Roller forming device and forming method thereof

Abstract

The invention relates to the field of tempering furnaces, and particularly discloses a roller forming device and a forming method.The roller forming device comprises a mold mechanism and a pay-off mechanism, and the mold mechanism is provided with a frame, a mandrel, two power connection assemblies, two mold discs and other parts and can position and electrify conductive rib plates; the invention further comprises a roller forming method based on the device. The roller forming method comprises the steps of arranging the conductive rib plate, unwinding the metal wire coil, winding and processing the net-shaped roller body, adjusting the wall thickness and the mesh size, welding and connecting all parts, cutting off the roller body, overturning and encircling, connecting and welding with the roller ring and the like. The technical effects that efficient forming of the roller is achieved, and the wall thickness and the mesh size of the net-shaped roller body of the roller can be flexibly adjusted are achieved.

Description

Technical Field

[0001] The present application relates to the field of tempering furnaces, and in particular to a roller forming device and a roller forming method. Background Art

[0002] Currently, a porous cylinder is installed in the hearth of a tempering furnace. This cylinder, with its uniformly distributed hollow pores, guides the airflow within the furnace to form a stable flow path. When the high-temperature gas flows through the pores, the airflow changes direction, effectively dispersing heat accumulation in localized high-temperature areas and preventing deformation or performance variations in the workpiece due to uneven heating. This structure is particularly suitable for tempering processes that require precise temperature control, improving the uniformity of the temperature field within the furnace. Furthermore, the porous structure accelerates heat transfer by increasing the gas-solid contact area.

[0003] To ensure the performance of the tempering furnace, the specifications of the porous cylinder, such as the cylinder thickness and the number of through holes, also need to be accurately set. In the related art, the porous cylinder method uses a forming device to coil and weld the metal plate into a shape, and then open holes in the formed cylinder.

[0004] The aforementioned related technologies have the following drawbacks: The process involves forming the cylindrical body by coiling and welding the metal sheets, and then drilling holes in the formed cylindrical body. This can lead to insufficient strength for thin cylindrical walls, and difficulty drilling holes for thicker cylindrical walls. Consequently, the forming device is cumbersome when processing porous cylindrical bodies of varying specifications. Summary of the Invention

[0005] In order to facilitate the processing and forming of porous cylinders of different specifications, the present application provides a roller forming device.

[0006] The first aspect of the present application provides a roller forming device that adopts the following technical solution: A roller forming device includes a mold mechanism and a wire pay-off mechanism, wherein the mold mechanism includes a frame, a core shaft, two power connection components and two mold plates, and the core shaft includes a hollow column rotatably connected to the frame; The two power connection components are respectively arranged at the two ends of the hollow column, and the power connection components include a plurality of conductive seats distributed along the circumference of the hollow column; The two mold plates are both arranged on the hollow column between the two power connection components, and the two mold plates are arranged corresponding to the two power connection components; The mold plate includes a plurality of rigid conductive rods corresponding to the plurality of conductive seats, wherein the first ends of the rigid conductive rods are movably mounted on the corresponding conductive seats, and the second ends of the rigid conductive rods are used to be plugged into one end of the conductive rib plate of the roller in the length direction; The wire-releasing mechanism is arranged on the side of the hollow column and can move back and forth along the axis direction of the hollow column.

[0007] By adopting the above technical solution, multiple conductive ribs can be arranged along the circumference of the hollow column and plugged into the rigid conductive rod to achieve the construction of a conductive path; the wire-releasing mechanism can move back and forth along the axis of the hollow column and rotate in conjunction with the hollow column, so that the metal wire is spirally wound on the outer circumference of the conductive ribs, realizing the processing of the roller mesh cylinder, and according to the wall thickness requirements of the mesh cylinder, the corresponding number of layers of metal wire are spirally wound on the outer circumference of the multiple conductive ribs, and the winding density of the metal wire is adjusted according to the mesh size of the mesh cylinder. The denser the spiral winding of the metal wire, the smaller the mesh, and the sparser the spiral winding of the metal wire, the smaller the mesh. After the mesh cylinder is processed, the conductive ribs and the metal wires are connected to low-voltage direct current using the power connection component, and the high resistance of the conductive ribs and the metal wires themselves is used to generate heat, so that the conductive ribs and the metal wires, and the metal wires can be welded together, thereby achieving the fixation between the mesh cylinder and the multiple conductive ribs. In summary, the present application can utilize metal wire winding to process a roller of suitable specifications according to the thickness and mesh specification requirements of the roller, thereby facilitating the processing and forming of porous cylinders of different specifications.

[0008] Preferably, the conductive seat is provided with two conductive clamping plates arranged opposite to each other, and the opposite sides of the two conductive clamping plates are provided with a limiting groove arranged along the axis direction of the hollow column; The first end of the rigid conductive rod is arranged between the two limiting grooves and is also in contact with the two conductive clamping plates.

[0009] By adopting the above technical solution, relative conductive clamps and limit grooves are provided on the conductive seat, so that the first end of the rigid conductive rod is placed therebetween and contacts the clamps, thereby ensuring effective conduction between the rigid conductive rod and the conductive seat, and making the rigid conductive rod movable in the axial direction of the hollow column, which is beneficial for the mold plate operation to fix the conductive rib plate.

[0010] Preferably, the mold plate further comprises a movable insulating ring sleeved on the hollow column, and the movable insulating ring is slidably connected to the hollow column in the axial direction of the hollow column.

[0011] By adopting the above technical solution, the sliding connection between the movable insulating ring and the hollow column in the axial direction of the hollow column can enable the mold plate to realize the movable function, thereby making the rigid conductive rod and one end of the conductive rib plate in the length direction stably plugged in, which is beneficial to the subsequent forming processing of the roller by the roller forming device.

[0012] Preferably, an elastic conductive member is provided at one end of the rigid conductive rod away from the conductive seat.

[0013] By adopting the above technical solution, when processing the roller, the elastic conductive part of the rigid conductive rod can be inserted into the slot opposite to the conductive rib plate and pressed against the conductive rib plate, which can ensure that an effective conductive path is formed between the elastic conductive part and the conductive rib plate, providing a basis for subsequent electrical welding of the conductive rib plate and the metal wire; at the same time, it is convenient to separate the rigid conductive rod from the conductive rib plate after processing is completed, which is convenient for removing the parts.

[0014] Preferably, the mold mechanism further comprises a central positioning ring provided between the two mold plates, the central positioning ring comprising a plurality of insulating plugs corresponding one-to-one to the plurality of rigid conductive rods, the plurality of insulating plugs being distributed along the circumference of the hollow column; In the radial direction of the hollow column, the first end of the insulating rod is slidably connected to the hollow column, and the second end of the insulating rod is used to be plugged into the side wall of the conductive rib plate.

[0015] By adopting the above technical solution, a central positioning ring is added, and the insulating rods are distributed along the circumference of the hollow column and are slidingly connected to the hollow column in the radial direction. The ends of the insulating rods are plugged into the side walls of the conductive rib plates, which facilitates the initial fixation of the conductive rib plates and facilitates the subsequent precise support of the two mold plates against the conductive rib plates through rigid conductive rods.

[0016] Preferably, the insulating rod is a non-round rod.

[0017] By adopting the above technical solution, when the middle positioning ring is running, the insulating rod extends out of the guide hole and is inserted into the first slot of the conductive rib plate. Since the insulating rod is a non-round rod, the conductive rib plate can be prevented from rotating automatically after being plugged in and fixed, thereby better fixing the conductive rib plate.

[0018] Preferably, the central positioning ring further comprises an insulating sleeve coaxially sleeved on the hollow column; the insulating sleeve is provided with a plurality of guide through holes arranged along the radial direction of the hollow column, and the plurality of guide through holes are distributed along the circumference of the hollow column; The plurality of insulating rods correspond to the plurality of guide through holes one by one, and the insulating rods are coaxially arranged in the corresponding guide through holes.

[0019] By adopting the above technical solution, the insulating sleeve can integrate multiple insulating rods together, which is convenient for overall layout and operation. The guide through hole can guide the movement of the insulating rod, so that the insulating rod can be accurately inserted into the slot of the conductive rib plate, thereby improving the fixing accuracy of the conductive rib plate.

[0020] Preferably, the central positioning ring further comprises a movable annular member coaxially arranged in the hollow column; the movable annular member is arranged on the side of the insulating sleeve and is slidably connected to the hollow column in the length direction of the hollow column; The guide through hole is communicated with the interior of the hollow column. A connecting rod is connected between the second end of each insulating plug and the movable ring member. The connecting rod is hinged to the second end of the insulating plug and the movable ring member.

[0021] By adopting the above technical solution, the movable ring can slide and the connecting rod can be used to drive the insulating rod to extend or retract into the guide hole, thereby realizing the fixing and releasing operations of the conductive rib plate, making it convenient to set and remove the conductive rib plate during the roller forming process.

[0022] Preferably, the connecting rod and the second end of the insulating plug are connected with a limiting rod coaxial with the connecting rod; the outer diameter of the limiting rod is greater than the outer diameter of the insulating plug.

[0023] By adopting the above technical solution, when the movable ring drives the insulating rod to move along the radial direction of the hollow column, the limit rod can limit the moving distance of the insulating rod, prevent the insulating rod from excessively extending, and ensure that the insulating rod can be accurately inserted into the slot of the conductive rib plate of the roller, thereby stably realizing the positioning and limiting functions of the conductive rib plate.

[0024] A roller forming method, based on the roller forming device, comprises the following steps: S1. Set up conductive rib plates. Arrange multiple conductive rib plates along the circumference of the core shaft. Fix the multiple conductive rib plates with a central positioning ring. Two mold plates respectively support the ends of the conductive rib plates through rigid conductive rods. S2. Setting a metal wire coil, unwinding the metal wire coil using a pay-off mechanism, and fixing the head end of the metal wire coil on the conductive rib plate; S3. Processing the mesh cylinder, the hollow column rotates, and the wire-releasing mechanism releases the wire and reciprocates along the axis of the hollow column, so that the metal wire can be spirally wound layer by layer on the outer peripheral surface of the plurality of conductive rib plates; S4. Adjust the wall thickness of the mesh cylinder. According to the wall thickness requirement of the mesh cylinder, spirally wind a corresponding number of layers of metal wire on the outer circumference of the plurality of conductive rib plates; S5. Adjust the mesh size of the mesh cylinder. Adjust the winding density of the metal wire according to the mesh size of the mesh cylinder. The denser the metal wire is spirally wound, the smaller the mesh size is. The sparser the metal wire is spirally wound, the smaller the mesh size is. S6. Connect the mesh cylinder and the conductive rib plates, connect one end of the metal wire to the rigid conductive rod of one die plate, and the other end of the metal wire to the rigid conductive rod of the other die plate, supply low-voltage direct current to the power connection assembly, and utilize the high resistance of the conductive rib plates and the metal wires to generate heat, thereby enabling the conductive rib plates and the metal wires, and the metal wires to be welded together, thereby achieving fixation between the mesh cylinder and the multiple conductive rib plates; S7. Cut the mesh cylinder axially, disconnect the power supply assembly, and cut the mesh cylinder along the length of the conductive ribs. Move the insulating rods and the die plate away from the conductive ribs, release the restraints on the conductive ribs, and then remove the mesh cylinder and the multiple conductive ribs from the core shaft. S8, turning the mesh cylinder inside out and then closing it, flattening the mesh cylinder, turning it inside out and then closing it, so that the conductive ribs are located outside the mesh cylinder; S9, connecting the conductive rib plates and the first cylinder ring, plugging and connecting the multiple conductive rib plates and the first cylinder ring to achieve preliminary fixation of the multiple conductive rib plates and the mesh cylinder; S10, connecting the conductive rib plates and the second barrel rings, wherein the two second barrel rings are respectively provided at both ends of the conductive rib plates, so that the plurality of conductive rib plates and the second barrel rings are plug-connected, thereby further fixing the plurality of conductive rib plates and the mesh barrel; S11, the conductive rib plate, the first barrel ring and the second barrel ring are welded together.

[0025] By adopting the above technical solution, multiple conductive rib plates can be arranged and fixed along the circumference of the core shaft, the head end of the metal wire coil is fixed on the conductive rib plate after unwinding, and the metal wire is spirally wound around the outer periphery of the conductive rib plate by rotating the hollow column and moving the wire-releasing mechanism to form a mesh cylinder. The wall thickness and mesh size of the mesh cylinder can be adjusted as needed, and the mesh cylinder and the conductive rib plate are welded together by energizing. The mesh cylinder can be conveniently cut axially and removed, and the mesh cylinder is turned inside out and then enclosed to realize the plug-in connection between the conductive rib plate and the first barrel ring and the second barrel ring and finally welded to form a roller.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. The pay-off mechanism moves back and forth along the axis of the hollow column and rotates in conjunction with the hollow column, allowing the metal wire to be quickly spirally wound around the outer circumference of the conductive rib plate, accelerating the roller forming speed, improving production efficiency, and facilitating the rapid processing of rollers of different specifications; 2. Supply low-voltage DC power to the power connection components, and utilize the high-resistance heat generation of the conductive ribs and metal wires to weld and fix the mesh cylinder and the conductive ribs. This avoids errors in traditional assembly methods, improves the accuracy and stability of the roller, and ensures the quality of rollers of different specifications. 3. The number of winding layers and density of the metal wire can be adjusted to flexibly change the wall thickness and mesh size of the mesh cylinder, which can meet the production needs of rollers of different specifications and shapes and facilitate the processing and forming of rollers of different specifications. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0028] Figure 1 This is a schematic diagram of the overall structure of a roller forming device of the present application; Figure 2 It is a schematic diagram of the overall structure of the mold mechanism; Figure 3 It is a schematic diagram of the axial cross-sectional structure of the mold mechanism; Figure 4 It is a schematic diagram of the radial cross-sectional structure of the mold mechanism; Figure 5 It is a structural diagram of the finished drum; Figure 6 This is a schematic diagram of the axial cross-section structure of the finished drum. Figure 7 This is a schematic flow chart of a roller forming method of the present application.

[0029] Reference numerals: 1. Machine tool; 2. Mold mechanism; 20. Frame; 21. Mandrel; 211. Hollow column; 212. Rotating shaft; 213. Turntable; 22. Power connection assembly; 221. Conductive seat; 222. Conductive splint; 2201. Limiting groove; 223. Power cord; 23. Middle positioning ring; 231. Insulating sleeve; 23101. Limiting blind hole; 23102. Guide through hole; 232. Insulating plug; 233. Limiting rod; 234. Movable ring; 235. Connecting rod; 24. Mold plate; 241. Movable insulating ring; 2 42. Rigid conductive rod; 243. Elastic conductive part; 3. Pay-off mechanism; 31. Movable base; 32. Pay-off wheel; 33. First clamping and conveying assembly; 34. Second clamping and conveying assembly; 35. Third clamping and conveying assembly; 36. Tension adjustment assembly; 37. Wire breaking assembly; 4. Roller; 41. Conductive rib plate; 4101. First slot; 4102. Second slot; 42. Mesh cylinder; 420. Metal wire; 43. First barrel ring; 431. First plug; 44. Second barrel ring; 441. Second plug. DETAILED DESCRIPTION

[0030] The following is combined with Figure 1-7 This application is described in further detail.

[0031] The embodiment of the present application discloses a roller forming device.

[0032] Reference Figure 1The roller forming device includes a machine tool 1, a mold mechanism 2 and a wire-releasing mechanism 3. The machine tool 1 is a conventional machine tool 1, and a suitable model can be selected according to processing requirements.

[0033] Reference Figure 2 、 Figure 3 and Figure 4 The mold mechanism 2 includes a frame 20, a core shaft 21, a power connection assembly 22, a central positioning ring 23, and a mold plate 24. The frame 20 is detachably mounted on the machine tool 1 and is used to integrate the core shaft 21, the power connection assembly 22, the central positioning ring 23, and the mold plate 24, thereby facilitating the disassembly and assembly of the mold mechanism 2 as a whole.

[0034] Reference Figure 2 、 Figure 3 and Figure 4 The core shaft 21 includes a hollow column 211, a rotating shaft 212, and a rotating disk 213. There are two rotating disks 213, which are coaxially mounted on the rotating shaft 212 and are both rotatably connected to the frame 20. The hollow column 211 is a linear cylinder with a cross-section that can be circular, elliptical, polygonal, etc. The hollow column 211 is coaxially mounted on the rotating shaft 212 between the two rotating disks 213. The rotating shaft 212 can be driven by a motor such as a servo motor.

[0035] Reference Figure 2 、 Figure 3 and Figure 4 The power connection assembly 22 comprises two components, one corresponding to each of the two rotating disks 213, and one mounted on each end of the hollow column 211. The power connection assembly 22 includes a plurality of conductive bases 221 and a plurality of power cords 223, each corresponding to each of the conductive bases 221. The conductive bases 221 are distributed along the circumference of the hollow column 211 and are detachably connected to the outer wall of the hollow column 211. The first end of the power cord 223 is connected to the corresponding conductive base 221, and the second end of the power cord 223 is mounted on the corresponding rotating disk 213. The second end of the power cord 223 also requires access to a power source, which can be done using conventional means. Each conductive base 221 is provided with two opposing conductive clamps 222 on one end facing away from the hollow column 211. The opposing sides of the conductive clamps 222 are each provided with a retaining groove 2201, which is arranged along the axis of the hollow column 211.

[0036] Reference Figure 2 、 Figure 3 and Figure 4The mold disc 24 has two mold discs 24, and the two mold discs 24 correspond one-to-one to the two power connection components 22, and the two mold discs 24 are both installed on the hollow column 211 between the two power connection components 22. The mold disc 24 includes a movable insulating ring 241 and a plurality of rigid conductive rods 242. The movable insulating ring 241 is composed of two semi-insulating rings that are detachably connected. The movable insulating ring 241 is coaxially sleeved on the hollow column 211, and the movable insulating ring 241 is movably connected to the hollow column 211 in the axial direction of the hollow column 211. Specifically, a slide rail is provided on the inner side of the movable insulating ring 241, and the slide rail is axially installed on the hollow column 211. A slider connected to the movable insulating ring 241 is provided on the slide rail. The movable insulating ring 241 is driven to move by the cooperation of the slide rail and the slider. Multiple rigid conductive rods 242 are arranged in a one-to-one correspondence with the multiple conductive seats 221 of the corresponding power connection assembly 22. The multiple rigid conductive rods 242 are distributed along the circumference of the hollow column 211 and are also arranged along the axial direction of the hollow column 211. The middle portion of the rigid conductive rod 242 is connected to the movable insulating ring 241. The first end of the rigid conductive rod 242 is located between the two limiting grooves 2201 on the corresponding conductive seat 221, and the two conductive clamping plates 222 are in contact with the first end of the rigid conductive rod 242. When the movable insulating ring 241 is driven to move, the first end of the rigid conductive rod 242 slides between the two conductive clamping plates 222, ensuring that the first end of the rigid conductive rod 242 and the two conductive clamping plates 222 are always in a conductive state. The second end of the rigid conductive rod 242 is provided with an elastic conductive member 243.

[0037] Reference Figure 2 、 Figure 3 and Figure 4The middle positioning ring 23 is mounted on the hollow column 211 between the two mold plates 24. The middle positioning ring 23 includes an insulating sleeve 231, an insulating plug 232, a limiting rod 233, a movable ring 234, and a connecting rod 235. The insulating sleeve 231 is coaxially sleeved on the hollow column 211. The inner wall of the insulating sleeve 231 is provided with a plurality of radially arranged limiting blind holes 23101. The plurality of limiting blind holes 23101 are arranged in a one-to-one correspondence with the plurality of conductive seats 221, and the limiting blind holes 23101 are connected to the interior of the hollow column 211. A coaxial guide through hole 23102 is provided at the bottom of each limiting blind hole 23101. The inner diameter of the guide through hole 23102 is smaller than the inner diameter of the limiting blind hole 23101. There are multiple insulating rods 232 and multiple limiting rods 233. The multiple insulating rods 232 correspond one-to-one with the multiple guide holes 23102, and the multiple limiting rods 233 correspond one-to-one with the multiple limiting blind holes 23101. The insulating rods 232 are coaxially disposed within the guide holes 23102, while the limiting rods 233 are coaxially disposed within the limiting blind holes 23101. The insulating rods 232 and corresponding limiting rods 233 are coaxially connected. Both the insulating rods 232 and limiting rods 233 are slidably connected to the hollow column 211 along the axis of the limiting blind holes 23101. The insulating rods 232 are non-round rods, such as angular rods.

[0038] Reference Figure 2 、 Figure 3 and Figure 4 Specifically, the movable annular member 234 is coaxially arranged on the hollow column 211 on the side of the insulating sleeve 231 and is slidably connected to the hollow column 211 in the axial direction of the hollow column 211. Specifically, the movable annular member 234 and the hollow column 211 are connected to a circumferentially arranged cylinder, screw rod or other telescopic member. Each limit rod 233 is connected to the movable annular member 234 at one end away from the insulating plug 232 by a connecting rod 235. The connecting rod 235 is hinged to the limit rod 233 and the movable annular member 234. When the telescopic member drives the movable annular member 234 to approach the insulating sleeve 231, the insulating plug 232 extends out of the guide hole 23102 under the transmission action of the connecting rod 235. The limit blind hole 23101 and the limit rod 233 cooperate to limit the length of the insulating plug 232 extending out of the guide hole 23102. When the telescopic member drives the movable annular member 234 away from the insulating sleeve 231 , the insulating plug 232 is retracted into the guide through hole 23102 under the transmission action of the connecting rod 235 .

[0039] Reference Figure 2 、 Figure 3 and Figure 4The pay-off mechanism 3 includes a movable base 31, a pay-off wheel 32, a first clamping and conveying assembly 33, a second clamping and conveying assembly 34, a third clamping and conveying assembly 35, a tension adjustment assembly 36 and a wire breaking assembly 37. The movable base 31 is arranged on the machine tool 1 on the side of the mold mechanism 2, and the movable base 31 is slidably connected to the machine tool 1 in the axial direction of the core shaft 21. Specifically, the movable base 31 can be driven by a displacement device with high precision such as a ball screw slide. The pay-off wheel 32 is rotatably mounted on the movable base 31, and the pay-off wheel 32 is driven by a motor to pay off the wire. From the pay-off end of the pay-off wheel 32 to the hollow column 211, the first clamping and conveying assembly 33, the tension adjustment assembly 36, the second clamping and conveying assembly 34, the wire breaking assembly 37 and the third clamping and conveying assembly 35 are sequentially mounted on the movable base 31. Specifically, the first clamping and conveying assembly 33, the second clamping and conveying assembly 34, and the third clamping and conveying assembly 35 can be conventional components that can clamp and convey wires, the tension adjustment assembly 36 can be conventional wire tension adjustment components, and the wire cutting assembly 37 can be a liftable electric saw, a hot melt device that can melt the metal wire 420, or other components that can cut, melt, or shorten the metal wire 420.

[0040] The implementation principle of the roller forming device in the embodiment of the present application is as follows: Reference Figure 5 and Figure 6 The drum 4 includes a mesh cylinder 42, a first cylinder ring 43, a plurality of conductive rib plates 41, and two second cylinder rings 44. The radial cross-section of the mesh cylinder 42 is circular, elliptical, polygonal, etc. Technicians can select a mesh cylinder 42 with a suitable cross-sectional shape according to actual needs. The mesh cylinder 42 is a mesh tube structure formed by spirally winding metal wires 420. The plurality of conductive rib plates 41 are distributed along the circumference of the mesh cylinder 42, and the conductive rib plates 41 are welded to the mesh cylinder 42 along the axial direction of the mesh cylinder 42. A first slot 4101 is provided on the side of the conductive rib plate 41 away from the mesh cylinder 42. The inner wall of the first cylinder ring 43 is provided with a first plug 431 corresponding to the plurality of first slots 4101. The first plug 431 is inserted into the corresponding first slot 4101. Two second rings 44 are provided at either end of the conductive rib plate 41. Axially disposed second slots 4102 are provided on the surface of the conductive rib plate 41 opposite the second rings 44. Each second slot 4102 receives a second plug 441 fixedly connected to the second ring 44. After the mesh cylinder 42, first ring 43, multiple conductive rib plates 41, and two second rings 44 are assembled, the drum 4 can be further reinforced by welding, bolting, or other methods at the connection points, as needed.

[0041] The embodiments of the present application also disclose a roller forming method based on any of the above-mentioned roller forming devices.

[0042] Reference Figure 5 、 Figure 6 and Figure 7 The roller forming method comprises the following steps: S1. Install the conductive rib plates 41. Arrange multiple conductive rib plates 41 along the circumference of the core shaft 21. Secure the multiple conductive rib plates 41 with the central positioning ring 23. The two mold plates 24 respectively support the ends of the conductive rib plates 41 through the rigid conductive rods 242. S2. Set a metal wire 420 roll and unwind the metal wire 420 roll using the unwinding mechanism 3. Fix the head end of the metal wire 420 roll on the conductive rib plate 41, and ensure that the head of the metal wire 420 extends to the mold plate 24. S3, the mesh cylinder 42 is processed, the hollow column 211 rotates, and the pay-off mechanism 3 pays off the wire and reciprocates along the axis direction of the hollow column 211, so that the metal wire 420 can be spirally wound layer by layer on the outer peripheral surface of the plurality of conductive rib plates 41; S4. Adjust the wall thickness of the mesh cylinder 42. Based on the required wall thickness of the mesh cylinder 42, spirally wind a corresponding number of layers of metal wire 420 around the outer circumference of the plurality of conductive ribs 41. Specifically, each reversal of the pay-off mechanism 3 indicates that a layer of metal wire 420 has been spirally wound around the outer circumference of the plurality of conductive ribs 41. Based on production requirements, the number of layers of metal wire 420 wound around the mesh cylinder 42 is determined according to the required wall thickness. S5. Adjust the mesh size of the mesh cylinder 42. The winding density of the metal wires 420 is adjusted according to the mesh size of the mesh cylinder 42. The denser the spiral winding of the metal wires 420, the smaller the mesh size. The sparser the spiral winding of the metal wires 420, the smaller the mesh size. Specifically, adjust the movement speed of the movable base 31. The faster the movement speed of the movable base 31, the sparser the metal wires 420 on the same layer, that is, the larger the mesh size. The slower the movement speed of the movable base 31, the denser the metal wires 420 on the same layer, that is, the smaller the mesh size. S6. Connect the mesh cylinder 42 and the conductive rib plates 41. Connect one end of the metal wire 420 to the rigid conductive rod 242 of one die plate 24, and the other end of the metal wire 420 to the rigid conductive rod 242 of another die plate 24. Supply low-voltage DC power to the power connection assembly 22. Utilize the high resistance of the conductive rib plates 41 and the metal wires 420 to generate heat, thereby enabling the conductive rib plates 41 and the metal wires 420, as well as the metal wires 420, to be welded together, thereby securing the mesh cylinder 42 and the multiple conductive rib plates 41. S7. Cut the mesh cylinder 42 axially, disconnect the power supply assembly 22, and cut the mesh cylinder 42 along the length of the conductive rib plates 41. Move the insulating rods 232 and the die plate 24 away from the conductive rib plates 41, release the restraints on the conductive rib plates 41, and then remove the mesh cylinder 42 and the multiple conductive rib plates 41 from the core shaft 21. S8, turning the mesh cylinder 42 inside out and then closing it, flattening the mesh cylinder 42, turning it inside out and then closing it, so that the conductive rib plate 41 is located outside the mesh cylinder 42; S9. Connect the conductive rib plates 41 and the first cylindrical ring 43. Insert the first plug 431 into the corresponding first slot 4101 to connect the conductive rib plates 41 to the first cylindrical ring 43, thereby achieving a preliminary fixation of the conductive rib plates 41 and the mesh cylindrical body 42. S10, connecting the conductive rib plates 41 and the second barrel rings 44. The two second barrel rings 44 are respectively provided at both ends of the conductive rib plates 41. Inserting the second plugs 441 into the corresponding second slots 4102, the plurality of conductive rib plates 41 are plug-connected with the second barrel rings 44, further securing the plurality of conductive rib plates 41 and the mesh barrel 42. S11 , the conductive rib plate 41 , the first barrel ring 43 and the second barrel ring 44 are welded together.

[0043] This application takes a circular drum 4 with a radial cross section as an example: First, set the conductive rib plates 41. When processing the roller 4, multiple conductive rib plates 41 are fixed along the circumference of the hollow column 211, and multiple conductive rib plates 41 are set along the axis of the hollow column 211. The middle positioning ring 23 is operated, and the movable annular member 234 moves toward the insulating sleeve 231, so that the insulating plug 232 extends out of the guide hole 23102, thereby allowing the insulating plug 232 to be inserted into the first slot 4101. The radial cross-sections of the insulating plug 232 and the first slot 4101 are both prismatic or other non-circular cross-sections to prevent the conductive rib plates 41 from rotating after being inserted and fixed. Then, operate the mold plate 24, and the two mold plates 24 are close to each other, so that the elastic conductive member 243 is inserted into the opposite second slot 4102, and the elastic conductive member 243 is pressed against the conductive rib plate 41, thereby ensuring that an effective conductive path is formed between the elastic conductive member 243 and the conductive rib plate 41. The power line 223 connector on the turntable 213 can be connected to a power source by conventional means.

[0044] Next, a coil of metal wire 420 is set. The coil of metal wire 420 is placed on the pay-off wheel 32, and the head end of the coil of metal wire 420 is manually pulled through the first clamping and conveying assembly 33, the tension adjustment assembly 36, the second clamping and conveying assembly 34, the wire breaking assembly 37, and the third clamping and conveying assembly 35. The technician then secures the head end of the coil of metal wire 420 to the outer wall of the conductive rib plate 41 by welding or other means, with the head of the metal wire 420 extending to the mold plate 24.

[0045] Next, the mesh cylinder 42 is processed. The rotating shaft 212 is driven to rotate, causing the rotating shaft 212 to rotate the hollow column 211, and the pay-off wheel 32 cooperates to pay off the wire. At the same time, the movable base 31 moves back and forth along the axis of the hollow column 211, thereby allowing the metal wire 420 to be spirally wound around the outer circumference of the plurality of conductive rib plates 41.

[0046] In the process of processing the mesh cylinder 42, a mesh cylinder 42 of appropriate thickness and mesh size is processed according to actual needs. When setting the thickness of the mesh cylinder 42, each time the movable base 31 changes direction, it indicates that a layer of metal wire 420 is spirally wound on the outer peripheral surface of the multiple conductive rib plates 41. According to production requirements, the thickness of the mesh cylinder 42 is required, and the corresponding number of layers of metal wire 420 are wound accordingly. When setting the mesh size of the mesh cylinder 42, the moving speed of the movable base 31 is adjusted. The faster the moving speed of the movable base 31, the larger the spacing between the metal wires 420 in the same layer, the sparser the metal wires 420, and the larger the mesh size. The slower the moving speed of the movable base 31, the smaller the spacing between the metal wires 420 in the same layer, the denser the metal wires 420, that is, the smaller the mesh size.

[0047] Secondly, the mesh cylinder 42 and the outer peripheral surfaces of the plurality of conductive rib plates 41 are connected together. After the mesh cylinder 42 is processed, the metal wire 420 at the discharge end of the wire-releasing mechanism 3 is cut. At this time, the mesh cylinder 42 is formed by winding a complete metal wire 420. One end of the metal wire 420 is connected to the rigid conductive rod 242 of one die plate 24, and the other end of the metal wire 420 is connected to the rigid conductive rod 242 of another die plate 24. Specifically, the metal wire 420 at the corresponding position can be clamped by the elastic conductive member 243 and the conductive rib plate 41, or the metal wire 420 can be directly tied to the rigid conductive rod 242. Then, low-voltage direct current is supplied to the power connection component 22, and the high resistance of the conductive rib plates 41 and the metal wires 420 themselves is used to generate heat, so that the conductive rib plates 41 and the metal wires 420, and the metal wires 420 and the metal wires 420 can be welded together, thereby achieving fixation between the mesh cylinder 42 and the multiple conductive rib plates 41.

[0048] Next, remove the mesh cylinder 42 and the multiple conductive ribs 41 from the core shaft 21. De-energize the power supply assembly 22 and cut the mesh cylinder 42 along the length of the conductive ribs 41. Then, move the insulating rods 232 and the mold plate 24 away from the conductive ribs 41, releasing the restraints on the conductive ribs 41. Finally, remove the mesh cylinder 42 and the multiple conductive ribs 41 from the core shaft 21.

[0049] Next, the mesh cylinder 42 is turned inside out and then closed. At this time, the plurality of conductive rib plates 41 are located outside the mesh cylinder 42 .

[0050] Finally, the first drum ring 43 , the two second drum rings 44 and the plurality of conductive rib plates 41 are assembled and welded together to form the drum 4 .

[0051] Unless otherwise defined, the technical or scientific terms used in this application shall have the usual meanings understood by persons of ordinary skill in the field to which this application belongs. The words "first", "second", "third" and similar terms used in the specification and claims of this application do not indicate any order, quantity or importance, but are only used to distinguish different components. Words such as "one" or "a" do not indicate a quantity limitation, but rather indicate the existence of at least one. Words such as "include" or "comprise" mean that the elements or objects appearing before "include" or "comprises" cover the elements or objects listed after "include" or "comprises" and their equivalents, and do not exclude other elements or objects. "Up", "down", "left", "right" and the like are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0052] The above are all optional embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A roller forming device, characterized in that: It comprises a mold mechanism (2) and a wire-paying mechanism (3), wherein the mold mechanism (2) comprises a frame (20), a core shaft (21), two power connection components (22) and two mold plates (24), and the core shaft (21) comprises a hollow column (211) rotatably connected to the frame (20); The two power connection components (22) are respectively arranged at two ends of the hollow column (211), and the power connection components (22) include a plurality of conductive seats (221) distributed along the circumference of the hollow column (211); The two mold plates (24) are both arranged on the hollow column (211) between the two power connection components (22), and the two mold plates (24) are arranged corresponding to the two power connection components (22); The mold plate (24) includes a plurality of rigid conductive rods (242) corresponding one-to-one to the plurality of conductive seats (221), a first end of the rigid conductive rod (242) being movably mounted on the corresponding conductive seat (221), and a second end of the rigid conductive rod (242) being used for plugging into one end of the conductive rib plate (41) of the roller (4) in the length direction; The pay-off mechanism (3) is arranged on the side of the hollow column (211) and is capable of reciprocating along the axial direction of the hollow column (211).

2. A roller forming device according to claim 1, characterized in that: Two conductive clamping plates (222) are provided on the conductive seat (221) and are arranged opposite to each other. The two conductive clamping plates (222) are provided with a limiting groove (2201) arranged along the axis direction of the hollow column (211) on the opposite sides thereof. The first end of the rigid conductive rod (242) is disposed between the two limiting grooves (2201) and is also in contact with the two conductive clamping plates (222).

3. The roller forming device according to claim 1, characterized in that: The mold plate (24) further comprises a movable insulating ring (241) sleeved on the hollow column (211), wherein the movable insulating ring (241) is slidably connected to the hollow column (211) in the axial direction of the hollow column (211).

4. The roller forming device according to claim 3, characterized in that: An elastic conductive member (243) is provided at one end of the rigid conductive rod (242) away from the conductive seat (221).

5. The roller forming device according to claim 1, characterized in that: The mold mechanism (2) further includes a central positioning ring (23) disposed between the two mold plates (24), the central positioning ring (23) including a plurality of insulating plugs (232) corresponding one-to-one to the plurality of rigid conductive rods (242), the plurality of insulating plugs (232) being distributed circumferentially along the hollow column (211); In the radial direction of the hollow column (211), the first end of the insulating plug (232) is slidably connected to the hollow column (211), and the second end of the insulating plug (232) is used for plugging into the side wall of the conductive rib plate (41).

6. The roller forming device according to claim 5, characterized in that: The insulating plug rod (232) is a non-round rod.

7. The roller forming device according to claim 5, characterized in that: The middle positioning ring (23) further includes an insulating sleeve (231) coaxially sleeved on the hollow column (211); The insulating sleeve (231) is provided with a plurality of guide through holes (23102) arranged along the radial direction of the hollow column (211), and the plurality of guide through holes (23102) are distributed circumferentially along the hollow column (211); The plurality of insulating rods (232) correspond one-to-one to the plurality of guide through holes (23102), and the insulating rods (232) are coaxially arranged in the corresponding guide through holes (23102).

8. The roller forming device according to claim 7, characterized in that: The central positioning ring (23) further includes a movable annular member (234) coaxially arranged in the hollow column (211); The movable annular member (234) is arranged on the side of the insulating sleeve (231) and is slidably connected to the hollow column (211) in the length direction of the hollow column (211); The guide through hole (23102) is in communication with the interior of the hollow column (211), and a connecting rod (235) is connected between the second end of each insulating plug (232) and the movable annular member (234), and the connecting rod (235) is hinged to the second end of the insulating plug (232) and the movable annular member (234).

9. The roller forming device according to claim 8, characterized in that: The connecting rod (235) and the second end of the insulating plug rod (232) are connected to a limiting rod (233) coaxial with the connecting rod (235); the outer diameter of the limiting rod (233) is greater than the outer diameter of the insulating plug rod (232).

10. A roller forming method, based on the roller forming device according to any one of claims 1 to 9, characterized in that: The steps include: S1. arranging a conductive rib plate (41), arranging a plurality of conductive rib plates (41) along the circumference of the core shaft (21), fixing the plurality of conductive rib plates (41) with a central positioning ring (23), and supporting the two ends of the conductive rib plates (41) respectively through rigid conductive rods (242); S2, setting a metal wire (420) roll, unwinding the metal wire (420) roll using a wire unwinding mechanism (3), and fixing the head end of the metal wire (420) roll on the conductive rib plate (41); S3, processing the mesh cylinder (42), rotating the hollow column (211), and the wire-releasing mechanism (3) releasing the wire and reciprocating along the axis direction of the hollow column (211), so that the metal wire (420) can be spirally wound layer by layer on the outer peripheral surface of the plurality of conductive rib plates (41); S4, adjusting the wall thickness of the mesh cylinder (42), and spirally winding a corresponding number of layers of metal wires (420) on the outer circumference of the plurality of conductive rib plates (41) according to the wall thickness requirement of the mesh cylinder (42); S5. Adjusting the mesh size of the mesh cylinder (42), and adjusting the winding density of the metal wire (420) according to the mesh size of the mesh cylinder (42). The denser the metal wire (420) is spirally wound, the smaller the mesh size; the sparser the metal wire (420) is spirally wound, the smaller the mesh size. S6, connecting the mesh cylinder (42) and the conductive rib plate (41), connecting one end of the metal wire (420) to the rigid conductive rod (242) of one mold plate (24), and connecting the other end of the metal wire (420) to the rigid conductive rod (242) of another mold plate (24), supplying low-voltage direct current to the power connection component (22), utilizing the high resistance of the conductive rib plate (41) and the metal wire (420) to generate heat, thereby enabling the conductive rib plate (41) and the metal wire (420), and the metal wire (420) and the metal wire (420) to be welded together, thereby achieving fixation between the mesh cylinder (42) and the plurality of conductive rib plates (41); S7, cutting the mesh cylinder (42) axially, disconnecting the power supply assembly (22), cutting the mesh cylinder (42) along the length direction of the conductive rib plate (41), moving the insulating plug (232) and the die plate (24) away from the conductive rib plate (41), releasing the position limit of the conductive rib plate (41), and then removing the mesh cylinder (42) and the plurality of conductive rib plates (41) from the core shaft (21); S8, turning the mesh cylinder (42) inside out and then closing it, flattening the mesh cylinder (42) and turning it inside out and then closing it, so that the conductive rib plate (41) is located outside the mesh cylinder (42); S9, connecting the conductive rib plates (41) and the first cylinder ring (43), plugging and connecting the plurality of conductive rib plates (41) and the first cylinder ring (43), thereby achieving preliminary fixation of the plurality of conductive rib plates (41) and the mesh cylinder (42); S10, connecting the conductive rib plate (41) and the second tube ring (44), wherein the two second tube rings (44) are respectively provided at both ends of the conductive rib plate (41), so that the plurality of conductive rib plates (41) and the second tube rings (44) are plug-connected, thereby further fixing the plurality of conductive rib plates (41) and the mesh tube (42); S11, the conductive rib plate (41), the first barrel ring (43), and the second barrel ring (44) are welded together.

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