Processing technology of multi-layer lapped wire

Abstract

The invention discloses a processing technology of a multi-layer lapped wire, and particularly relates to the technical field of material processing, and the processing technology comprises the following steps: S1, material selection: copper meeting the standards of conductivity, hardness and heat resistance is selected, the conductivity is greater than or equal to 58 MS / m, the hardness is 100-160 HV, and the heat resistance is greater than or equal to 200 DEG C; s2, conducting wire cutting is conducted, the cutting error is + / -0.1 mm, surface dirt and an oxide layer are removed through high-temperature cleaning, and the cleaning temperature is 200 DEG C; s3, the surface of the wire is coated with a coating material, the coating thickness ranges from 0.2 mm to 0.5 mm, the curing temperature ranges from 150 DEG C to 200 DEG C, and it is ensured that the coating is uniform and firm through thermocuring; high-precision automation equipment, an intelligent monitoring system and a high-performance material are utilized, the precision and efficiency of wire production are remarkably improved, the electrical performance and mechanical strength of the wire are improved through combination of intelligent, environment-friendly and high-performance materials, the electromagnetic compatibility is enhanced, and the production cost is reduced. The cable is especially suitable for the fields of high-end electronic products, communication facilities, high-frequency transmission and the like.

Description

Technical Field

[0001] The present invention relates to the field of material processing, and in particular to a processing technology for multi-layer wrapped electric wires. Background Art

[0002] Traditional multi-layer wrapped wire processing technology often uses manual operation and basic mechanical equipment, resulting in low processing precision and low efficiency. Due to the lack of intelligent monitoring and feedback mechanisms, quality fluctuations are prone to occur during the production process, and product consistency is poor. During the coating and covering process, the performance of the wires is easily unstable due to uneven process. In addition, traditional processes rarely use environmentally friendly materials and high-performance materials, resulting in limited environmental protection and long-term performance of the products. These factors not only increase production costs, but also limit the application of products in the high-end market.

[0003] Chinese patent document CN110706861A discloses a multi-layer wrapped wire and its processing technology, which relates to the field of communication equipment technology. It aims to solve the technical problem that wires are prone to bending after long-term use, and the degree of fit between the wire and the outer layer of the wrapping structure is greatly reduced after bending, which increases the local current of the conductor and increases the electromagnetic wave loss, thereby affecting the normal transmission of the conductor to the signal. The key points of the technical solution are to set concentrically wrapped conductors, insulating media and shielding layers so that the influence of external factors and signal crosstalk on the conductor transmission signal during use is effectively reduced; the drawing, annealing and twisting processes are set to make the conductor's own ductility, toughness and volume reach a balanced and optimal state; the outer sheath is set to further enhance the mechanical strength of the wire, and at the same time make the wire have certain flame retardant and waterproof capabilities, achieving the effect of effectively protecting the wire from running straight in various harsh environments and reducing the bending of the finished wire. However, the above patent still has the following defects:

[0004] Due to the lack of intelligent monitoring and feedback mechanisms during use, the above-mentioned patent documents are prone to quality fluctuations during the production process and have poor product consistency. During the coating and covering process, the performance of the wires is easily unstable due to uneven processes. In addition, traditional processes rarely use environmentally friendly materials and high-performance materials, resulting in limited environmental friendliness and long-term performance of the products. Summary of the Invention

[0005] The main purpose of the present invention is to provide a processing technology for multi-layer wrapped electric wires, which can effectively solve the problem of unstable wire performance caused by uneven process during the processing of multi-layer wrapped electric wires.

[0006] To achieve the above object, the technical solution adopted by the present invention is:

[0007] A process for processing a multi-layer wrapped electric wire comprises the following steps:

[0008] S1. Material selection: Choose copper that meets the standards of conductivity, hardness and heat resistance. The conductivity is ≥58MS / m, the hardness is 100-160HV, and the heat resistance is ≥200°C.

[0009] S2, wire cutting, cutting error ± 0.1mm, remove surface dirt and oxide layer by high temperature cleaning, the cleaning temperature is 200℃;

[0010] S3. Apply the coating material on the surface of the conductor with a coating thickness of 0.2-0.5 mm and a curing temperature of 150-200°C. Ensure that the coating is uniform and firm through thermal curing.

[0011] S4, perform multi-layer wrapping, the number of wrapping layers is 5-10 layers, and the tension control error is ≤0.2N;

[0012] S5. Interference test: perform electromagnetic interference test on the wrapped wire to ensure that the electromagnetic interference level is ≤30dB;

[0013] S6. Integrate a sensor system inside the wire to monitor parameters including but not limited to current, temperature, and pressure in real time. The current range is 1-10A, the temperature range is -10℃ to 150℃, and the pressure is ≤2MPa. The data analysis results provide a self-repair solution.

[0014] S7. Apply nanomaterials to the coating and insulation layer of the wire, with a thickness of 5-10 μm, conductivity ≤ 58 MS / m, and electromagnetic interference resistance ≥ 40 dB, to enhance the heat resistance, conductivity, and electromagnetic interference resistance of the wire;

[0015] S8. Use degradable and environmentally friendly materials or recyclable materials to replace traditional insulation materials. The degradation period of environmentally friendly materials shall be ≤5 years and the recycling rate shall be ≥90%.

[0016] Preferably, the coating material is a thermosetting insulating material.

[0017] Preferably, in step S6, the sensor system includes a current sensor, a temperature sensor and a pressure sensor to monitor the working status of the wire in real time.

[0018] Preferably, in step S7, the nanomaterial is a conductive nanocomposite material, which can enhance the electrical conductivity and anti-electromagnetic interference capability of the wire.

[0019] Preferably, in step S5, the electromagnetic interference tester detects whether each layer of wrapping effectively reduces electromagnetic interference.

[0020] Preferably, the packaging process uses an automated tracking system to ensure the traceability of each wire.

[0021] Preferably, the packaging speed is 200 pieces / minute, and the tracking system accuracy is ≤0.5mm.

[0022] Preferably, the environmentally friendly materials are polyamide and polyethylene, which are used to reduce environmental impact and maintain high performance of the wire.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] 1. The present invention significantly improves the precision and efficiency of wire production by utilizing high-precision automated equipment, an intelligent monitoring system, and high-performance materials. The multi-layer wrapped wire, through the combination of intelligence, environmental protection, and high-performance materials, not only improves the electrical performance and mechanical strength of the wire, but also enhances electromagnetic compatibility. It is particularly suitable for high-end electronic products, communication facilities, high-frequency transmission and other fields.

[0025] 2. The present invention improves the safety and maintenance efficiency of wires by adopting nanotechnology and intelligent self-diagnosis technology, can detect and repair potential problems in real time, and reduce subsequent maintenance costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 This is a schematic diagram of the overall process of the present invention DETAILED DESCRIPTION

[0027] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0028] See also Figure 1 A process for processing a multi-layer wrapped wire comprises the following steps:

[0029] S1. Material selection: Use a high-precision automated material testing system to select copper or aluminum materials that meet the conductivity, hardness and heat resistance standards. The conductivity should be ≥58MS / m, the hardness should be 100-160HV, and the heat resistance should be ≥200°C.

[0030] S2. Wire cutting: precision cutting technology is used for wire cutting with a cutting error of ±0.1mm. Surface dirt and oxide layer are removed by high-temperature cleaning at a temperature of 200°C.

[0031] S3. Use an automated coating system to evenly coat the insulation material on the surface of the conductor. The coating thickness is 0.2-0.5 mm and the curing temperature is 150-200°C. Thermal curing is used to ensure that the coating is even and firm.

[0032] S4, multi-layer wrapping, using computer numerical control technology for multi-layer wrapping, setting specific wrapping angle and number of layers, wrapping number of layers is 5-10 layers, tension control error ≤ 0.2N;

[0033] S5. Electromagnetic compatibility testing and optimization: Conduct electromagnetic interference testing on the wrapped wires to optimize electromagnetic compatibility and ensure that the electromagnetic interference level is ≤30dB;

[0034] S6, intelligent monitoring and self-diagnosis, integrating a sensor system inside the wire to monitor current, temperature, pressure and other parameters in real time. The current range is 1-10A, the temperature range is -10℃ to 150℃, and the pressure is ≤2MPa. The data analysis results provide a self-repair solution;

[0035] S7. Use high-performance nanomaterials and apply them to the coating and insulation layers of wires. The thickness of the nanomaterials is 5-10 μm, the conductivity is ≤58 MS / m, and the anti-electromagnetic interference performance is ≥40 dB, which can enhance the heat resistance, conductivity and anti-electromagnetic interference performance of wires.

[0036] S8. Use degradable and environmentally friendly materials and recyclable materials to replace traditional insulation materials. The degradation period of environmentally friendly materials is ≤5 years and the recycling rate is ≥90%. Reduce the impact on the environment through green production processes.

[0037] Through precise material selection, cutting, coating and wrapping technology, the high performance and high reliability of the wires are ensured. Through electromagnetic compatibility testing and optimization, electromagnetic interference is effectively reduced and the stability of the wires in complex environments is improved. At the same time, the integrated intelligent monitoring system enables the wires to have self-diagnosis and self-repair functions, further enhancing their safety. The use of nanomaterials and environmentally friendly materials not only improves the heat resistance, anti-electromagnetic interference and electrical conductivity of the wires, but also meets environmental protection requirements and reduces the impact on the environment. Overall, these measures have significantly improved the durability, performance and environmental friendliness of the wires.

[0038] The coating material is a thermosetting insulating material.

[0039] In this process, by using thermosetting insulation materials as coating design, the heat resistance, mechanical strength and electrical insulation of the wires can be significantly improved. The thermosetting materials solidify into a stable structure after heating, have excellent high temperature resistance and chemical corrosion resistance, and can work stably for a long time in harsh environments. In addition, the thermosetting materials have a high hardness after curing, which can effectively resist external friction and mechanical damage, thereby improving the durability and safety of the wires and ensuring their long-term stable operation.

[0040] In step S6, the sensor system includes a current sensor, a temperature sensor, and a pressure sensor to monitor the working status of the wire in real time;

[0041] In step S6, the design of integrated current sensors, temperature sensors and pressure sensors can monitor the working status of wires in real time to ensure the safety and stability of system operation. The current sensor can detect current changes and detect overload or faults in time; the temperature sensor monitors the temperature of the wires to prevent damage caused by overheating; the pressure sensor can detect external pressure changes to avoid physical damage. Through real-time monitoring, potential problems can be warned in advance, effectively avoiding faults and improving the reliability and safety of the system.

[0042] In step S7, the nanomaterial is a conductive nanocomposite material that can enhance the electrical conductivity and anti-electromagnetic interference capability of the wire;

[0043] In step S7, the use of conductive nanocomposites can significantly improve the conductivity and anti-electromagnetic interference capabilities of wires. The introduction of nanomaterials can effectively reduce the resistance of wires, thereby improving conductivity and ensuring more efficient current transmission. At the same time, nanocomposites have excellent electromagnetic shielding properties, which can effectively reduce external electromagnetic interference and ensure the stable operation of wires in complex environments. This process not only optimizes the performance of wires, but also improves their reliability in high-frequency and high-power environments.

[0044] In step S5, the electromagnetic interference tester detects whether each layer of wrapping effectively reduces electromagnetic interference;

[0045] Using an electromagnetic interference tester to test the effectiveness of each layer of wrapping helps ensure that the wires have adequate electromagnetic shielding performance during operation. This test verifies that each layer of wrapping material effectively reduces electromagnetic interference, preventing external electromagnetic waves from interfering with the wire's internal signals or other devices, thereby ensuring system stability and reliability. This design can improve the wire's anti-interference ability in complex electromagnetic environments, avoid electromagnetic pollution and signal distortion, and ensure the normal operation of the equipment.

[0046] The packaging process uses an automated tracking system to ensure the traceability of each wire. The packaging speed is 200 wires per minute, and the tracking system accuracy is ≤0.5mm.

[0047] By using an automated tracking system for packaging, the traceability of each wire can be effectively ensured, and the transparency and management efficiency of the production process can be improved. The tracking system has an accuracy of 0.5mm and can accurately record the packaging information of each wire to ensure the integrity and consistency of the product. The automated packaging speed is 200 wires / minute, which not only greatly improves production efficiency, but also reduces errors and time delays in manual operations, ensuring an efficient and accurate production process.

[0048] The environmentally friendly materials are polyamide and polyethylene, which are used to reduce environmental impact and maintain the high performance of the wire;

[0049] Using biodegradable and recyclable environmentally friendly materials as packaging materials can not only effectively reduce environmental impact, but also meet the needs of sustainable development while maintaining the high performance of the wires, thereby helping to reduce environmental pollution caused by plastics and other harmful substances, reduce resource waste, and at the same time ensure the quality and function of the wires.

[0050] The following combines the above content to further explain the processing technology of different cables.

[0051] Example 1: Processing technology for conventional conductivity wires

[0052] Material selection: Select high-purity copper with conductivity ≥58MS / m as the conductor material, hardness of 120HV, heat resistance ≥200℃, which meets the standard requirements.

[0053] Wire cutting: The selected copper material is cut into the specified length, with the cutting error controlled within ±0.1mm. The surface is treated by high-temperature cleaning method at a temperature of 200℃ to remove surface dirt and oxide layer.

[0054] Coating: Coat the conductor surface with thermosetting insulation material with a coating thickness of 0.3mm. The material is cured at 150℃ to 200℃ to ensure uniform and firm adhesion of the coating.

[0055] Multi-layer wrapping: Use a wrapping machine for multi-layer wrapping, with 6 layers of wrapping and a tension control error of no more than 0.2N to ensure that each layer is wrapped evenly and firmly.

[0056] Electromagnetic interference test: After wrapping, the wires are tested for electromagnetic interference. An electromagnetic interference tester is used to check whether each layer of wrapping effectively reduces electromagnetic interference. The test results ensure that the electromagnetic interference level is ≤30dB.

[0057] Integrated sensor system: Current sensor, temperature sensor and pressure sensor are integrated inside the wire to monitor the working status of the wire in real time. The current range is 1-10A, the temperature range is -10℃ to 150℃, and the pressure is ≤2MPa.

[0058] Application of nanomaterials: A conductive nanocomposite material with a thickness of 5-10μm is coated on the coating and insulation layer. The material enhances the conductivity and anti-electromagnetic interference ability of the wires, with a conductivity of ≥58MS / m and an anti-electromagnetic interference performance of ≥40dB.

[0059] Use of environmentally friendly materials: Use degradable environmentally friendly materials instead of traditional insulation materials, with a degradation period of ≤5 years and a recycling rate of ≥90%.

[0060] Automated tracking system: An automated tracking system is set up during the wrapping process to ensure the traceability of each wire. The tracking accuracy is controlled at ≤0.5mm and the packaging speed is 200 wires / minute.

[0061] Example 2: Processing technology for high-temperature heat-resistant wires

[0062] Material selection: Select copper with conductivity ≥58MS / m, hardness of 150HV, and heat resistance of more than 250℃ to meet the needs of high temperature environment.

[0063] Wire cutting: Laser cutting technology is used for precise cutting, with the cutting error controlled within ±0.1mm, and the high temperature cleaning process is controlled at 250℃ to ensure that all impurities and oxides are removed.

[0064] Coating: Use high temperature resistant thermosetting insulating coating, the coating thickness is controlled at 0.4mm, and the coating is cured at a temperature of 175℃ to ensure the uniformity and firmness of the coating.

[0065] Multi-layer wrapping: Advanced wrapping equipment is used for 6-layer wrapping, and the tension error is kept within ±0.2N to ensure that each layer of the wire is wrapped stably and reliably.

[0066] Electromagnetic interference test: Perform electromagnetic interference test on each wire to ensure that the electromagnetic interference level is ≤25dB to meet more stringent electromagnetic compatibility requirements.

[0067] Integrated sensor system: Temperature, pressure and current sensors are integrated inside the wires, with a temperature range of -10°C to 250°C, a current range of 1-20A, and a pressure sensor that can measure a maximum pressure of ≤2MPa, ensuring real-time monitoring of the working status of the wires.

[0068] Application of nanomaterials: Use nanocomposites with strong electrical conductivity and anti-electromagnetic interference capabilities to coat the coating and insulation layers. The thickness of the nanomaterial is 8μm, the electrical conductivity is not less than 60MS / m, and the anti-electromagnetic interference performance is ≥50dB.

[0069] Use of environmentally friendly materials: Use degradable and highly recyclable environmentally friendly materials to ensure the high performance and environmental friendliness of the wires. The degradation period of the materials is ≤5 years and the recycling rate is ≥90%.

[0070] Automated Tracking System: Equipped with a high-precision automated tracking system to ensure the quality and traceability of each wire. Tracking accuracy is controlled to ≤ 0.5mm, and the packaging speed is maintained at 200 wires / minute.

[0071] Example 3: Processing technology for high-performance cables

[0072] Material selection: Choose copper with conductivity ≥58MS / m, hardness 130HV, and heat resistance ≥200℃, which is suitable for high-performance cable requirements.

[0073] Wire cutting: Use precision cutting equipment to cut the wires with an error control of ±0.1mm. After cutting, the wire surface oxide layer and impurities are removed by high-temperature cleaning at 200℃.

[0074] Coating: The conductor is coated with thermosetting insulation material with a coating thickness of 0.3mm. The coating is cured at 160°C to ensure that the coating is firm and uniform.

[0075] Multi-layer wrapping: Automated wrapping equipment is used for 5-layer wrapping, with a tension control error of ±0.2N to ensure the stability and uniformity of each layer.

[0076] Electromagnetic interference test: Use an electromagnetic interference tester to test the electromagnetic interference level to ensure that the electromagnetic interference of each wire is less than 30dB.

[0077] Integrated sensor system: Integrated current, temperature, pressure and other sensor systems monitor the working status of the wires in real time. The current range is 1-10A, the temperature range is -10℃ to 150℃, and the pressure is ≤2MPa. Self-repair solutions are also provided.

[0078] Application of nanomaterials: Conductive nanocomposites are used in the coating and insulation layers of the conductors. The thickness of the nanomaterial is 6μm, the conductivity is ≥58MS / m, and the anti-electromagnetic interference capability is enhanced, with performance reaching above 40dB.

[0079] Use of environmentally friendly materials: Use degradable and recyclable environmentally friendly materials to replace traditional insulation materials. The degradation period of environmentally friendly materials is ≤5 years and the recycling rate is ≥90%.

[0080] Automated tracking system: A high-precision automated tracking system is used during the packaging process to ensure the traceability of each wire. The system accuracy is ≤0.5mm and the packaging speed is 200 wires / minute, ensuring production efficiency and quality.

[0081] The following compares the processing techniques of three different cables in combination with Example 1, Example 2, and Example 3:

[0082]

[0083] As can be seen from the figure, all three examples use copper with a conductivity of ≥58MS / m as the base material. However, Example 2 has higher requirements for heat resistance and selects copper with stronger heat resistance (≥250°C). Example 3 also has higher heat resistance requirements (≥200°C). All examples require the wire cutting error to be controlled within ±0.1mm. For the cleaning process, Examples 1 and 3 use a high-temperature cleaning temperature of 200°C, while Example 2 uses a high-temperature cleaning temperature of 250°C. This shows that Example 2 requires higher decontamination and oxide removal effects.

[0084] Furthermore, the thickness and curing conditions of the coatings of different cable devices are different. Examples 1 and 3 use a 0.3 mm thick coating, while Example 2 uses a thicker 0.4 mm coating. The coating curing temperature of Example 2 is relatively high at 175°C, while the coating curing temperature of Examples 3 and 1 is lower at 160°C to 200°C. All three examples use nanocomposites to enhance electrical conductivity and anti-electromagnetic interference performance. Example 2 uses an 8 μm thick nanomaterial, which requires higher electrical conductivity (≥60MS / m) and the strongest resistance to electromagnetic interference (≥50 dB).

[0085] In summary, the three processing techniques of this solution reflect the special needs of different types of wires. Example 2 is suitable for high-temperature environments and has higher heat resistance and more stringent electromagnetic interference requirements, while Example 1 is suitable for conventional applications, and Example 3 focuses more on the requirements of high-performance cables. The processing technology of each embodiment takes into account the requirements of material properties, processing accuracy, environmental protection and efficient production. Operators can select and apply the cables in Example 1, Example 2 and Example 3 according to actual needs.

[0086] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A process for processing multi-layer wrapped electric wires, characterized in that: The following steps are involved: S1. Material selection: Choose copper that meets the standards of conductivity, hardness and heat resistance. The conductivity is ≥58MS / m, the hardness is 100-160HV, and the heat resistance is ≥200°C. S2, wire cutting, cutting error ± 0.1mm, remove surface dirt and oxide layer by high temperature cleaning, the cleaning temperature is 200℃; S3. Apply the coating material on the surface of the conductor with a coating thickness of 0.2-0.5 mm and a curing temperature of 150-200°C. Ensure that the coating is uniform and firm through thermal curing. S4, perform multi-layer wrapping, the number of wrapping layers is 5-10 layers, and the tension control error is ≤0.2N; S5. Interference test: perform electromagnetic interference test on the wrapped wire to ensure that the electromagnetic interference level is ≤30dB; S6. Integrate a sensor system inside the wire to monitor parameters including but not limited to current, temperature, and pressure in real time. The current range is 1-10A, the temperature range is -10℃ to 150℃, and the pressure is ≤2MPa. The data analysis results provide a self-repair solution. S7. Apply nanomaterials to the coating and insulation layer of the wire, with a thickness of 5-10 μm, conductivity ≤ 58 MS / m, and electromagnetic interference resistance ≥ 40 dB, to enhance the heat resistance, conductivity, and electromagnetic interference resistance of the wire; S8. Use degradable and environmentally friendly materials or recyclable materials to replace traditional insulation materials. The degradation period of environmentally friendly materials shall be ≤5 years and the recycling rate shall be ≥90%.

2. The processing technology of multi-layer wrapped electric wire according to claim 1, characterized in that: The coating material is a thermosetting insulating material.

3. The processing technology of multi-layer wrapped electric wire according to claim 1, characterized in that: In step S6, the sensor system includes a current sensor, a temperature sensor, and a pressure sensor to monitor the working status of the wire in real time.

4. The processing technology of multi-layer wrapped electric wire according to claim 1, characterized in that: In step S7, the nanomaterial is a conductive nanocomposite material, which is used to enhance the electrical conductivity and anti-electromagnetic interference capability of the wire.

5. The processing technology of multi-layer wrapped electric wire according to claim 1, characterized in that: In step S5, the electromagnetic interference tester detects whether each layer of wrapping effectively reduces electromagnetic interference.

6. The processing technology of multi-layer wrapped electric wire according to claim 1, characterized in that: The packaging process uses an automated tracking system to ensure the traceability of each wire.

7. The processing technology of multi-layer wrapped electric wire according to claim 1, characterized in that: The packaging speed is 200 pieces / minute, and the tracking system accuracy is ≤0.5mm.

8. The processing technology of multi-layer wrapped electric wire according to claim 1, characterized in that: The environmentally friendly materials are polyamide and polyethylene, which are used to reduce environmental impact and maintain high performance of the wire.

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