Winding mechanism and winding method for metal wire annealing equipment

Abstract

The invention relates to a winding mechanism and method for metal wire annealing equipment. A first driving shaft and a second driving shaft are arranged on a main body in parallel, and a first guide part and a second guide part are coaxially and detachably sleeved and rotate along with the shafts; and a first guide gap and a second guide gap are formed by equidistant coplanar orientation pieces on the first fixed rod and the second fixed rod parallel to the shaft, so that the metal wire runs along the paths of the first guide piece, the first gap, the second gap and the second guide piece, and a preset axial gap is kept between target contact belts of the two guide pieces. The annealing equipment is provided with a monitoring assembly and a controller (spark, surface profile, vibration and infrared temperature sensors), after threshold judgment, a guide piece is exchanged and reset, and it is guaranteed that the preset gap ranges from 5 mm to 25 mm, and the deviation is smaller than or equal to 2 mm. The combination disperses contact abrasion, stabilizes spanning posture and tension, inhibits sparks and vibration, realizes rapid reuse of a guide piece, shortens shutdown, early finds instability on line, prolongs the service life, and improves the consistency of yield and high-speed process.

Description

Technical Field

[0001] This invention relates to an annealing apparatus, and more particularly to a winding mechanism and winding method for a metal wire annealing apparatus. Background Technology

[0002] Continuous annealing equipment for metal wire typically consists of functional sections such as unwinding, cleaning, heating / cooling, winding / guiding, and take-up. The winding / guiding section is responsible for stably defining the wire's running path and wrap angle under high wire speed, constant tension, and heating conditions. This section is often affected by a combination of factors including dust, scale, lubricant residue, and thermal expansion and contraction. The long-term sliding contact between the guide surface and the wire makes it highly susceptible to wear and surface scratches. If the grooves on the guide surface deepen or contact stability decreases, it can lead to wire surface defects, sparks, and vibrations, forcing frequent equipment shutdowns for maintenance and impacting continuous production cycle time and yield.

[0003] Existing annealing machines mostly use paired guide components (such as guide wheels or guide cylinders) in conjunction with several guide plates / baffles to achieve bypassing and crossing.

[0004] However, although the two guide members are arranged in parallel and rotate on their respective axes, they often press the metal wire into essentially identical axial contact zones for long-term operation, resulting in concentrated wear and the formation of annular grooves at the same location. The guide plates / baffles are mostly arranged empirically, lacking equally spaced, repeatable geometric references to stabilize the crossing path, causing fluctuations in tension and lateral position of the wire bundle during crossing. Furthermore, many guide members and shafts are semi-fixed or integrally installed, making disassembly and assembly inconvenient. Once a contact zone wears to the point of producing sparks, the entire guide member often needs to be replaced. These factors combined result in a short lifespan for the guide members and increased downtime. Therefore, there is an urgent need to propose a winding mechanism and method for metal wire annealing equipment to solve these problems. Summary of the Invention

[0005] The purpose of this invention is to provide an annealing machine winding mechanism and control method that can stably limit the wire path and wrap angle, homogenize the contact pressure in the bandwidth direction, and realize axial dispersion and misalignment of the contact area, thereby reducing local wear and grooving, suppressing friction sparks and vibration, improving the service life and operational stability of the guide component under high wire speed and constant tension conditions, and facilitating quick repositioning and reuse and shortening downtime due to the detachable connection between the guide component and the drive shaft.

[0006] The technical solution adopted by the present invention to solve the above problems is: a winding mechanism for a metal wire annealing equipment, comprising: main body; A first drive shaft and a second drive shaft are disposed on the main body and rotated in a controlled manner, and the first drive shaft and the second drive shaft are arranged in parallel. The first guide member is coaxially sleeved outside the first drive shaft to rotate with the first drive shaft, and the first guide member is detachably connected to the first drive shaft. The second guide is coaxially sleeved outside the second drive shaft to rotate with the second drive shaft, and the second guide is detachably connected to the second drive shaft. The first positioning component includes: A first fixing rod arranged parallel to the first drive shaft; A plurality of first directional members are arranged sequentially on the outer surface of the first fixed rod along the axial direction of the first fixed rod. Each first directional member is located on the same plane, and the distance between each two adjacent first directional members is equal. The gap between two adjacent first directional members is a first guide gap. The second positioning component includes: A fixing rod arranged parallel to the second drive shaft; A plurality of second directional members are arranged sequentially along the axial direction of the second fixing rod on the outer surface of the second fixing rod. Each second directional member is located on the same plane, and the distance between each two adjacent second directional members is equal. The gap between two adjacent second directional members is the second guide gap.

[0007] When the winding mechanism is in operation, the metal wire sequentially passes through the outer surface of the first guide, the first guide gap, the second guide gap, and the outer surface of the second guide, and a preset gap is left between the first target contact zone where the metal wire contacts the outer surface of the first guide and the second target contact zone where the metal wire contacts the outer surface of the second guide.

[0008] Preferably, both the first guide and the second guide are guide cylinders, and the two ends of the first guide are aligned with the two ends of the second guide.

[0009] Preferably, the winding mechanism includes: Both the end of the first guide member near the main body and the end of the second guide member near the main body are provided with a slot; A first shifting seat and a second shifting seat, the first shifting seat is fixedly sleeved on the outside of the first drive shaft, and the second shifting seat is fixedly sleeved on the outside of the second drive shaft. Both the side of the first shifting seat away from the main body and the side of the second shifting seat away from the main body are provided with engaging parts that engage with the corresponding slots. A first fastener and a second fastener, wherein the first fastener is sleeved outside the first drive shaft and abuts against the side of the first guide away from the main body to restrict the first guide between the first shift seat and the first fastener; the second fastener is sleeved outside the second drive shaft and abuts against the side of the second guide away from the main body to restrict the second guide between the second shift seat and the second fastener.

[0010] Preferably, the preset gap is defined as the distance between the axial centerline of the first target contact strip and the axial centerline of the second target contact strip, and the preset gap is 5mm to 25mm.

[0011] Preferably, the outer working surface of the guide cylinder is slightly convex, and the slightly convex shape is symmetrical about the axial vertical plane of the guide cylinder; and, per 100 mm, the difference between the maximum diameter at the axial center of the guide cylinder and the diameter near the two ends is 0.02 mm to 0.20 mm; the highest point of the slightly convex shape is located at the axial center of the guide cylinder and the deviation between its axial projection and the center line of the first target contact zone or the second target contact zone on the corresponding guide cylinder is no more than 2 mm.

[0012] Preferably, both the first guide member and the second guide member have rounded corners on the side facing the metal wire, and the radius of the rounded corners is at least 0.20 mm; and the first guide gap is smaller than the second guide gap, with the difference between the two being 0.10 mm to 0.50 mm.

[0013] Preferably, the slot is a tapered slot, the engaging member is a tapered member that engages with the slot, and the engaging member and the slot are configured such that, in the engaged state, the central axis of the first guide member or the second guide member is collinear with the central axis of the first drive shaft or the second drive shaft.

[0014] Preferably, the first fastener and / or the second fastener are eccentric quick-change clamps or nut assemblies with torque limiting structures.

[0015] Specifically, a winding method for annealing metal wire, applied to the winding mechanism of the annealing machine as described above, includes: The annealing machine includes a monitoring component and a controller. The monitoring component is disposed on the main body and is signal-connected to the controller. The monitoring component includes: A spark detection sensor facing the area spanned between the first guide and the second guide, wherein the detection end of the spark detection sensor points to the contact area between the metal wire and the first guide and the contact area between the metal wire and the second guide, for detecting spark events and outputting a pulse counting signal; A surface profile sensor facing the outer working surfaces of the first guide and the second guide is used to measure the equivalent displacement signal of the surface groove depth of the first guide and the second guide; Vibration sensors arranged on the first transposition seat and the second transposition seat are used to acquire acceleration spectrum amplitude values; A temperature sensor facing the contact area between the first guide and the second guide, wherein the temperature sensor is a non-contact infrared temperature sensor; The controller stores preset thresholds for spark event counts, trench depths, temperature rises, and vibration amplitudes, and is used to compare and trigger the outputs of the monitoring components in real time. The winding method includes: The wire moves sequentially through the outer surface of the first guide, the first guide gap, the second guide gap, and the outer surface of the second guide at a preset linear speed and a preset tension, while maintaining the preset gap between the first target contact strip and the second target contact strip. During operation, at least one wear or instability characterization index is collected, including spark event count, guide surface groove depth, contact area temperature rise and / or vibration acceleration spectrum amplitude, and compared with a preset threshold. When any of the wear or instability indicators reaches the preset threshold, the operation stops, the first fastener and the second fastener are loosened, and the first guide and the second guide are disengaged from the first shift seat and the second shift seat respectively. The first guide and the second guide are swapped and installed so that the swapped metal wire falls into the unworn area on the third target contact strip of the first guide and the fourth target contact strip of the second guide. The first fastener and the second fastener are then reset and tightened. The third target contact strip and the fourth target contact strip refer to the stable contact areas of the metal wire on the corresponding outer surfaces of the first guide and the second guide after the first guide and the second guide are swapped and installed. Reset the operation and confirm that the preset gap is within the range of 5mm to 25mm.

[0016] Preferably, the preset threshold is any one or any combination of the following: Within a predetermined time window, the number of spark events reaches a preset value, the depth of the groove on the guide surface reaches a preset value, the temperature rise in the contact area reaches a preset value, and / or the amplitude of the vibration acceleration spectrum in the target frequency band reaches a preset value; and after the first guide and the second guide are swapped and installed, the crossing position of the metal wire between the first guide gap and the second guide gap is defined by the first positioning component and the second positioning component, so that the deviation of the preset gap is not greater than 2mm.

[0017] The beneficial effects of the embodiments of the present invention are as follows: 1. By employing a first and second drive shaft arranged parallel to the main body, and a first and second guide component coaxially sleeved and detachably connected to the drive shaft, as well as a first and second positioning assembly composed of a fixed rod parallel to the drive shaft and directional components arranged equidistantly and coplanarly along the axial direction, the metal wire runs sequentially along a predetermined path of the outer surface of the first guide component, the first guide gap, the second guide gap, and the outer surface of the second guide component, while maintaining a preset axial gap between the first and second target contact zones on the first and second guide components. Therefore, this effectively solves the problems in the prior art, such as the metal wire being pressed on the same axial contact zone for a long time, resulting in concentrated wear and annular grooves, the lack of geometric reference for the crossing path leading to tension and lateral position fluctuations, and the inconvenience of disassembling and assembling the guide component causing long downtime. This achieves the technical effects of axial dispersion and uniform wear in the contact area, repeatable and stable limitation of the crossing posture, significant reduction of friction sparks and vibration, easy and quick maintenance and replacement of the guide component, improved guide life, and guaranteed stable wrap angle and improved yield at high linear speeds.

[0018] 2. By employing two guide cylinders with their ends aligned, a slot is provided at the end of the guide cylinder near the main body, a shifting seat with engaging components is provided on the first and second drive shafts, and the guide cylinder is axially confined between the shifting seat and the fasteners by the first and second fasteners, the problems in the prior art, such as inconsistent guide cylinder geometry leading to changes in the wrap angle and thread length after shifting, poor positioning repeatability leading to inaccurate preset gaps, cumbersome and time-consuming disassembly and assembly steps, and difficulty in ensuring coaxiality, are effectively solved. This achieves the following technical effects: guide cylinders can be swapped for immediate use, repeatable self-positioning and reliable clamping in angular and axial directions, maintaining preset axial gaps and stable crossing posture, shortening downtime and extending the service life of guide cylinders, thereby reducing friction sparks and vibrations, and improving yield and equipment availability.

[0019] 3. By incorporating monitoring components connected to the controller signal on the main body (including a spark detection sensor facing the crossing area, a surface profile sensor for measuring the depth of the grooves on the guide surface, a vibration sensor arranged on the transposition seat, and an infrared temperature sensor facing the contact area), and triggering the rapid swapping and installation of the guide cylinder based on threshold judgment, and by limiting the crossing path through the positioning component and maintaining the preset gap between the two target contact zones at 5mm to 25mm with a deviation of no more than 2mm after reset, the technology effectively solves the problems of difficulty in timely identification of wear and instability in existing technologies, reliance on manual experience during guide replacement, and difficulty in maintaining geometric consistency and contact zone gap after swapping. This achieves the technical effects of early online detection and quantifiable decision-making for wear / instability, reduced unplanned downtime due to swapping and reuse, repeatable stabilization of the running path and wrap angle, significant reduction in sparks and vibrations, improved guide life and yield, and maintenance of process consistency at high line speeds. Attached Figure Description

[0020] Figure 1 A schematic structural diagram of an annealing apparatus according to an embodiment of the present invention is shown.

[0021] Figure 2 The diagram shows a schematic state of a metal wire passing sequentially through a first guide, a first positioning component, a second guide, and a second positioning component, according to an embodiment of the present invention.

[0022] Figure 3 A schematic structural diagram of a first transposition seat according to an embodiment of the present invention is shown.

[0023] Figure 4 A schematic structural diagram of a first fastener according to an embodiment of the present invention is shown.

[0024] Wherein: 10, main body; 20, first drive shaft; 30, second drive shaft; 40, first guide member; 50, second guide member; 60, first positioning assembly; 610, first fixing rod; 620, first directional member; 70, second positioning assembly; 710, first fixing rod; 720, second directional member; 80, first shift seat; 90, second shift seat; 1000, first fastener; 1010, second fastener. Detailed Implementation

[0025] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0026] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the scope of protection of this application. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0027] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art will understand the specific meaning of the above terms in this application based on the specific circumstances.

[0028] See Figures 1 to 4A preferred embodiment of this application provides a winding mechanism for a metal wire annealing device, including a main body 10, a first drive shaft 20 and a second drive shaft 30 disposed on the main body 10 and controlled to rotate, a first guide member 40, a second guide member 50, a first positioning component 60, and a second positioning component 70. The first drive shaft 20 and the second drive shaft 30 are arranged in parallel; the first guide member 40 is coaxially sleeved outside the first drive shaft 20 to rotate with the first drive shaft 20, and the first guide member 40 is detachably connected to the first drive shaft 20; the second guide member 50 is coaxially sleeved outside the second drive shaft 30 to rotate with the second drive shaft 30, and the second guide member 50 is detachably connected to the second drive shaft 30; the first positioning component 60 includes a first fixing rod 710610 arranged parallel to the first drive shaft 20 and a plurality of first directional members 620, the directional members being sequentially arranged along the axial direction of the first fixing rod 710610 on the first drive shaft 20 and the second positioning component 70. The outer surface of a fixed rod 710610 has each of the first directional members 620 located on the same plane, with equal distances between adjacent first directional members 620, and the gap between adjacent first directional members 620 is a first guide gap. The second positioning assembly 70 includes a fixed rod parallel to the second drive shaft 30 and several second directional members 720. The directional members are sequentially arranged along the axial direction of the second fixed rod on its outer surface. Each second directional member 720 is located on the same plane, with equal distances between adjacent second directional members 720, and the gap between adjacent second directional members 720 is a second guide gap. When the winding mechanism is in operation, the metal wire sequentially passes through the outer surface of the first guide member 40, the first guide gap, the second guide gap, and the outer surface of the second guide member 50. A preset gap exists between the first target contact zone where the metal wire contacts the outer surface of the first guide member 40 and the second target contact zone where the metal wire contacts the outer surface of the second guide member 50.

[0029] Specifically: The first drive shaft 20 and the second drive shaft 30 are arranged in parallel to each other and preferably installed in the same frame reference plane. The center lines of the two shafts form a stable geometric relationship with the reference plane of the main body 10, which facilitates subsequent assembly, adjustment and testing.

[0030] The first guide member 40 is coaxially sleeved outside the first drive shaft 20 and rotates with the shaft; similarly, the second guide member 50 is sleeved outside the second drive shaft 30. The detachable connection can be achieved through a clamping sleeve at the axial end, a wedge-shaped locking ring, a tapered mating clamping member, or a spline mating end face pressure plate, all of which are optional structures in this embodiment.

[0031] The first positioning component 60 includes a fixed rod parallel to the first drive shaft 20 and a plurality of first directional members 620 arranged sequentially along the axial direction of the fixed rod. The first directional members 620 are fixed on the outer surface of the fixed rod, and their installation posture is constrained by the same reference plane, so that each first directional member 620 is in the same plane and maintains an equal distance in the axial direction, and a first guide gap is formed by adjacent first directional members 620.

[0032] The second positioning component 70 is mirrored thereon and includes a fixed rod parallel to the second drive shaft 30 and several second directional members 720. Each second directional member 720 is also located on the same plane and is arranged axially at equal intervals to form a second guide gap.

[0033] The first directional component 620 and the second directional component 720 can be plate-shaped limiting teeth, rounded corner baffles, or comb-shaped teeth with blunted edges, and their materials can be wear-resistant metals, ceramics, or coated parts. The fixing rod is preferably mounted on the main body 10 via an adjustable support so that its relative position with the corresponding guide component can be finely adjusted during assembly or maintenance.

[0034] In its working principle and operation, after the metal wire enters the mechanism from the upstream section, it first adheres to the outer surface of the first guide member 40 to form a first target contact zone. Then, it crosses the first guide gap formed by the first positioning component 60, and then crosses the second guide gap formed by the second positioning component 70. Finally, it adheres to the outer surface of the second guide member 50 to form a second target contact zone. Two sets of positioning components geometrically limit the crossing path, controlling the lateral position and attitude of the wire bundle in the crossing area, preventing rubbing and deviation between wires. The first and second target contact zones maintain a preset gap in the axial direction. This preset gap causes the contact areas of the two guide members to be staggered, thereby dispersing contact load and wear. The detachable connection allows for quick disassembly or repositioning of the guide members during maintenance. The coplanar and equidistant relationship between the fixed rod and the directional component ensures good repeatability of the guide gap, allowing the predetermined wire path to be restored without significant adjustments after replacement.

[0035] Regarding the operating environment and applicable conditions, this mechanism is suitable for the winding and guiding stages of continuous annealing production lines, and can operate in environments with high linear speeds, constant tension, and heat exposure. The main body 10 should be mounted on a rigid and vibration-damping base, with necessary perimeter protection to isolate dust, scale, and lubricant splashes. The fixing rods and guiding components should be wear-resistant, corrosion-resistant, and easy to clean. The outer surface of the guiding components should be made of low-friction, scratch-resistant materials or have a surface treatment. It is suitable for guiding various metal wires and multi-strand or bundled wires. During installation, the relative positions should be set according to the height and wrap angle requirements of the upstream and downstream equipment.

[0036] In some optional embodiments and alternatives, the first guide member 40 and the second guide member 50 can be an integral cylindrical body or a cylindrical structure with a replaceable outer sleeve; their detachable connection can be achieved by key connection with end clamping, tapered hole and tapered shaft with end face clamping, split jacket locking, etc.; the first directional member 620 and the second directional member 720 can be integral comb plates, split limiting plates, or limiting units with rolling contact parts; the fixing rod can be circular or square cross-section, and can be finely adjusted in a small range by using longitudinal elongated holes and adjusting shims to adapt to the path requirements of different wire diameters and bandwidths. The above changes do not alter the technical points defined in the claims.

[0037] In this embodiment, by employing a driving shaft arranged parallel to the main body 10 and a guide component detachably and coaxially mounted on its exterior, as well as two sets of guide gaps formed by a fixed rod parallel to the driving shaft and directional components arranged equidistantly and coplanarly along the axial direction, the metal wire is attached to and crosses the guide in a predetermined order while maintaining a preset axial gap between the target contact zones of the two guide components. Therefore, this embodiment effectively solves the technical problems in the prior art, such as the lack of stable geometric constraints on the crossing of the wire path, the long-term overlap of the contact area leading to concentrated wear and grooving, and the inconvenience of disassembling and maintaining the guide component. As a result, it achieves repeatable control of the wire path attitude and lateral position, axial dispersion of contact load and wear, significant suppression of friction sparks and vibration, and improved maintenance efficiency of the guide component and reduced downtime.

[0038] In some embodiments, the first guide member 40 and the second guide member 50 are both guide cylinders, with the two ends of the first guide member 40 aligned with the two ends of the second guide member 50. A slot is provided at the end of the first guide member 40 near the main body 10 and at the end of the second guide member 50 near the main body 10. The winding mechanism also includes a first shifting seat 80 and a second shifting seat 90, a first fastener 1000 and a second fastener 1010. The first shifting seat 80 is fixedly sleeved on the outside of the first drive shaft 20, and the second shifting seat 90 is fixedly sleeved on the outside of the second drive shaft 30. Both the side of the first shifting seat 80 away from the main body 10 and the side of the second shifting seat 90 away from the main body 10 are provided with slots... Corresponding to the engaging parts of the slot, the first fastener 1000 is sleeved on the outside of the first drive shaft 20 and abuts against the side of the first guide 40 away from the main body 10, so as to restrict the first guide 40 between the first shifting seat 80 and the first fastener 1000; the second fastener 1010 is sleeved on the outside of the second drive shaft 30 and abuts against the side of the second guide 50 away from the main body 10, so as to restrict the second guide 50 between the second shifting seat 90 and the second fastener 1010.

[0039] Specifically: In this embodiment, both the first guide member 40 and the second guide member 50 are guide cylinders. The two ends of the two guide cylinders are aligned with each other, and their end faces serve as a unified reference for assembly and inspection. The first guide cylinder is coaxially sleeved outside the first drive shaft 20 and rotates with it, and the second guide cylinder is similarly sleeved outside the second drive shaft 30. The two guide cylinders are detachably connected to their respective drive shafts, preferably by end-to-end clamping and end-face positioning.

[0040] The first guide cylinder has a groove at one end near the main body 10, and the second guide cylinder also has a groove at one end near the main body 10. The grooves can be located near the end face or edge of the guide cylinder, forming a geometric fit interface with the shifting seat engaging component. The first shifting seat 80 is fixedly sleeved on the outside of the first drive shaft 20, and the second shifting seat 90 is fixedly sleeved on the outside of the second drive shaft 30. Engaging components are provided on the side of each shifting seat away from the main body 10. These engaging components engage with the grooves of the corresponding guide cylinders to achieve angular and axial repeatable positioning of the guide cylinder relative to the drive shaft. The engaging components can be end-face positioning structures with an annular boss engaging an annular groove, or self-centering structures with wedge, cone, or key shapes. The shifting seat and the drive shaft can be reliably connected by interference fit, keying, or locating pins to ensure the coaxiality and torsional resistance of the seat relative to the drive shaft.

[0041] The first fastener 1000 is sleeved outside the first drive shaft 20 and abuts against the side of the first guide cylinder away from the main body 10. The second fastener 1010 is sleeved outside the second drive shaft 30 and abuts against the side of the second guide cylinder away from the main body 10. The fasteners and the shifting seat clamp the guide cylinder in the axial direction, thereby restricting the axial position of the guide cylinder and providing end face preload. To improve clamping stability, a washer or wear-resistant end ring can be provided between the fastener and the end face of the guide cylinder to distribute contact pressure and reduce wear during loading and unloading.

[0042] During assembly, the aforementioned components are first fixed to the corresponding drive shaft. Then, the guide cylinder's slot near the main body 10 is aligned with the shifting seat's engaging component and pushed into place. Finally, the fastener is tightened to clamp the guide cylinder between the shifting seat and the fastener. Because the two guide cylinders are aligned at both ends, and the shifting seat's engaging component and slot provide a unified reference, the angular and axial positions of the guide cylinders on either drive shaft can be repeatedly positioned, facilitating subsequent adjustments.

[0043] During operation, the drive shaft rotates the corresponding guide cylinder, and the metal wire forms a stable coating on the outer surface of the guide cylinder. The guide cylinder is positioned angularly and axially by engaging with the shifting seat, and clamped and pre-tightened at the ends by fasteners, thus achieving reliable torque transmission and coaxial rotation. When reversal is required, loosen the fasteners on both sides in sequence to disengage the guide cylinder from the shifting seat engagement, swap the positions of the two guide cylinders, engage them again with the corresponding shifting seat, and tighten the fasteners to complete the reversal. Due to the end face alignment and engagement positioning, the installation posture of the guide cylinder remains consistent with the reference before and after reversal, and the operating geometry is stable.

[0044] In the locked state, the shifting seat engagement piece provides angular and axial reference positioning, while the fastener provides axial clamping and pre-tightening. In the released state, the guide cylinder can move axially for quick assembly and disassembly. To prevent end face scratches during assembly and disassembly, a replaceable thrust member can be installed on the fastener end face. To prevent misalignment during assembly, orientation marks can be installed at the engagement piece and slot to ensure consistent engagement direction.

[0045] This embodiment is applicable to continuous wire annealing stations. The installation space is mainly for straight-line entry and exit, and the main body 10 should have sufficient rigidity and vibration resistance. The guide cylinder material can be selected from wear-resistant metals or wear-resistant coatings, or a ceramic outer layer with wear-resistant and corrosion-resistant properties, depending on the medium and temperature. The shift seat and fasteners should preferably be made of fatigue-resistant and wear-resistant materials. The device can operate in environments with dust, oil mist, and heat radiation. It is recommended to install necessary protective covers and cleaning passages to simplify maintenance.

[0046] In some alternative embodiments and solutions, the guide cylinder's groove can be an annular groove, an axial keyway, or a composite groove; the engaging element can be a conical tenon, a wedge block, or a resilient locking pin; the fastener can be a handle-type quick-change clamp or a threaded assembly with an anti-loosening structure; the shifting seat can be an integral or separate structure, and a positioning step can be added to the end face to enhance the end face fit. These variations do not change the basic concept of aligning the two ends of the guide cylinder, engaging the groove and engaging element, and axially limiting the guide cylinder by the fastener and shifting seat.

[0047] In this embodiment, by adopting a unified reference for aligning both ends of the guide cylinder, setting a slot at one end near the main body 10 to achieve snap-fit ​​positioning with the snap-fit ​​component on the shift seat, and using fasteners and the shift seat to axially clamp and detachably assemble the guide cylinder, the technical problems of large repeated positioning errors caused by inconsistent geometric references after shifting, low maintenance efficiency caused by cumbersome disassembly and assembly steps, and difficulty in guaranteeing coaxiality and torsional reliability in the prior art are effectively solved. Thus, it achieves rapid swapping and disassembly, repeatable installation posture, stable torque transmission, reduced downtime, and improved operational stability.

[0048] In some embodiments, the preset gap is defined as the distance between the axial centerline of the first target contact strip and the axial centerline of the second target contact strip, and the preset gap is 5mm to 25mm.

[0049] Specifically: To facilitate assembly and verification, a visible reference line or shallow marking can be set between the outer circle and end face reference of the two guide members (first guide member 40 and second guide member 50) to indicate the axial center position of their respective target contact strips. A scale surface or positioning reference surface is set on the mounting area of ​​the main body 10 opposite to the two guide members to read the axial distance between the two center lines and determine the preset gap accordingly. When a detachable end-clamping structure is used between each guide member and each drive shaft, the position of the contact strip can be slightly changed by micro-movement of the end face, adjustment of the spacer, or micro-adjustment of the seat to obtain the required gap. The preset gap is between five millimeters and twenty-five millimeters.

[0050] During stable operation, the metal wires adhere to the outer circumferences of the two guide members, forming a first target contact band and a second target contact band on their outer surfaces. The positions of the two bands are axially aligned with their respective bandwidth centers. By aligning and reading the center lines during assembly, the two center lines are maintained at a preset gap in the axial direction. If the relative positions of the two bands change due to thermal expansion and contraction or wear during operation, the center lines of the two bands can be restored to the positions corresponding to the preset gap by loosening the end clamps of the guide members, making a slight displacement along the axial direction, and then tightening and locking them again.

[0051] During the cold assembly stage, the end face positions of the two guide components are first checked against the 10-plane reference surface of the main body, and their respective center lines are marked. After the hot stabilization, the center line distance is re-measured. If there is a deviation, axial fine-tuning is performed in small steps, and the measurement is checked again until the center line distance reaches the preset gap. To avoid introducing new deviations during the adjustment process, the adjustment is carried out symmetrically, and a short-term idle run or low-speed test run is performed after each fine movement to confirm the stability of the belt position.

[0052] In some optional embodiments and alternatives, the center line of the target contact strip can be marked by shallow surface engravings, wear-resistant colored strips, or fine knurling; the reading method can be direct reading from the frame scale surface, alignment with the viewing window mark, or touch-stop reading from the positioning block; axial fine adjustment can be achieved by stacking thin shims, rotating the eccentric sleeve, or pushing with a micro-pitch; as long as the axial distance between the two center lines can be stably maintained within the range of five to twenty-five millimeters with the center of the bandwidth as a reference, it is an alternative to this embodiment.

[0053] In this embodiment, by adopting a technical means that uses the center line of the bandwidth of the contact zone of the two targets as a reference and limits the axial distance to five millimeters to twenty-five millimeters, the technical problems of co-position wear and grooving caused by overlapping contact areas and the difficulty in controlling lateral fluctuations caused by unstable posture after crossing are effectively solved in the prior art. Thus, the axial dispersion of contact load, uniform wear, stable maintenance of crossing posture and wrap angle, and simultaneous improvement of operation quality and maintenance efficiency are achieved.

[0054] In some embodiments, the outer working surface of the guide cylinder is slightly convex, and the slightly convex shape is symmetrical about the axial vertical plane of the guide cylinder; and, per 100 mm, the difference between the maximum diameter at the axial center of the guide cylinder and the diameter near the two ends is 0.02 mm to 0.20 mm; the highest point of the slightly convex shape is located at the axial center of the guide cylinder and the deviation between its axial projection and the center line of the first target contact strip or the second target contact strip on the corresponding guide cylinder is no more than 2 mm.

[0055] Specifically: Specific structure and composition The outer working surface of the guide cylinder is machined into a slightly bulging shape, with its profile symmetrical about the axial vertical plane of the guide cylinder. The slightly bulging shape is defined as a continuous, smooth raised area that transitions from both ends to a larger outer diameter along the axial direction of the guide cylinder. To ensure geometric consistency, a positioning reference surface is set on the end face of the guide cylinder, and a marker line for the highest point of the profile is set in the middle of the outer working surface, with the axial position of the highest point coinciding with this vertical plane. The guide cylinder and the corresponding drive shaft are coaxially fitted and detachably connected, with preload applied at the ends by a clamping member to ensure rotational stability. The slightly bulging profile of the outer working surface of the guide cylinder can be obtained through form grinding or CNC cutting, with a smooth transition between the end and the bulging area to avoid sharp edges. For ease of assembly verification, a reading or alignment reference is set at a visible position of the main body 10 relative to the guide cylinder to indicate the relative positional relationship between the target contact zone centerline and the highest point of the bulge.

[0056] During equipment operation, metal wires adhere to the outer circumference of the micro-drum to form the target contact band. Since the diameter at the center of the outer circumference is larger than the diameter at the ends, the metal wires, under tension, tend to adhere stably near the highest point of the drum, thus achieving repeatable axial band positioning. By aligning the axial projection of the highest point of the drum with the centerline of the target contact band during assembly, and maintaining this relationship within the deviation range defined in the claims during operation, the contact band can be kept stable in the geometrically predetermined area for an extended period. If band positioning shifts due to thermal expansion and contraction or wear, the axial position of the guide cylinder or endoscopic pre-tightening can be fine-tuned after shutdown to restore the alignment of the highest point with the centerline.

[0057] During the cold assembly stage, the relative position of the guide cylinder and the main body 10 is first checked using the end face reference, and then the outer circle marking line is aligned with the center line of the target contact strip. After the hot stabilization, a second check is performed. If the deviation between the center line and the highest point is found to be close to the upper limit, a small stroke axial micro-movement is made according to the on-site reference and then tightened. To prevent the adjustment from introducing new out-of-roundness and runout, a short period of low-speed idle rotation is performed after the micro-movement to confirm the smoothness of the bonding trajectory before resuming normal linear speed.

[0058] In some alternative embodiments and solutions, the micro-drum profile can be a circular arc transition, a spline transition, or a multi-segment linear transition, as long as it achieves symmetry about the axial vertical plane and forms a highest point in the middle. The highest point of the drum can be marked with a shallow etched line, a wear-resistant coated line, or a replaceable thin ring mark; the reference for alignment can be a fixed ruler, a viewing window, or an adjustable positioning block. Axial fine-tuning can be achieved by stacking thin shims, rotating an eccentric sleeve, or using an end micro-feed mechanism; any equivalent substitution is acceptable as long as the axial projection deviation between the highest point and the center line of the target contact zone remains within the range described in the claims.

[0059] In this embodiment, by employing a micro-drum-shaped outer circle symmetrical about the axial vertical plane and ensuring that the axial projection of the highest point of the drum and the center line of the target contact strip remain coincident as defined in the claims during assembly and operation, and that the diameter difference between the middle and end of the outer circle is within the range defined in the claims per 100 mm of cylinder length, the technical problems of easy axial drift of the contact strip, easy scratching of grooves due to stress concentration at the edges, and difficulty in repeating the strip position after line change in the prior art are effectively solved. Thus, the self-centering and repeatable maintenance of the strip position, uniform distribution of contact pressure in the bandwidth direction, suppression of deviation and vibration, and simultaneous improvement of surface quality and lifespan are achieved.

[0060] In some embodiments, both the first guide member 620 and the second guide member 720 have rounded corners on the side facing the metal wire, and the radius of the rounded corners is at least 0.20 mm; and the first guide gap is smaller than the second guide gap, with the difference between the two being 0.10 mm to 0.50 mm.

[0061] Specifically: Both the first directional component 620 and the second directional component 720 are mounted on the outer surface of their respective fixing rods, with rounded corners on the wire-facing side, the radius of which is not less than 0.2 mm. The rounded corners can be obtained after the directional components are formed by rounding, rolling, or polishing, and deburring and fine polishing are performed in the rounded corner transition area to eliminate micro-cracks and sharp edges. To ensure consistency in the rounded corner dimensions, the same rounded corners can be formed on both the wire-entry and wire-exit edges of the directional components. The first directional components 620 are arranged at equal intervals along the axial direction of the fixing rod, forming a first guide gap between adjacent directional components; the second directional components 720 are arranged in the same manner, forming a second guide gap. The nominal dimensions of the two sets of gaps are set during assembly using shims, fine-tuning screws, or eccentric sleeves, wherein the first guide gap is smaller than the second guide gap, and the difference between the two is controlled within the range of 0.1 mm to 0.5 mm. For ease of inspection, a scale reference or gauge window opposite to the directional components can be provided on the main body 10 for reading and verification.

[0062] After entering from upstream, the metal wire is first guided near the edge of the first directional member 620 with rounded corners and crosses the first guide gap. The rounded corner transition changes the contact between the metal wire and the directional member from line contact to strip contact, reducing contact stress and micro-cutting action at the wire entry point. The first guide gap is small, providing primary restraint and shaping of the lateral position and bandwidth of the metal wire; subsequently, the metal wire crosses the second guide gap, which, due to its larger size, provides secondary buffering and widening areas, reducing local lateral pressure and friction caused by the primary restraint, ultimately stabilizing the crossing posture. If fine-tuning of the band position and tension distribution is required during operation, the two guide gaps can be changed through the adjustment mechanism while the machine is stopped, keeping the difference between them within a specified range.

[0063] During assembly, first confirm the actual dimensions of the first and second guide gaps using gauges or feeler gauges, ensuring that the first guide gap is smaller than the second guide gap and the difference is within the allowable range; then confirm that the fillet radius of the orienting component is not less than the limit value and is consistent along its entire length using a fillet radius gauge or projection inspection. During trial operation, observe the contact trajectory and crossing posture of the metal wire at the fillet of the orienting component by low-speed idle rotation. If edge scratches or bandwidth fluctuations occur, prioritize checking the setting of the first guide gap and the surface roughness of the fillet, and perform polishing repair if necessary. After thermal stabilization, remeasure the two guide gaps. If changes occur due to thermal expansion and contraction, make small stroke corrections to the fine-tuning mechanism to restore the difference to the required range.

[0064] In some optional embodiments and alternatives, the fillet geometry can adopt constant radius fillets, variable radius fillets, or composite fillets, as long as the infeed and outfeed edges form a smooth transition and the radius is not less than the specified value. The setting of the two guide gaps can be achieved by replacing spacers of different thicknesses, adjusting the eccentric sleeve angle, or using a micro-pitch push mechanism; the difference between the first guide gap and the second guide gap can also be set in stages within the above range to adapt to different wire diameters, linear speeds, and tension conditions. The end edge of the orientation component can also be covered with a wear-resistant thin layer to enhance the retention and contamination resistance of the fillet area.

[0065] In this embodiment, by employing a rounded transition on the side facing the metal wire and ensuring that the rounded radius reaches the specified lower limit, and by setting the first guide gap to be smaller than the second guide gap and the difference between the two within a controlled range, the technical problems of sharp edges easily scratching the wire surface, large impact stress during wire insertion, and unstable belt positioning caused by the lack of distinction between the cross-forming and buffer zones in the prior art are effectively solved. This results in smooth wire insertion, coordinated lateral limiting and width release, more uniform distribution of contact pressure and wear, significant reduction of scratches and vibration, and improved operational stability.

[0066] In some embodiments, the slot is a tapered groove, and the engaging member is a tapered member that mates with the slot. The engaging member and the slot are configured such that, in the engaged state, the central axis of the first guide member 40 or the second guide member 50 is collinear with the central axis of the first drive shaft 20 or the second drive shaft 30. The first fastener 1000 and / or the second fastener 1010 are eccentric quick-change clamping members or nut assemblies with torque limiting structures.

[0067] Specifically: The guide member has a tapered groove at its end, and the mating component at the opposite end is a matching tapered part. The axis of the tapered groove coincides with the central axis of the guide member, and the axis of the tapered part coincides with the axis of the drive shaft it is mating with. During assembly, the tapered part is inserted into the tapered groove, forming a surface contact fit under axial clamping force. Utilizing the self-guiding effect of the tapered surface, the central axis of the guide member and the central axis of the drive shaft are made collinear. The tapered surface can be a continuously smooth conical profile, and the surface is precision machined and polished to improve fit repeatability and reduce wear. To ensure loading / unloading efficiency and clamping stability, a clamping bearing surface is provided on the outer side of the guide member, and fasteners apply a preload force to the guide member axially. The fasteners can be eccentric quick-change clamping parts or nut assemblies with torque-limiting functions; both mate with the bearing surface at the end of the guide member to form reliable endoscopic clamping. The eccentric quick-change clamping component achieves rapid locking and releasing through the cooperation of the eccentric cam and the bearing surface; the torque limiting nut assembly automatically slips out or issues a prompt after reaching the set tightening torque, thereby obtaining repeatable preload.

[0068] During assembly, first roughly align the tapered component with the tapered groove, push the guide component to the contact position, and then apply axial preload to the drive fastener. As the preload increases, the tapered surfaces gradually come into contact and self-center, and the central axis of the guide component is pulled to be collinear with the central axis of the drive shaft. When using an eccentric quick-change clamping component, clamping or loosening can be completed within a short stroke by rotating the eccentric structure; when using a torque-limiting nut assembly, a stable preload is achieved after tightening until the torque-limiting mechanism activates. For disassembly, first release the fastener, then gently push the guide component axially to separate the tapered surfaces and complete the disassembly.

[0069] To achieve stable coaxiality and repeatability, the conical surface must be kept clean and intact; oil and particles should be removed before assembly. If uneven insertion or increased coaxiality deviation is found, first check the conical surface for scratches and deposits, and verify that the fasteners have reached the designed pre-tightening. If the eccentric clamping mechanism experiences a shortened stroke or abnormal feel after high-frequency operation, check the wear of the eccentric wheel and bushing, and replenish lubrication or replace vulnerable parts. If the torque limiting nut assembly slips prematurely or fails to limit torque, check the internal friction pair and reset or replace it as needed.

[0070] In some alternative embodiments, the tapered groove can be arranged as an internal end face or an external end edge, and the tapered component can be an integral boss, a split sleeve, or an elastic clamp structure; the tapered surface contact can be a single tapered surface, or a bidirectional symmetrical tapered surface can be used to enhance self-centering and anti-overturning performance. The eccentric quick-change clamping component can adopt a handle-type, knob-type, or folding force transmission structure; the torque limiting nut assembly can adopt a friction plate-type, roller-type, or ratchet-type torque limiting unit. As long as the central axis of the guide component is ensured to be collinear with the central axis of the drive shaft in the snap-fit ​​state, and stable and repeatable axial preload can be provided, it is considered an equivalent substitution.

[0071] In this embodiment, the use of a tapered groove and tapered component to achieve self-centering alignment, supplemented by an eccentric quick-change clamping component or a torsion-limiting nut assembly to provide repeatable axial pre-tightening, effectively solves the technical problems in the prior art where alignment relies on manual alignment, resulting in large coaxial errors, long disassembly and assembly time, and unstable pre-tightening that easily leads to deviation and vibration. Thus, it achieves the technical effects of quick loading and unloading, high positioning repeatability, stable coaxiality and consistent pre-tightening, improved operational stability and reduced maintenance downtime.

[0072] To adapt to the above scheme, a winding method for annealing metal wire is proposed and applied to the winding mechanism of the annealing machine.

[0073] It should also be noted that the annealing machine includes a monitoring component and a controller. The monitoring component is mounted on the main body 10 and signal-connected to the controller. The monitoring component includes a spark detection sensor facing the area spanning the first guide 40 and the second guide 50, a surface profile sensor facing the outer working surfaces of the first guide 40 and the second guide 50, a vibration sensor arranged on the first transposition seat 80 and the second transposition seat 90, and a temperature sensor facing the contact area between the first guide 40 and the second guide 50. The spark detection sensor's detection end points to the contact area between the wire and the first guide 40 and the second guide 50, and is used to detect spark events and output a pulse count signal. The surface profile sensor is used to measure the equivalent displacement signal of the surface groove depth of the first guide 40 and the second guide 50. The vibration sensor is used to acquire the acceleration spectrum amplitude. The temperature sensor is a non-contact infrared temperature sensor. The controller stores preset thresholds for spark event counts, groove depths, temperature rise, and vibration amplitude, and is used to compare and trigger the outputs of the monitoring component in real time.

[0074] The winding method specifically includes the following steps: Step S100: Run at a preset linear speed and preset tension, so that the metal wire sequentially passes through the outer surface of the first guide 40, the first guide gap, the second guide gap and the outer surface of the second guide 50, and maintains the preset gap between the first target contact strip and the second target contact strip; Step S200: During operation, collect at least one wear or instability characterization index, including spark event count, guide surface groove depth, contact area temperature rise and / or vibration acceleration spectrum amplitude, and compare it with a preset threshold. Step S300: When any of the wear or instability characterization indicators reaches the preset threshold, stop the operation, loosen the first fastener 1000 and the second fastener 1010, so that the first guide 40 and the second guide 50 are disengaged from the first shift seat 80 and the second shift seat 90 respectively. Step S400: Swap the first guide 40 and the second guide 50, so that the swapped wire falls into the unworn area on the third target contact strip of the swapped first guide 40 and the fourth target contact strip of the swapped second guide 50. Reset and tighten the first fastener 1000 and the second fastener 1010. Wherein, the third target contact strip and the fourth target contact strip refer to the stable contact areas of the wire on the corresponding outer surfaces of the first guide 40 and the second guide 50 after the swapped installation. Step S500: Reset the operation and confirm that the preset gap is within the range of 5mm to 25mm.

[0075] Specifically: This method is applied to the winding mechanism of the aforementioned annealing machine. The annealing machine is equipped with a monitoring component connected to the controller via a signal connection. The monitoring component includes a spark detection sensor facing the crossing area, a surface profile sensor facing the outer working surfaces of the two guide members, a vibration sensor arranged on the two transposition seats, and a non-contact infrared temperature sensor facing the contact area. The controller stores preset thresholds for spark event counts, groove depths, temperature rises, and vibration amplitudes, and performs real-time comparison and trigger determination of the monitoring outputs.

[0076] Step S100 involves initialization and stable crossing. The target values ​​for linear speed and tension, as well as the preset gap target, are set in the controller via the human-machine interface. After starting the drive, the speed is increased in a ramp manner, causing the metal wire to sequentially cover the outer surface of the first guide member 40, cross the first guide gap and the second guide gap, and cover the outer surface of the second guide member 50. During the low-speed phase, the controller reads the static baseline of each sensor and completes zero-point calibration. When the linear speed and tension reach the target and the contact strips of the first and second targets on the two guide members maintain the preset gap, the system is determined to have entered a stable crossing state.

[0077] Step S200 involves online monitoring and index calculation. During operation, the spark detection sensor outputs event pulses, which the controller accumulates according to a time window and performs de-jitter processing to obtain the spark event count; the surface profile sensor outputs an equivalent displacement signal, which the controller calculates the groove depth characterization of the outer working surface of the guide component and performs a moving average; the vibration sensor outputs an acceleration signal, which the controller extracts as the vibration amplitude indicator from the target frequency band; the infrared temperature sensor outputs the near-contact temperature, which the controller calculates the relative temperature rise. The above indicators are compared hourly with their corresponding thresholds, and hysteresis and multi-window verification are used to avoid false triggering caused by occasional disturbances.

[0078] Step S300 involves triggering a shutdown and unlocking / disengaging the device. When any indicator reaches a preset threshold, the controller issues a controlled shutdown command, using a deceleration ramp to smoothly reduce the linear speed and tension to a safe value and stop the machine. After the metal wire has completely released the dynamic load, the first fastener 1000 and the second fastener 1010 are loosened sequentially, causing the first guide 40 and the second guide 50 to disengage from the first shifting seat 80 and the second shifting seat 90, respectively. At this time, the controller records the triggering reason and the peak values ​​of each indicator for maintenance and traceability.

[0079] The preset threshold is any one or any combination of the following: the number of spark events within a predetermined time window reaches a preset value, the groove depth on the guide surface reaches a preset value, the temperature rise in the contact area reaches a preset value, and / or the amplitude of the vibration acceleration spectrum in the target frequency band reaches a preset value; and after the first guide 40 and the second guide 50 are swapped and installed, the first positioning component 60 and the second positioning component 70 limit the crossing position of the metal wire between the first guide gap and the second guide gap, so that the deviation of the preset gap is not greater than 2mm.

[0080] Specifically: Threshold and Time Window Initialization: In the controller, set the time window length for judgment, spark event count threshold, guide surface groove depth threshold, contact area temperature rise threshold, vibration acceleration spectrum target frequency band and amplitude threshold, and select the trigger logic as a strategy where any one of the thresholds or a combination of multiple thresholds is reached. The combined strategy can adopt parallel comparison and threshold voting, supporting both single-index triggering and multi-index linkage triggering modes.

[0081] Data Acquisition and Preprocessing: Spark event counts are accumulated within each time window. The equivalent displacement of the guide surface contour is obtained to calculate the groove depth. The contact area temperature is read and the relative temperature rise is calculated. The amplitude of the vibration signal is extracted within the target frequency band. To improve the stability of the judgment, de-jittering, anomaly removal, and moving average are performed on each indicator to obtain robust statistics within the time window.

[0082] Threshold comparison and trigger determination: The spark count, groove depth, temperature rise and vibration amplitude within the time window are compared with the corresponding thresholds. When any indicator reaches the threshold, or when the triggering condition is met according to the selected combination strategy, a transposition trigger signal is generated and the transposition process begins. If the condition is not met, monitoring and comparison continue in the next time window.

[0083] Positioning and Path Limitation: Guide components are swapped and installed based on a trigger signal. After swapping, the first positioning component 60 and the second positioning component 70 are used to limit the spatial position of the wire crossing the first guide gap and the second guide gap, ensuring that the wire's crossing path and entry / exit posture between the two sets of guide components fall into the expected geometric channel, avoiding lateral drift and positional jumps in the crossing area.

[0084] Preset gap verification and fine-tuning: After the swap and reset, measure the distance between the axial center lines of the first target contact strip and the second target contact strip, and compare it with the preset gap target; if the deviation is no more than two millimeters, it is judged to pass; if the deviation exceeds the limit, make small-step fine-tuning based on the positioning component, and use the symmetrical adjustment method to correct the crossing position until the deviation of the preset gap is no more than two millimeters.

[0085] Confirmation and Resumption of Operation: After completing the gap review, the cumulative count is cleared, the current status is updated to "transposed" and normal monitoring is resumed; if any or a combination of indicators reaches the threshold again, the above process is repeated to achieve threshold-based closed-loop transposition and geometric consistency maintenance.

[0086] The key technical points in this step are: First, the coordinated setting of the time window and threshold needs to balance sensitivity and interference resistance, and it is recommended to manage them in accordance with line speed, tension, and working condition formula. Second, the triggering logic should provide two channels: individual triggering and combined triggering, to adapt to different products and working conditions. Third, the path limitation after transposition depends on the geometric reference of the two sets of positioning components, and fine-tuning should be carried out within the limited channel to ensure consistency between crossing posture and belt position. Fourth, the verification of the preset gap is based on the axial centerline, and a deviation control of no more than two millimeters is the release condition.

[0087] The application sequence and parameter settings are illustrated below: First, set the time window, thresholds, and trigger logic, then start monitoring and comparison; when the trigger condition is met, execute the position shift, limit the crossing position, and verify the preset gap; after verification, reset the count and start a new round of monitoring. Parameters can be customized according to batch or specification changes to ensure consistent judgment and control effects for different products under the same process.

[0088] The above-mentioned process, through clear time window acquisition, threshold judgment, geometric channel limitation after swapping and reset, and quantitative verification of preset gaps, constitutes a closed-loop process from detection to execution and then to verification, ensuring the necessity, timeliness and consistency of the swapping action.

[0089] Step S400 involves swapping the installation and resetting the clamp. The first guide 40 and the second guide 50 are interchanged, aligned with their respective snap-fit ​​interfaces, and pushed in until they contact the positioning surfaces. The snap-fit ​​is reset, and the corresponding fasteners are tightened to restore axial clamping and angular positioning. The swapped wires form a third target contact band on the swapped first guide 40 and a fourth target contact band on the swapped second guide 50; both should be located in unworn areas. After reassembly, a low-speed idle self-test is performed under the controller's guidance to confirm proper snap-fit ​​alignment and rotational coaxiality.

[0090] Step S500 involves resetting the operation and verifying the gap. Operation resumes, and the linear speed and tension are gradually increased to the target values. The target contact strip position is re-measured online using the monitoring components to confirm that the preset gap is within the range of 5 mm to 25 mm, and that all indicators are below the threshold during short-term operation. If the verification passes, the closed-loop judgment method is complete, and the system enters normal continuous operation. If it fails, a prompt is made to perform fine-tuning until the requirements are met.

[0091] The key technical points and implementation guidelines of this winding method are as follows: First, the monitoring signal needs to be baseline-calibrated, de-jittered, and smoothed on the controller side to improve the reliability of threshold determination. Second, controlled deceleration is used to trigger the stop, avoiding new scratches caused by transient tension. Third, the installation and adjustment must be strictly reset according to the snap-fit ​​reference, and then the coaxial and bonding trajectory should be verified by low-speed idle running. Fourth, after reset, the preset gap must be confirmed to be within the specified range by online measurement to ensure that the contact belt misalignment shares the wear.

[0092] This method is applicable to the winding and guiding processes in continuous annealing production environments and can be implemented in conditions involving heat radiation, dust, and oil mist. The main body 10 must possess sufficient rigidity and vibration damping capabilities, and necessary visual inspection and maintenance channels must be provided. Target values ​​for threshold, linear speed, tension, and preset gap are given by the process and stored in the controller, allowing for customized management based on product specifications and wire diameter.

[0093] The above description is merely illustrative of the invention. Those skilled in the art can make various modifications or additions to the described specific embodiments or use similar methods to replace them, as long as they do not depart from the content of this specification or exceed the scope defined by the claims, all of which should fall within the protection scope of this invention.

Claims

1. A winding mechanism for a metal wire annealing equipment, characterized in that, include: main body; A first drive shaft and a second drive shaft are disposed on the main body and rotated in a controlled manner, and the first drive shaft and the second drive shaft are arranged in parallel. The first guide member is coaxially sleeved outside the first drive shaft to rotate with the first drive shaft, and the first guide member is detachably connected to the first drive shaft. The second guide is coaxially sleeved outside the second drive shaft to rotate with the second drive shaft, and the second guide is detachably connected to the second drive shaft. The first positioning component includes: A first fixing rod arranged parallel to the first drive shaft; A plurality of first directional members are arranged sequentially on the outer surface of the first fixed rod along the axial direction of the first fixed rod. Each first directional member is located on the same plane, and the distance between each two adjacent first directional members is equal. The gap between two adjacent first directional members is a first guide gap. The second positioning component includes: A fixing rod arranged parallel to the second drive shaft; A plurality of second directional members are arranged sequentially on the outer surface of the second fixing rod along the axial direction of the second fixing rod. Each second directional member is located on the same plane, and the distance between each two adjacent second directional members is equal. The gap between two adjacent second directional members is the second guide gap. When the winding mechanism is in operation, the metal wire sequentially passes through the outer surface of the first guide, the first guide gap, the second guide gap, and the outer surface of the second guide, and a preset gap is left between the first target contact zone where the metal wire contacts the outer surface of the first guide and the second target contact zone where the metal wire contacts the outer surface of the second guide.

2. The winding mechanism according to claim 1, characterized in that, Both the first guide and the second guide are guide cylinders, and the two ends of the first guide are respectively aligned with the two ends of the second guide.

3. The winding mechanism according to claim 2, characterized in that, include: Both the end of the first guide member near the main body and the end of the second guide member near the main body are provided with a slot; A first shifting seat and a second shifting seat, the first shifting seat is fixedly sleeved on the outside of the first drive shaft, and the second shifting seat is fixedly sleeved on the outside of the second drive shaft. Both the side of the first shifting seat away from the main body and the side of the second shifting seat away from the main body are provided with engaging parts that engage with the corresponding slots. A first fastener and a second fastener, wherein the first fastener is sleeved outside the first drive shaft and abuts against the side of the first guide away from the main body to restrict the first guide between the first shift seat and the first fastener; the second fastener is sleeved outside the second drive shaft and abuts against the side of the second guide away from the main body to restrict the second guide between the second shift seat and the second fastener.

4. The winding mechanism according to claim 1, characterized in that, The preset gap is defined as the distance between the axial centerline of the first target contact strip and the axial centerline of the second target contact strip, and the preset gap is 5mm to 25mm.

5. The winding mechanism according to claim 2, characterized in that, The outer working surface of the guide cylinder is slightly convex, and the slightly convex shape is symmetrical about the axial vertical plane of the guide cylinder; and, per 100 mm, the difference between the maximum diameter at the axial center of the guide cylinder and the diameter near the two ends is 0.02 mm to 0.20 mm; the highest point of the slightly convex shape is located at the axial center of the guide cylinder and the deviation between its axial projection and the center line of the first or second target contact zone on the corresponding guide cylinder is no more than 2 mm.

6. The winding mechanism according to claim 1, characterized in that, Both the first and second directional members have rounded corners on the side facing the metal wire, and the radius of the rounded corners is at least 0.20 mm; and the first guide gap is smaller than the second guide gap, with a difference of 0.10 mm to 0.50 mm.

7. The winding mechanism according to claim 3, characterized in that, The slot is a tapered slot, and the engaging member is a tapered member that mates with the slot. The engaging member and the slot are configured such that, in the engaged state, the central axis of the first guide member or the second guide member is collinear with the central axis of the first drive shaft or the second drive shaft.

8. The winding mechanism according to claim 3, characterized in that, The first fastener and / or the second fastener are eccentric quick-change clamps or nut assemblies with torque limiting structures.

9. A winding method for annealing metal wire, applied to the winding mechanism of an annealing machine as described in claim 3, 7, or 8, characterized in that: The annealing machine includes a monitoring component and a controller. The monitoring component is disposed on the main body and is signal-connected to the controller. The monitoring component includes: A spark detection sensor facing the area spanned between the first guide and the second guide, wherein the detection end of the spark detection sensor points to the contact area between the metal wire and the first guide and the contact area between the metal wire and the second guide, for detecting spark events and outputting a pulse counting signal; A surface profile sensor facing the outer working surfaces of the first guide and the second guide is used to measure the equivalent displacement signal of the surface groove depth of the first guide and the second guide; Vibration sensors arranged on the first transposition seat and the second transposition seat are used to acquire acceleration spectrum amplitude values; A temperature sensor facing the contact area between the first guide and the second guide, wherein the temperature sensor is a non-contact infrared temperature sensor; The controller stores preset thresholds for spark event counts, trench depths, temperature rises, and vibration amplitudes, and is used to compare and trigger the outputs of the monitoring components in real time. The winding method includes: The wire moves sequentially through the outer surface of the first guide, the first guide gap, the second guide gap, and the outer surface of the second guide at a preset linear speed and a preset tension, while maintaining the preset gap between the first target contact strip and the second target contact strip. During operation, at least one wear or instability characterization index is collected, including spark event count, guide surface groove depth, contact area temperature rise and / or vibration acceleration spectrum amplitude, and compared with a preset threshold. When any of the wear or instability indicators reaches the preset threshold, the operation stops, the first fastener and the second fastener are loosened, and the first guide and the second guide are disengaged from the first shift seat and the second shift seat respectively. The first guide and the second guide are swapped and installed so that the swapped metal wire falls into the unworn area on the third target contact strip of the first guide and the fourth target contact strip of the second guide. The first fastener and the second fastener are then reset and tightened. The third target contact strip and the fourth target contact strip refer to the stable contact areas of the metal wire on the corresponding outer surfaces of the first guide and the second guide after the first guide and the second guide are swapped and installed. Reset the operation and confirm that the preset gap is within the range of 5mm to 25mm.

10. The winding method according to claim 9, characterized in that, The preset threshold is any one or any combination of the following: The number of spark events within a predetermined time window reaches a preset value, the depth of the groove on the guide surface reaches a preset value, the temperature rise in the contact area reaches a preset value, and / or the amplitude of the vibration acceleration spectrum in the target frequency band reaches a preset value. Furthermore, after the first guide and the second guide are swapped and installed, the first positioning component and the second positioning component limit the crossing position of the metal wire between the first guide gap and the second guide gap, so that the deviation of the preset gap is no greater than 2mm.

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