting a pressure sensor in the coating chamber, the pressure of the paint liquid in the chamber can be monitored in real time to ensure that the paint liquid always completely submerges the wire guide and forms a predetermined pressure. The liquid supply flow rate of the coating chamber is closed-loop dynamically adjusted through the feedback of the pressure sensor to maintain a constant paint liquid pressure in the chamber. The constant pressure ensures that the aluminum wire is always wrapped by the paint liquid, reduces the mixing of air, and decreases the probability of bubble residue.

[0067] For the simultaneous processing of multiple aluminum wires, the above closed-loop control system automatically adjusts the liquid supply volume through pressure feedback to ensure that the pressure distribution of the paint liquid around each wire guide is uniform, avoiding the coating thickness difference caused by uneven flow distribution in the traditional process. Since each wire guide passes through the perforations of the independent inner and outer shells, and the uniform wrapping of the paint liquid brought by the stable superimposed pressure, a double consistency guarantee of physical limit and dynamic compensation is achieved.

[0068] In addition, the pressure and flow rate data generated during the production process can be stored and analyzed to identify the process fluctuation rules, such as the flow rate attenuation caused by the aging of the paint liquid pump, etc., and early warning maintenance can be achieved.

[0069] Although the present invention has been disclosed above with preferred embodiments, it is not intended to limit the present invention. Those with ordinary knowledge in the technical field to which the present invention pertains can make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be subject to what is defined by the claims.

Claims

1. A device for controlling the film thickness of the paint film on the surface of an enameled aluminum wire, characterized in that, Comprising: A coating bath (1000) provided with a paint solution therein. A plurality of painting dies arranged above the coating bath (1000), each painting die allowing only one aluminum wire to pass through. An internal coating cavity is provided in each painting die, and a pressure sensor (400) for monitoring the pressure in the coating cavity is provided on the painting die. A paint solution pump (1100) with multiple delivery pipes connected to the painting dies at its output end. A flow valve (1200) is provided on each delivery pipe, and the flow valve (1200) is used to control the flow rate of the paint solution entering the painting die. A wire feeding device (3000) including a plurality of wire feeding wheel sets (3100), each wire feeding wheel set (3100) being used to control the aluminum wire to pass through the painting die at a predetermined speed. A controller (2000) electrically connected to the wire feeding wheel sets (3100), the flow valves (1200), and the pressure sensors (400). Wherein, the controller (2000) is configured to adjust the opening degree of the flow valve (1200) according to the pressure in the coating cavity monitored by the pressure sensor (400) so that the pressure in each coating cavity is the same, and the controller (2000) controls the rotation speed of the wire feeding wheel sets (3100) so that the speed of each aluminum wire passing through the coating cavity is consistent.

2. The surface paint film thickness control device for enameled aluminum wire according to claim 1, characterized in that, The coating cavity is configured to surround the path through which the aluminum wire passes, and the pressure sensor (400) is provided at the uppermost part of the coating cavity, higher than the path through which the aluminum wire passes.

3. The surface paint film thickness control device for enameled aluminum wire according to claim 1, wherein The painting die includes a first housing (100), a second housing (200), and a third housing (300). The second housing (200) is arranged in the inner cavity of the first housing (100). A liquid supply pipe (210) is provided below the second housing (200), and a liquid supply channel (211) in the liquid supply pipe (210) is communicated with the delivery pipe. An immersion coating cavity (201) is formed inside the second housing (200), and the liquid supply channel (211) in the liquid supply pipe (210) is communicated with the immersion coating cavity (201). The third housing (300) is arranged above the first housing (100). A liquid return cavity (301) is formed inside the third housing (300), and a liquid return hole (302) is provided on the outer wall of the third housing (300) to communicate the liquid return cavity (301) with the inner cavity of the first housing (100). The coating cavity is constituted by the immersion coating cavity (201) and the liquid return cavity (301). The pressure sensor (400) is connected to the first housing (100) and is located above the liquid return cavity (301).

4. A device for controlling the film thickness of the paint film on the surface of an enameled aluminum wire according to claim 3, characterized in that, First through holes (104) for the aluminum wire to penetrate in and out are provided on both side wall surfaces of the first housing (100). Second through holes (202) for the aluminum wire to penetrate in and out are provided on both side wall surfaces of the second housing (200), and the second through holes (202) and the first through holes (104) are coaxially arranged. Among them, a liquid discharge pipe (110) is provided at the bottom of the first housing (100), a liquid discharge channel in the liquid discharge pipe (110) is communicated with the cavity in the first housing (100), and the liquid discharge pipe (110) is connected to the coating bath (1000).

5. The surface paint film thickness control device for enameled aluminum wire according to claim 3, wherein The diameter of the second perforation (202) is 1.5 to 2.0 times the diameter of the first perforation (104).

6. The surface paint film thickness control device for enameled aluminum wire according to claim 3, characterized in that, Define the diameter of the aluminum wire for the target paint layer thickness as d1, the diameter of the first perforation (104) as d2, and the thickness of the target paint layer as h1. Among them, (d2 - d1) / 2 = 1.5h1 to 2h1.

7. A device for controlling the film thickness of the paint film on the surface of an enameled aluminum wire according to claim 3, characterized in that, The cord between the liquid return cavity (301) and the liquid supply channel (211) intersects the aluminum wire passing through the second perforation (202).

8. A device for controlling the film thickness of the paint film on the surface of an enameled aluminum wire according to claim 3, characterized in that, The cross-sectional dimension of the liquid return hole (302) is smaller than the cross-sectional dimension of the liquid supply channel (211).

9. The surface paint film thickness control device for enameled aluminum wire according to claim 1, characterized in that A plurality of the paint application molds are arranged in the upstream direction of the coating bath (1000) for feeding the aluminum wire.

10. A device for controlling the surface paint film thickness of enameled aluminum wire according to claim 1, characterized in that, The paint liquid pump (1100) is arranged in the downstream direction of the coating bath (1000) for feeding the aluminum wire.

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