A calender molding process for square enameled wire

Abstract

The application provides a calendering plastic molding process for square enameled wire and relates to the technical field of wire and cable manufacturing, and comprises the following steps: S1, primary calendering of round blank wire; S2, measurement of the size of the square wire after primary calendering; S3, plastic molding of the square wire according to the difference between the measured size and the predetermined size; and S4, repeating steps S1 to S3 until the wire size reaches the range of target size requirements. The application has the advantages of higher precision and the like.

Description

Technical Field

[0001] This invention relates to the field of wire and cable manufacturing technology, and in particular to a calendering and molding process for square enameled wire. Background Technology

[0002] Small-sized (less than 0.5mm) square enameled wires have a conductor size deviation of more than 0.02mm when using traditional rolling methods (rough rolling + finish rolling). The large conductor size deviation places extremely high demands on the uniformity of the coating film in the enameling process. Coupled with the problem of uneven coating film at the R-angle of the square wire, the finished square wires have pinholes and poor pressure resistance, with a batch yield of no more than 60%, resulting in high manufacturing costs.

[0003] As the conductor part of enameled wire, when the size is small and the flatness ratio (the aspect ratio of the square wire cross-section) is greater than 1.5, it is difficult for traditional rolling methods to maintain a small dimensional deviation while ensuring that the wire does not break, resulting in a low yield. This is because the smaller the size and the larger the flatness ratio of the conductor wire, the larger the deformation ratio and the smaller the deformation amplitude during rolling, which requires extremely high precision in controlling the rolling force. In addition, in traditional processes, it is difficult to form a regular R angle by simply rolling multiple times, and obvious unevenness will remain on the surface of the wire, affecting the mechanical and electrical properties of the conductor. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention proposes a process for forming small-sized enameled wire conductors from round to square shapes.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a calendering and molding process for square enameled wire, characterized by comprising the following steps:

[0006] S1. Perform a single rolling process on the circular billet;

[0007] S2. Measure the dimensions of the square wire after one rolling process;

[0008] S3. Shape the square wire according to the difference between the measured size and the predetermined size;

[0009] S4. Repeat steps S1 to S3 until the wire size reaches the target size requirement range.

[0010] Furthermore, the square conductor is measured using a laser rangefinder.

[0011] Furthermore, the dimensional data of the square wire obtained from the measurement is fed back to the preceding rolling process.

[0012] As another possibility, the measured dimensions of the square wire are fed back to the rolling process in front and the molding process in the back.

[0013] Furthermore, the mold used for molding includes several clamping mechanisms. Each clamping mechanism includes two symmetrically arranged guide components. Each guide component includes a spring rod and a guide wheel. The outer end of the spring rod is fixedly connected to a mounting plate, and the guide wheel is rotatably connected to the inner end of the spring rod. The guide wheel has a guide groove. Each clamping mechanism is arranged longitudinally, and the guide wheel axes of adjacent clamping mechanisms are perpendicular to each other.

[0014] Furthermore, the outer side of the mounting plate is wedge-shaped, and the base for connecting the mounting plate has a dovetail groove adapted to the mounting plate. The top of the mounting plate is provided with a drive unit that can drive the mounting plate to move longitudinally within the dovetail groove.

[0015] As a further refinement, the driving unit can be magnetic or hydraulic.

[0016] The magnetically driven structure includes a permanent magnet block at the upper end of the mounting plate and an electromagnetic component on a base located above the mounting plate. The position of the mounting plate can be adjusted by controlling the magnitude and direction of the current.

[0017] Compared with the prior art, the present invention has the following advantages:

[0018] 1. This solution combines calendering and molding, which solves the problem of low dimensional accuracy caused by calendering alone;

[0019] 2. The molding die used in this solution is not a traditional fixed die for adjusting the size and shape of metal materials. Generally, in existing technologies, the preferred method for shaping wire is a wire-passing die, which uses a closed mold to allow the wire to pass through under pressure, thus adjusting the material's outline after demolding. In this solution, due to the small size of the wire and the fact that traditional fixed dies lack buffering performance, easily causing wire breakage and surface defects, this solution uses multiple elastic rods as connecting components for the guide wheels. The guide wheels are arranged in pairs to position and compress the two opposite surfaces of the wire. The longitudinally connected guide wheels are responsible for pressing different surfaces of the wire. The guide grooves form the wire passage channel. The elastic rods can be bent slightly to adjust the size of the passage channel. That is, when the resistance to wire passage is high, the elastic rods can be driven to deform elastically to increase the cross-sectional area of ​​the passage channel, and vice versa. The wire size adjustment is achieved through continuous small-amplitude molding.

[0020] 3. Traditional molds suffer from overheating. This solution addresses this by designing a multi-layered structure. The contact area between the two guide rollers of each clamping mechanism and the wire is extremely small, and there is a gap between the longitudinal guide rollers. This significantly improves the heat dissipation performance of both the wire and the mold itself. Overheating is a major factor affecting the physical properties of the wire, leading to wire breakage, air pockets, and damage to the wire's density. In addition, the rolling method makes the clamping force on the wire gentler, preventing the wire surface from being pulled out and developing structural defects.

[0021] 4. Based on the measurement of the wire size, the data is fed back to the drive unit, so that the clamping force of the guide wheel on the wire can be actively controlled. In addition, the distance between the guide wheels can be increased during wire drawing to improve the ease of operation. Attached Figure Description

[0022] Figure 1 This is a flowchart of the calendering and molding process for this square enameled wire;

[0023] Figure 2 This is a schematic diagram of the molding mechanism;

[0024] Figure 3 for Figure 2 Top view;

[0025] Figure 4 This is a structural diagram of a single guide component.

[0026] Legend: 1. Calendering mechanism; 2. Inspection mechanism; 3. Shaping mechanism; 31. Guide wheel; 32. Mounting plate; 33. Guide groove; 34. Drive unit; 35. Spring rod. Detailed Implementation

[0027] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0028] like Figure 1 As shown, the process involves two calendering and two shaping processes. The first calendering and shaping completes the initial deformation of the wire, while the second calendering and shaping completes the forming of the predetermined size. The calendering mechanism 1 is a double-roller structure. The calendered wire is controlled for smooth wire passage through two wire mechanisms with a short distance between them. The wire is then measured using laser ranging, where two opposing laser beams are projected onto two parallel surfaces of the wire. The distance between the measured surface and the laser source is measured. The difference between the distance between the two laser sources and the projection distance of the laser beams at both ends is the distance between the two parallel surfaces of the wire, i.e., the thickness of the wire. Similarly, the width is measured. This dimensional data is fed back to the calendering mechanism 1 to adjust the calendering force and the calendering roller speed. At the same time, this data can also be fed back to the shaping mechanism 3 to adjust the size of the wire passage. Through continuous data feedback, the dimensional accuracy and performance fluctuations during equipment operation can be adjusted.

[0029] like Figures 2 to 4As shown, the molding mechanism 3 includes several clamping mechanisms. Each clamping mechanism includes two symmetrically arranged guide components. The guide components include a spring rod 35 and a guide wheel 31. The outer end of the spring rod 35 is fixedly connected to a mounting plate 32, and the guide wheel 32 is rotatably connected to the inner end of the spring rod 35. The guide wheel 31 has a guide groove 33. Each clamping mechanism is arranged longitudinally, and the axes of the guide wheels 31 of adjacent clamping mechanisms are perpendicular to each other. The outer surface of the mounting plate 32 is wedge-shaped. The base for connecting the mounting plate 32 has a dovetail groove adapted to the mounting plate 32. The top of the mounting plate 32 is provided with a drive unit 34 that can drive the mounting plate 32 to move longitudinally within the dovetail groove. The drive unit 34 can be magnetic, including a permanent magnet block at the upper end of the mounting plate 32 and an electromagnetic component on the base above the mounting plate 32. The position of the mounting plate 32 can be adjusted by controlling the magnitude and direction of the current.

[0030] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A calendering and molding process for square enameled wire, characterized in that, Includes the following steps: S1. Perform a single rolling process on the circular billet; S2. Measure the dimensions of the square wire after one rolling process; S3. The square wire is shaped according to the difference between the measured size and the predetermined size. The mold used for shaping includes several clamping mechanisms. The clamping mechanism includes two symmetrically arranged guide components. The guide components include a spring rod (35) and a guide wheel (31). The outer end of the spring rod (35) is fixedly connected to a mounting plate (32). The guide wheel (31) is rotatably connected to the inner end of the spring rod (35). The guide wheel (31) has a guide groove (33). Each clamping mechanism is arranged longitudinally. The axes of the guide wheels (31) of adjacent clamping mechanisms are perpendicular to each other. S4. Repeat steps S1 to S3 until the wire size reaches the target size requirement range.

2. The calendering and molding process for a square enameled wire according to claim 1, characterized in that, The square conductor is measured using a laser rangefinder.

3. The calendering and molding process for a square enameled wire according to claim 2, characterized in that, The measured dimensions of the square conductor are fed back to the rolling process ahead.

4. The calendering and molding process for a square enameled wire according to claim 2, characterized in that, The dimensional data of the square wire obtained from the measurement is fed back to the rolling process in front and the molding process in the back.

5. The calendering and molding process for a square enameled wire according to claim 1, characterized in that, The outer side of the mounting plate (32) is wedge-shaped. The base for connecting the mounting plate (32) has a dovetail groove adapted to the mounting plate (32). The top of the mounting plate (32) is provided with a drive unit (34) that can drive the mounting plate (32) to move longitudinally in the dovetail groove.

6. The calendering and molding process for a square enameled wire according to claim 5, characterized in that, The drive unit (34) is a magnetic or hydraulic structure.

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