Litz wire processing production process and detection device thereof

Abstract

The invention relates to a litz wire processing production process and a detection device thereof, and relates to the technical field of litz wire production, and the litz wire processing production process comprises the following steps: S1, wire preparation; s2, manufacturing an enameled single wire; s3, bunching; s4, twisting is carried out; s5, squaring; and S6, film covering and insulation treatment. According to the Litz wire processing production technology and the detection device thereof, the high-precision CCD camera and the automatic control detection device are introduced, the detection precision and efficiency of scratches and cracks on the surface of the copper wire are remarkably improved, compared with traditional manual detection and fixed-point monitoring equipment, the device can comprehensively detect the surface of the copper wire, personal errors are reduced, and the detection efficiency is improved. The production efficiency is improved, the product quality is ensured, impurities such as grease, dust and oxide possibly existing on the surface of the copper bar are removed through the cleaning assembly, the cleanliness of the surface of the copper wire is ensured through the step, the influence of the impurities on the adhesion performance of insulating paint is avoided, and therefore the uniformity and integrity of a paint film are ensured; and the cleaned copper bar is quickly and thoroughly dried.

Description

Technical Field

[0001] This invention relates to the field of Leeds wire production technology, specifically to a Leeds wire processing and production process and its testing device. Background Technology

[0002] Litz wire is a conductor made of multiple strands of insulated wire twisted or braided together. It is used to reduce losses caused by the skin effect and proximity effect during high-frequency operation. This structure allows the electromagnetic field to be distributed more evenly, thereby mitigating the influence of the skin effect and proximity effect on the current distribution.

[0003] During the production process, it is crucial to measure scratches and cracks in copper wires, as any minor damage can affect the performance of the final product. Specifically, scratches or cracks can lead to increased local resistance, resulting in hot spots and reduced conductivity. These defects can also weaken the overall strength of the copper wire, making it more prone to breakage during use. For subsequent processes such as painting, the quality of the copper wire surface directly affects the adhesion and smoothness of the coating.

[0004] Meanwhile, the reasons for measuring the varnish thickness after coating during the production of Litz wire are mainly as follows: the varnish thickness directly affects the insulation performance of Litz wire. If the varnish is too thin, the insulation effect may be poor; if the varnish is too thick, it may affect the flexibility and mechanical properties of the conductor. By measuring the varnish thickness, it can be ensured that the varnish thickness of each conductor is consistent, thereby ensuring the overall performance of Litz wire. Precise varnish thickness measurement helps to improve product quality and meet the requirements of different applications.

[0005] However, in the existing technology, the detection methods are divided into two types: manual detection and equipment detection. First, manual detection mainly relies on the operator's visual inspection. This method is not only time-consuming and labor-intensive, but also easily affected by subjective factors, resulting in unstable detection results. Second, equipment detection is fixed-point monitoring, which can only detect local areas of the copper wire and is difficult to conduct comprehensive detection of the entire copper wire surface, thus having certain limitations.

[0006] In summary, this application overcomes the shortcomings of existing technologies, such as insufficient detection accuracy, low efficiency, limited detection range, unstable detection environment, complex operation, and high maintenance costs, by introducing an improved detection device into the production process. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides a Litz wire processing production process and its testing device, which has the advantages of efficient and comprehensive detection of scratches and cracks on the surface of copper wire. It solves the problems of traditional manual inspection being time-consuming, labor-intensive, and easily affected by subjective factors, as well as the limitations of fixed-point monitoring equipment in covering the entire surface of the copper wire.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a Litz wire processing technology, comprising the following steps:

[0009] S1 wire preparation: The wire enters the wire drawing machine and the copper strip is drawn into copper wire using liquid copper drawing oil. The drawing speed is controlled during the drawing process. After the wire drawing is completed, optical inspection equipment is used to inspect the surface of the wire.

[0010] S2 Enameled Single Wire Production: After the inspected wire undergoes pretreatment before coating, the surface of the copper wire, which moves at a constant speed, is dragged through the insulating varnish tank of the coating machine and then dried. After drying, a non-contact varnish thickness measuring instrument is used to perform a second measurement of the wire.

[0011] S3 wire bundle: Combines multiple single wires by transposing them into a single enameled wire;

[0012] S4 stranding: at least nine strands of enameled wire are twisted together to form a stranded wire;

[0013] S5 square pressing: Pressing rollers are used to evenly press the nine strands of enameled wire on all four sides of each strand to turn the circular cross-section stranded wire into a square cross-section stranded wire.

[0014] S6 Coating and Insulation Treatment: After the stranded wire is pressed into square shape, a layer of polyimide film and a layer of polyimide composite non-woven fabric are wrapped around it to form a winding wire with a square cross-section; then, two identical winding wires are arranged in parallel and wrapped with insulation material to form a straight-welded rectangular high-frequency Litz wire.

[0015] Furthermore, in step S1, the diameter of the copper wire is ≤0.5mm, the drawing speed is 1500-1800m / min, and the drawing speed ratio is 1.20.

[0016] Furthermore, in step S2, the inlet temperature of the paint coating machine is 200°C, the lower layer temperature is 300°C, the middle layer temperature is 400°C, and the upper layer temperature is 460°C.

[0017] Furthermore, during the wire bundling process in step S3, the control pitch is 35-50mm; during the stranding process in step S4, the control pitch is 22-26mm.

[0018] This application also proposes a testing device for Litz wire processing, including the aforementioned Litz wire processing process, comprising: a workbench, four support columns, a top plate, and a coating machine. The four support columns are all fixed vertically to the upper surface of the workbench. The top plate is fixed to the top of the four support columns and is arranged parallel to the workbench. The coating machine is located on the right side of the workbench and placed on the ground. The upper surface of the workbench is provided with a testing mechanism for testing the drawn wire. The upper surface of the workbench, located to the right of the testing mechanism, is provided with a pretreatment mechanism for facilitating the measurement of the coating thickness.

[0019] The testing institutions include:

[0020] Two support bases are fixed to the upper surface of the worktable;

[0021] Two light boxes, each rotatably connected to the interior of two support bases;

[0022] The mounting base is fixed between the two light boxes on opposite sides;

[0023] Two gears, which are fixed to opposite sides of the two light boxes respectively;

[0024] An electric actuator, which is fixed to the lower surface of the top plate;

[0025] The movable plate is horizontal and fixed to one end of the output shaft of the electric actuator;

[0026] Two toothed plates are symmetrically fixed to the lower surface of the movable plate and mesh with two gears respectively for transmission.

[0027] Two CCD cameras are fixed to the front and rear sides of the mounting base, respectively.

[0028] Multiple light strips are fixed to the inner walls of two light boxes.

[0029] Furthermore, the detection mechanism also includes two positioning columns, and two positioning grooves are formed on the upper surface of the top plate. The positioning columns move linearly within the positioning grooves and do not disengage from each other.

[0030] Furthermore, one end of the CCD camera lens extends through and into the mounting base, and multiple reinforcing columns are fixed between the two light boxes on opposite sides. Reflective film is laid inside both the mounting base and the light boxes.

[0031] Furthermore, the pretreatment mechanism includes:

[0032] Cleaning components for cleaning copper bars;

[0033] A drying assembly for drying cleaned copper strips;

[0034] A paint film thickness measuring instrument fixed to the right side of the painting machine and used to measure the thickness of the copper strip after painting;

[0035] The cleaning assembly includes a cleaning box, a filter plate, a support plate, two hollow rods, two annular nozzles, a water pump, and a splitter pipe. The cleaning box is fixed to the upper surface of the workbench. The filter plate is horizontally fixed between the four inner walls of the cleaning box. The support plate is located above the filter plate and fixed to the rear inner wall of the cleaning box. The two hollow rods are fixedly connected to the upper surface of the support plate, with one end connected to the annular nozzle and the other end extending through and to the lower side of the support plate. The water pump is fixed to the upper surface of the workbench and located in front of the cleaning box. The inlet and outlet of the water pump are both fixedly connected to connecting pipes. One end of the connecting pipe at the inlet end extends through and into the interior of the cleaning box, and one end of the connecting pipe at the outlet end is fixed to one end of the splitter pipe. The other two ends of the splitter pipe are rotatably connected to the bottom ends of the two hollow rods through sealed bearings.

[0036] Furthermore, the drying assembly includes an air duct, two horizontal pipes, multiple high-pressure nozzles, a fan, an air inlet box, and two air outlet pipes. The air duct is fixedly connected between the painting machine and the cleaning box on opposite sides. The two horizontal pipes are fixed to the upper and lower sides of the air duct, respectively. The multiple high-pressure nozzles are respectively connected and fixed to the opposite sides of the two horizontal pipes. The fan is fixed to the upper surface of the top plate. The air inlet box is fixed to the upper surface of the top plate and located to the left of the fan. The two air outlet pipes are respectively connected and fixed to the two horizontal pipes, and the other ends of the two air outlet pipes are connected and fixed to the air outlet end of the fan through a T-junction.

[0037] Furthermore, the air inlet box is a rectangular prism with a hollow interior and a missing left side. The right side of the air inlet box is connected and fixed to the fan via a pipe. Multiple heating wires are fixed inside the air inlet box, and dustproof nets are fixed to the left side of the heating wires and located between the four inner walls of the air inlet box.

[0038] Compared with the prior art, the technical solution of this application has the following beneficial effects:

[0039] 1. The Litz wire processing production process and its testing device: By introducing a high-precision CCD camera and an automated control testing device, this invention significantly improves the accuracy and efficiency of detecting scratches and cracks on the surface of copper wire. Compared with traditional manual inspection and fixed-point monitoring equipment, this device can comprehensively inspect the surface of copper wire, reduce human error, improve production efficiency, and ensure product quality.

[0040] 2. The processing technology and testing device for this Litz wire removes impurities such as grease, dust, and oxides from the surface of the copper strip through a cleaning component. This step ensures the cleanliness of the copper wire surface and avoids the impact of these impurities on the adhesion performance of the insulating varnish, thereby ensuring the uniformity and integrity of the varnish film. The drying component quickly and thoroughly dries the cleaned copper strip. Through the above pretreatment steps, not only is the quality of the coating improved, but more ideal measurement conditions are also provided for the non-contact varnish film thickness measuring instrument. A clean, dry, and flat copper wire surface helps to obtain more accurate and stable varnish film thickness data, thereby ensuring the consistency of the varnish film thickness of each conductor and ultimately improving the overall quality and performance of the product. Attached Figure Description

[0041] Figure 1 This is a schematic diagram of the structure of the present invention;

[0042] Figure 2 This is a schematic diagram of the detection mechanism of the present invention;

[0043] Figure 3 This is a schematic diagram of the pretreatment mechanism of the present invention;

[0044] Figure 4 This is a partial structural diagram of the cleaning component of the present invention.

[0045] In the diagram: 1. Workbench, 2. Support column, 3. Top plate, 4. Painting machine, 5. Inspection mechanism, 51. Support base, 52. Light box, 53. Mounting base, 54. Gear, 55. Electric push rod, 56. Movable plate, 57. Tooth plate, 58. CCD camera, 59. Light strip, 510. Positioning column, 6. Pretreatment mechanism, 61. Cleaning assembly, 611. Cleaning box, 612. Filter plate, 613. Support plate, 614. Hollow rod, 615. Annular nozzle, 616. Water pump, 617. One-to-two pipe, 62. Drying assembly, 621. Air duct, 622. Horizontal pipe, 623. High-pressure nozzle, 624. Fan, 625. Air inlet box, 63. Membrane thickness measuring instrument. Detailed Implementation

[0046] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0047] Please see Figure 1-4 The Litz wire processing technology in this embodiment includes the following steps:

[0048] S1 wire preparation: The wire enters the wire drawing machine and the copper strip is drawn into copper wire using liquid copper drawing oil. The drawing speed is controlled during the drawing process. After the wire drawing is completed, optical inspection equipment is used to inspect the surface of the wire.

[0049] S2 Enameled Single Wire Production: After the inspected wire undergoes pretreatment before coating, the surface of the copper wire, which moves at a constant speed, is dragged through the insulating varnish tank of the coating machine and then dried. After drying, a non-contact varnish thickness measuring instrument is used to perform a second measurement of the wire.

[0050] S3 wire bundle: Combines multiple single wires by transposing them into a single enameled wire;

[0051] S4 stranding: at least nine strands of enameled wire are twisted together to form a stranded wire;

[0052] S5 square pressing: Pressing rollers are used to evenly press the nine strands of enameled wire on all four sides of each strand to turn the circular cross-section stranded wire into a square cross-section stranded wire.

[0053] S6 Coating and Insulation Treatment: After the stranded wire is pressed into square shape, a layer of polyimide film and a layer of polyimide composite non-woven fabric are wrapped around it to form a winding wire with a square cross-section; then, two identical winding wires are arranged in parallel and wrapped with insulation material to form a straight-welded rectangular high-frequency Litz wire.

[0054] It should be noted that the Litz wire processing technology in this embodiment significantly improves production efficiency and product quality through a series of optimized steps. First, in the conductor preparation stage, the copper wire surface is ensured to be free of defects by precisely controlling the wire drawing speed and using optical inspection equipment. Subsequently, in the enameled single wire production process, pretreatment, varnishing, drying, and non-contact varnish thickness measurement are adopted to ensure that the varnish film is uniform and of consistent thickness. The wire bundling and stranding steps optimize the wire structure by controlling the pitch, while the squaring process changes the cross-section of the stranded wire from round to square, enhancing mechanical properties. Finally, the coating and insulation treatment not only improves the insulation performance but also meets the requirements of high-frequency applications through specific winding wire design. Overall, this process achieves efficient and high-quality transformation from raw materials to finished products and is particularly suitable for the production of high-frequency Litz wire.

[0055] In step S1, the diameter of the copper wire is ≤0.5mm, the drawing speed is 1500-1800m / min, and the drawing speed ratio is 1.20. In step S2, the inlet temperature of the coating machine is 200℃, the lower layer temperature is 300℃, the middle layer temperature is 400℃, and the upper layer temperature is 460℃. In step S3, the pitch is controlled to be 35~50mm during the wire bundling process. In step S4, the pitch is controlled to be 22~26mm during the stranding process.

[0056] It should be noted that in step S1, by controlling the copper wire diameter (≤0.5mm), drawing speed (1500-1800m / min), and drawing speed ratio (1.20), the high quality and production efficiency of the copper wire were ensured. In step S2, the multi-layer temperature settings of the coating machine (inlet 200℃, lower layer 300℃, middle layer 400℃, upper layer 460℃) optimized the adhesion and uniformity of the coating film. In steps S3 and S4, the bundle pitch (35~50mm) and stranding pitch (22~26mm) were controlled respectively, further optimizing the structure and performance of the wire and ensuring the overall quality and high-frequency application performance of the Litz wire.

[0057] This application also proposes a testing device for Litz wire processing, including a Litz wire processing process, comprising: a workbench 1, four support columns 2, a top plate 3, and a painting machine 4. The four support columns 2 are all fixed vertically to the upper surface of the workbench 1. The top plate 3 is fixed to the top of the four support columns 2 and is arranged parallel to the workbench 1. The painting machine 4 is located on the right side of the workbench 1 and placed on the ground. The upper surface of the workbench 1 is provided with a testing mechanism 5 for testing the wire after drawing. The upper surface of the workbench 1 and the right side of the testing mechanism 5 are provided with a pretreatment mechanism 6 for facilitating the measurement of the paint film thickness.

[0058] It should be noted that a stable production platform is constructed by rationally arranging the workbench 1, support column 2, top plate 3, and painting machine 4. The inspection mechanism 5 set on the workbench 1 can conduct comprehensive inspection of the drawn wire to ensure that there are no defects such as scratches or cracks on the surface of the copper wire. The pretreatment mechanism 6 provides conditions for measuring the coating thickness. Through cleaning and drying steps, the surface of the copper wire is ensured to be clean and dry, thereby improving the coating adhesion and measurement accuracy, and ultimately improving the overall quality of Litz wire.

[0059] Testing agency 5 includes:

[0060] Two support bases 51 are fixed to the upper surface of the worktable 1;

[0061] Two light boxes 52 are rotatably connected to the interior of two support bases 51;

[0062] Mounting base 53, which is fixed between the two light boxes 52 on opposite sides;

[0063] Two gears 54 are fixed to opposite sides of the two light boxes 52, respectively;

[0064] Electric push rod 55, which is fixed to the lower surface of top plate 3;

[0065] The movable plate 56 is horizontal and fixed to one end of the output shaft of the electric push rod 55;

[0066] Two toothed plates 57 are symmetrically fixed to the lower surface of the movable plate 56 and mesh with two gears 54 respectively for transmission.

[0067] Two CCD cameras 58 are fixed to the front and rear sides of the mounting base 53, respectively;

[0068] Multiple light strips 59 are fixed to the inner walls of two light boxes 52.

[0069] It should be noted that the testing mechanism 5, through the coordinated work of carefully designed components, achieves efficient and comprehensive testing of the drawn wire. The two support seats 51 are firmly fixed on the workbench 1, providing a solid foundation for the entire testing mechanism 5. The two light boxes 52 are driven by the meshing of gears 54 and toothed plates 57, enabling them to rotate under the drive of the electric push rod 55, ensuring the flexibility of the testing angle. The two CCD cameras 58 fixed on the mounting base 53 can take pictures of the copper wire from different angles, while the multiple light strips 59 on the inner wall of the light box 52 provide uniform illumination, ensuring a stable testing environment. This design not only improves the testing accuracy but also enhances the testing efficiency, enabling the rapid identification of scratches and cracks on the surface of the copper wire, thereby ensuring product quality and production efficiency.

[0070] The testing mechanism 5 also includes two positioning columns 510. Two positioning grooves are opened on the upper surface of the top plate 3. The positioning columns 510 move linearly in the positioning grooves and do not separate from each other. One end of the CCD camera 58 lens passes through and extends into the mounting base 53. Multiple reinforcing columns are fixed between the opposite sides of the two light boxes 52. Reflective film is laid inside both the mounting base 53 and the light box 52.

[0071] It should be noted that the further optimized design of the detection mechanism 5, by adding two positioning posts 510 and positioning slides, ensures the stability and accuracy of the detection mechanism 5 during movement, effectively avoiding positional deviations during the detection process. The CCD camera 58 lens extends into the mounting base 53, and the setting of reinforcing posts and reflective film between the light boxes 52 not only enhances the stability and reliability of the detection, but also improves the utilization rate of light and the clarity of the detection image, further improving the detection accuracy and efficiency.

[0072] The pretreatment unit 6 includes:

[0073] Cleaning assembly 61 for cleaning copper bars;

[0074] Drying assembly 62 for drying the cleaned copper strips;

[0075] A paint film thickness measuring instrument 63 is fixed to the right side of the paint coating machine 4 and measures the thickness of the copper strip after painting;

[0076] The cleaning assembly 61 includes a cleaning box 611, a filter plate 612, a support plate 613, two hollow rods 614, two annular nozzles 615, a water pump 616, and a split-pipe 617. The cleaning box 611 is fixed to the upper surface of the workbench 1. The filter plate 612 is horizontally fixed between the four inner walls of the cleaning box 611. The support plate 613 is located above the filter plate 612 and fixed to the rear inner wall of the cleaning box 611. The two hollow rods 614 are both fixedly connected to the upper surface of the support plate 613, and one end is connected to... The annular nozzles 615 are connected and fixed together, with one end extending through and to the lower side of the support plate 613. The water pump 616 is fixed to the upper surface of the workbench 1 and located in front of the cleaning box 611. The inlet and outlet ends of the water pump 616 are both fixedly connected to connecting pipes. One end of the inlet connecting pipe extends through and into the interior of the cleaning box 611. One end of the outlet connecting pipe is fixed to one end of the one-to-two pipe 617. The other two ends of the one-to-two pipe 617 are rotatably connected to the bottom ends of the two hollow rods 614 through sealed bearings.

[0077] It should be noted that the cleaning component 61, through its complex structural design, achieves efficient cleaning of the copper wire. The cleaning box 611 serves as the main body, with an internal filter plate 612 for filtering impurities to ensure the cleanliness of the cleaning solution. Two hollow rods 614 fixed on the support plate 613 are connected to annular nozzles 615. Driven by the water pump 616, the cleaning solution is evenly sprayed onto the surface of the copper wire through a one-to-two pipe 617, achieving all-round cleaning. This design not only improves cleaning efficiency but also reduces resource consumption through filtration and recycling of the cleaning solution, while ensuring the cleanliness of the copper wire surface, providing a good foundation for subsequent painting and paint film thickness measurement.

[0078] The drying assembly 62 includes an air duct 621, two horizontal pipes 622, multiple high-pressure nozzles 623, a fan 624, an air inlet box 625, and two air outlet pipes 626. The air duct 621 is fixedly connected between the paint machine 4 and the cleaning box 611 on opposite sides. The two horizontal pipes 622 are fixed to the upper and lower sides of the air duct 621 respectively. The multiple high-pressure nozzles 623 are connected and fixed to the opposite sides of the two horizontal pipes 622 respectively. The fan 624 is fixed to the upper surface of the top plate 3. The air inlet box 625 is fixed to the upper surface of the top plate 3 and located to the left of the fan 624. The two air outlet pipes 626 are connected and fixed to the two horizontal pipes 622 respectively, and the other end of each of the two air outlet pipes 626 is connected and fixed to the air outlet end of the fan 624 through a T-junction.

[0079] It should be noted that the drying assembly 62, through its carefully designed structure, achieves rapid and uniform drying of the copper wire. The air duct 621 connects the paint coating machine 4 and the cleaning box 611, ensuring smooth airflow. Two horizontal pipes 622 are fixed on the upper and lower sides of the air duct 621. Multiple high-pressure nozzles 623 are evenly distributed, which can efficiently spray air onto the surface of the copper wire. The fan 624 is installed on the top plate 3 to provide power, while the air inlet box 625 ensures uniform air distribution. The air outlet pipe 626 is connected to the air outlet of the fan 624 through a three-way pipe, further optimizing the airflow distribution. This design not only improves the drying efficiency but also ensures the uniformity of drying on the surface of the copper wire, providing ideal conditions for the subsequent painting process, thereby improving the adhesion of the paint film and the overall product quality.

[0080] The air inlet box 625 is a rectangular prism with a hollow interior and a missing left side. The right side of the air inlet box 625 is connected and fixed to the fan 624 through a pipe. Multiple heating wires are fixed inside the air inlet box 625, and a dustproof net is fixed on the right side between the four inner walls of the air inlet box 625 on the left side of the heating wires.

[0081] It should be noted that the air inlet box 625, through its unique internal structure, achieves efficient heating and filtration of air. Its internal heating wire can quickly heat the air to the required temperature, thereby accelerating the evaporation of moisture on the surface of the copper wire and improving drying efficiency. At the same time, the dust filter located on the left side of the heating wire effectively filters impurities in the air, ensuring that the air entering the air duct 621 is clean and preventing impurities from contaminating the surface of the copper wire. This further enhances the performance and reliability of the drying component 62. This design not only improves drying efficiency but also ensures the cleanliness of the copper wire surface, providing a high-quality guarantee for subsequent processes.

[0082] The working principle of the above embodiment is as follows: A copper strip enters the wire drawing machine, and liquid copper drawing oil is used to draw it into a copper wire with a diameter ≤0.5mm. The drawing speed is controlled at 1500-1800m / min, and the drawing speed ratio is 1.20. After drawing, the copper wire undergoes surface inspection through the detection mechanism 5. The light strip 59 inside the light box 52 provides uniform illumination to ensure a stable detection environment. The reflective film further concentrates the light. The electric push rod 55 controls the movable plate 56 to move back and forth. Through the transmission of the gear 54 and the toothed plate 57, the two CCDs on the upper side of the mounting base 53 move in tandem. The CCD camera 58 swings back and forth at 180 degrees to capture images, thus covering the entire copper strip. This allows the CCD camera 58 to perform a comprehensive inspection of the copper wire, detecting scratches and cracks. Simultaneously, the positioning column 510 moves within the positioning groove on the top plate 3, ensuring the stability and accuracy of the inspection mechanism 5. After inspection, the copper wire enters the pre-treatment mechanism 6 for cleaning and drying. The copper wire is cleaned by the cleaning component 61, and the filter plate 612 in the cleaning box 611 filters out impurities after cleaning. The water pump 616 sprays water onto the copper wire through the hollow rod 614 and the annular nozzle 615. The copper wire surface is thoroughly cleaned under the action of the air duct 621. After cleaning, the copper wire enters the drying assembly 62 for drying. The fan 624 blows air through the air duct 621 and horizontal pipe 622 and high-pressure nozzle 623 onto the copper wire to remove surface moisture. The dried copper wire is then coated with paint in the insulating varnish tank of the coating machine 4 and then dried. The inlet temperature of the coating machine 4 is 200℃, the lower layer temperature is 300℃, the middle layer temperature is 400℃, and the upper layer temperature is 460℃. After drying, a non-contact paint film thickness measuring instrument 63 is used to measure the copper wire a second time to ensure that the paint film thickness is uniform. After testing, multiple single wires are transposed and combined into a single enameled wire, with the pitch controlled at 35-50mm. Next, at least nine enameled wires are twisted into a stranded wire, with the pitch controlled at 22-26mm. Pressure is applied evenly to all four sides of each nine stranded enameled wires using pressure rollers, turning the circular cross-section stranded wire into a square cross-section stranded wire. A layer of polyimide film and a layer of polyimide composite non-woven fabric are then wrapped around the outside of the square-faced stranded wire to form a winding wire with a square cross-section. Finally, two identical winding wires are arranged in parallel and wrapped with insulation material to form a straight-welded rectangular high-frequency Litz wire.

[0083] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0084] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for Leeds wire, characterized in that, Includes the following steps: S1 wire preparation: The wire enters the wire drawing machine and the copper strip is drawn into copper wire using liquid copper drawing oil. The drawing speed is controlled during the drawing process. After the wire drawing is completed, optical inspection equipment is used to inspect the surface of the wire. S2 Enameled Single Wire Production: After the inspected wire undergoes pretreatment before coating, the surface of the copper wire, which moves at a constant speed, is dragged through the insulating varnish tank of the coating machine and then dried. After drying, a non-contact varnish thickness measuring instrument is used to perform a second measurement of the wire. S3 wire bundle: Combines multiple single wires by transposing them into a single enameled wire; S4 stranding: at least nine strands of enameled wire are twisted together to form a stranded wire; S5 square pressing: Pressing rollers are used to evenly press the nine strands of enameled wire on all four sides of each strand to turn the circular cross-section stranded wire into a square cross-section stranded wire. S6 Coating and Insulation Treatment: After the stranded wire is pressed into square shape, a layer of polyimide film and a layer of polyimide composite non-woven fabric are wrapped around it to form a winding wire with a square cross-section; then, two identical winding wires are arranged in parallel and wrapped with insulation material to form a straight-welded rectangular high-frequency Litz wire.

2. The Litz wire processing technology according to claim 1, characterized in that: In step S1, the diameter of the copper wire is ≤0.5mm, the drawing speed is 1500-1800m / min, and the drawing speed ratio is 1.

20.

3. The Litz wire processing technology according to claim 1, characterized in that: In step S2, the inlet temperature of the paint coating machine is 200℃, the lower layer temperature is 300℃, the middle layer temperature is 400℃, and the upper layer temperature is 460℃.

4. The Litz wire processing technology according to claim 1, characterized in that: During the wire bundling process in step S3, the control pitch is 35-50mm; during the stranding process in step S4, the control pitch is 22-26mm.

5. A testing device for Litz wire machining production, comprising the Litz wire machining production process as described in any one of claims 1-4, including: The system comprises a workbench (1), four support columns (2), a top plate (3), and a painting machine (4). The four support columns (2) are all fixed vertically to the upper surface of the workbench (1). The top plate (3) is fixed to the top of the four support columns (2) and is arranged parallel to the workbench (1). The painting machine (4) is located on the right side of the workbench (1) and placed on the ground. The workbench (1) is characterized in that a detection mechanism (5) for detecting the wire after drawing is provided on the upper surface of the workbench (1), and a pretreatment mechanism (6) for measuring the paint film thickness is provided on the upper surface of the workbench (1) and to the right of the detection mechanism (5). The testing organization (5) includes: Two support bases (51) are fixed to the upper surface of the workbench (1); Two light boxes (52) are rotatably connected to the interior of two support bases (51); Mounting base (53), which is fixed between the two light boxes (52) on opposite sides; Two gears (54) are fixed to opposite sides of two light boxes (52); An electric push rod (55) is fixed to the lower surface of the top plate (3); The movable plate (56) is horizontal and fixed to one end of the output shaft of the electric push rod (55); Two toothed plates (57) are symmetrically fixed to the lower surface of the movable plate (56) and mesh with two gears (54) respectively. Two CCD cameras (58) are fixed to the front and rear sides of the mounting base (53), respectively; Multiple light strips (59) are fixed to the inner walls of two light boxes (52).

6. The testing device for Litz wire processing according to claim 5, characterized in that: The detection mechanism (5) also includes two positioning columns (510). Two positioning grooves are provided on the upper surface of the top plate (3). The positioning columns (510) move linearly in the positioning grooves and do not separate from each other.

7. The testing device for Litz wire processing according to claim 5, characterized in that: One end of the CCD camera (58) lens extends through and into the mounting base (53). Multiple reinforcing columns are fixed between the opposite sides of the two light boxes (52). Reflective film is laid inside both the mounting base (53) and the light box (52).

8. The testing device for Litz wire processing according to claim 5, characterized in that: The pretreatment unit (6) includes: Cleaning assembly (61) for cleaning copper bars; A drying assembly (62) for drying the cleaned copper strips; A paint film thickness measuring instrument (63) fixed on the right side of the paint coating machine (4) and used to measure the thickness of the copper strip after painting; The cleaning assembly (61) includes a cleaning box (611), a filter plate (612), a support plate (613), two hollow rods (614), two annular nozzles (615), a water pump (616), and a splitter pipe (617). The cleaning box (611) is fixed to the upper surface of the workbench (1). The filter plate (612) is horizontally fixed between the four inner walls of the cleaning box (611). The support plate (613) is located above the filter plate (612) and fixed to the rear inner wall of the cleaning box (611). The two hollow rods (614) are both fixedly connected to the upper surface of the support plate (613). One end of the pump is fixedly connected to the annular nozzle (615), and the other end extends through and to the lower side of the support plate (613). The water pump (616) is fixed on the upper surface of the workbench (1) and located in front of the cleaning box (611). The water inlet and outlet of the water pump (616) are both fixedly connected to the connecting pipe. One end of the connecting pipe at the water inlet extends through and to the interior of the cleaning box (611). One end of the connecting pipe at the water outlet is fixed to one end of the one-to-two pipe (617). The other two ends of the one-to-two pipe (617) are rotatably connected to the bottom ends of the two hollow rods (614) through sealed bearings.

9. The testing device for Litz wire processing according to claim 8, characterized in that: The drying assembly (62) includes an air duct (621), two horizontal pipes (622), multiple high-pressure nozzles (623), a fan (624), an air inlet box (625), and two air outlet pipes (626). The air duct (621) is fixedly connected between the paint machine (4) and the cleaning box (611) on opposite sides. The two horizontal pipes (622) are fixed on the upper and lower sides of the air duct (621), respectively. The multiple high-pressure nozzles (623) are respectively connected and fixed on opposite sides of the two horizontal pipes (622). The fan (624) is fixed on the upper surface of the top plate (3). The air inlet box (625) is fixed on the upper surface of the top plate (3) and located to the left of the fan (624). The two air outlet pipes (626) are respectively connected and fixed between the two horizontal pipes (622), and the other end of the two air outlet pipes (626) is connected and fixed to the air outlet end of the fan (624) through a T-junction.

10. The testing device for Litz wire processing according to claim 9, characterized in that: The air inlet box (625) is a rectangular prism with a hollow interior and a missing left side. The right side of the air inlet box (625) is connected and fixed to the fan (624) through a pipe. Multiple heating wires are fixed inside the air inlet box (625), and a filter screen is fixed on the right side between the four inner walls of the air inlet box (625) on the left side of the heating wires.

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