Low-loss aluminum-clad steel single wire continuous extrusion coating process and device thereof

Abstract

The invention belongs to the technical field of aluminum-clad steel production equipment, and particularly relates to a low-loss aluminum-clad steel single wire continuous extrusion coating process and device thereof.The process comprises the steps that S1, raw materials are selected and pretreated, specifically, steel wire cores and thin aluminum rods of corresponding specifications are selected according to the specifications of aluminum-clad steel single wires to be extruded and coated; a traditional low-loss aluminum-clad steel single wire continuous extrusion coating technology is optimized through the four thin aluminum rods and pre-extrusion, the distribution uniformity of an aluminum layer material during extrusion coating is improved, the resistance of extrusion coating of the aluminum layer material can be reduced, the quality and efficiency of continuous extrusion coating of the low-loss aluminum-clad steel single wire are effectively improved, and the service life of the low-loss aluminum-clad steel single wire is prolonged. And the extrusion coating device also has the functions of detecting the online centering degree of the steel wire core and accurately marking the unqualified position of the centering degree of the steel wire core, so that not only is the centering degree of the steel wire core adjusted in time through the steel wire core centering control mechanism, but also the convenience of repairing the unqualified position of the low-loss aluminum-clad steel single wire can be improved.

Description

Technical Field

[0001] This invention belongs to the technical field of aluminum-clad steel production equipment, and in particular relates to a low-loss aluminum-clad steel single-line continuous extrusion coating process and its apparatus. Background Technology

[0002] Low-loss aluminum-clad steel single-wire is the core basic form of aluminum-clad steel products. It refers to a single composite wire with a high-strength steel wire core and a uniform and continuous aluminum layer material on the outside. The aluminum and steel are metallurgically combined through continuous extrusion and other processes. It has the high strength of steel and the excellent conductivity and corrosion resistance of aluminum layer material. It has a compact structure and precise dimensions. It is widely used in power transmission, communication optical cables, special cables and other fields. It is a high-efficiency composite wire with both mechanical and electrical properties. At present, in the production process of low-loss aluminum-clad steel single-wire, the aluminum rod is plastically treated by an extruder. Finally, under the cooperation of the mold cavity, the plastically deformed aluminum rod material is uniformly covered around the steel wire core. For example, the patent with patent authorization number CN210995855U discloses an aluminum-clad steel continuous coating production line.

[0003] Currently, in the low-loss aluminum-clad steel single-line continuous extrusion coating process, the extruder needs to extrude a single thick-diameter aluminum rod (usually 9-12mm in diameter) and uniformly coat it around the steel wire core. However, due to the long radial heat conduction path of the thick-diameter aluminum rod, the heating uniformity is poor, and the temperature difference between the surface and the center of the thick-diameter aluminum rod is too large. The temperature in the center area of ​​the thick-diameter aluminum rod is lower than the optimal plastic deformation temperature of 400-500℃. This not only increases the frictional resistance between the thick-diameter aluminum rod and the extrusion die, leading to accelerated die wear and reduced cavity precision, but also further damages the uniformity of aluminum layer material coating, affecting the quality of the low-loss aluminum-clad steel single-line continuous extrusion coating process. It also increases the extrusion power consumption, limiting the production line speed to a lower range, which seriously affects the efficiency of the low-loss aluminum-clad steel single-line continuous extrusion coating process. Furthermore, during the extrusion process of coarse aluminum rods, the aluminum layer material of the coarse-diameter aluminum rods is prone to forming flow eddies and stagnant zones within the die cavity, resulting in uneven distribution of the aluminum layer material in the circumferential direction of the steel wire core. This leads to circumferential displacement of the steel wire core, with the eccentricity often exceeding the industry allowable range of 8%. This not only reduces the quality of low-loss aluminum-clad steel single wires but also causes uneven conductivity and fluctuations in mechanical strength. In power transmission or communication applications, it can easily lead to problems such as localized heating and fatigue fracture, significantly affecting the reliability of low-loss aluminum-clad steel single wires.

[0004] To address these issues, we propose a low-loss aluminum-clad steel single-line continuous extrusion coating process and its apparatus. Summary of the Invention

[0005] The purpose of this invention is to address the above-mentioned problems by providing a low-loss aluminum-clad steel single-line continuous extrusion coating process and apparatus.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a low-loss aluminum-clad steel single-line continuous extrusion coating process, which includes the following steps: S1. Raw material selection and pretreatment: Select steel wire core and thin aluminum rod of corresponding specifications according to the specifications of the aluminum-clad steel single wire to be extruded and coated. After being unfolded by the wire feeding equipment, the wire core and thin aluminum rod are subjected to surface impurity removal, pickling to remove oxide layer, water washing and cleaning, surface drying and heat pretreatment in sequence. S2. Pre-extrusion of thin aluminum rods: The thin aluminum rods pre-treated in step S1 are fed into the pre-extrusion process, so that the circular cross-section thin aluminum rods are pre-extruded into arc cross-section aluminum rods. S3. Steel wire core centering control: The steel wire core pre-treated in step S1 is sent into the centering adjustment process so that the steel wire core is in the center of the low-loss aluminum-clad steel single-wire continuous extrusion coating. S4. Aluminum-clad steel single-wire coating: The arc-shaped aluminum rod and steel wire core processed in steps S2 and S3 are simultaneously fed into the extrusion coating mold for continuous extrusion coating. S5. Cooling and straightening: The low-loss aluminum-clad steel single wire processed in step S4 is sequentially fed into the cooling water tank for cooling and straightening in the straightening machine for straightening. S6. Wire core centering test: Online non-contact wire core centering test is performed on the low-loss aluminum-clad steel single wire that has been straightened in step S5. S7. Feedback adjustment and marking: If the centering of the steel wire core is found to be unqualified, the steel wire core centering control process is repeated, and marking liquid is sprayed on the unqualified position to mark it. S8. Wire winding: After testing, all low-loss aluminum-clad steel single wires are wound up by a winding machine. Qualified products are stored in the warehouse after winding, while unqualified products are sent to the rework station for processing after winding.

[0007] In the above-mentioned low-loss aluminum-clad steel single-line continuous extrusion coating process, in step S1, the number of steel wire cores is one strand, and the number of fine aluminum rods is four strands, with the four fine aluminum rods arranged in a ring evenly on the outside of the steel wire core.

[0008] A low-loss aluminum-clad steel single-line continuous extrusion coating device is applied to the above-mentioned low-loss aluminum-clad steel single-line continuous extrusion coating process. The device includes a heat insulation shell, a cooling water tank and a straightening machine. The heat insulation shell, the cooling water tank and the straightening machine are arranged in a linear sequence. A support frame is fixedly connected to the bottom end of the heat insulation shell. A horizontal plate is fixedly connected to the bottom end of the support frame. A PLC controller and a cooling mechanism are fixedly connected to the upper surface of the horizontal plate. An extension tube is fixedly embedded on one side of the heat insulation shell, and an extrusion coating mold is fixedly embedded on the other side of the heat insulation shell by bolts. An annular cooling cavity is opened inside the extrusion coating mold. A pre-extrusion mechanism is fixedly connected to the inner wall of the heat insulation shell; A steel wire core centering control mechanism is fixedly connected to the upper surface of the heat insulation shell; An extension frame is fixedly connected to the outer wall of the outlet end of the straightening machine. A wire core centering detection mechanism is fixedly connected to the side of the extension frame away from the straightening machine. A marking mechanism is fixedly connected to the outer wall of the extension frame.

[0009] In the aforementioned low-loss aluminum-clad steel single-line continuous extrusion coating device, the cooling mechanism includes an air supply box fixedly connected to the upper surface of a horizontal plate, an air pump fixedly connected to the lower surface of the horizontal plate, an activated carbon filter canister fixedly connected to the air inlet of the air pump, a one-way valve fixedly connected to the air outlet of the air pump, the outlet of the one-way valve passing through the upper surface of the horizontal plate and fixedly connected to the bottom of the air supply box, a partition fixedly connected inside the air supply box, a pressure relief valve fixedly connected to the top of the partition, and the upper surface of the partition and the inner wall of the top of the air supply box being fixed together. The system has two vertical plates, both of which are fitted with multiple vortex tubes. The two vertical plates divide the air at the top of the air supply box into a hot zone, a cold zone, and an intake zone. The outlet of the pressure relief valve is located inside the intake zone. The outer wall of the air supply box in the cold zone is fixedly connected to a first conduit. The outlet of the first conduit passes through the bottom of the extrusion coating mold and communicates with the annular cooling cavity. The top of the extrusion coating mold is fixedly connected to an outlet pipe, and the intake of the outlet pipe communicates with the annular cooling cavity. The outer wall of the air supply box in the hot zone is fixedly connected to a second conduit.

[0010] In the aforementioned low-loss aluminum-clad steel single-line continuous extrusion coating device, the pre-extrusion mechanism includes a heat-conducting cylinder fixedly connected to the inner wall of the heat insulation shell. Multiple electric heating tubes in contact with the outer wall of the heat-conducting cylinder are fixedly connected to the side wall of the heat insulation shell. Four J-shaped square tubes arranged in a uniform ring are fixedly embedded in the inner wall of the heat-conducting cylinder. Two sets of symmetrically distributed metal bearings are fixedly embedded in the inner ends of the J-shaped square tubes. A pre-extrusion cylinder is fixedly connected to the inner walls of the two metal bearings in each set. The outer walls of both pre-extrusion cylinders are provided with mutually cooperating arc-shaped extrusion grooves. The ends of the four J-shaped square tubes penetrate the outer wall of the heat insulation shell. A sealing cover is fixedly fitted onto the outer walls of the air outlet ends of the four J-shaped square tubes. The inner wall of the sealing cover is fixedly connected to the outer wall of the heat insulation shell. The air inlet ends of the four J-shaped square tubes are located inside the sealing cover. The air outlet end of the air outlet pipe is fixedly connected to the side end of the sealing cover.

[0011] In the aforementioned low-loss aluminum-clad steel single-wire continuous extrusion coating device, the steel wire core centering control mechanism includes a U-shaped frame fixedly connected to the outer wall of the heat insulation shell. A first micro electric push rod is fixedly embedded at the top of the U-shaped frame. A horizontal rectangular cylinder is fixedly connected to the moving end of the first micro electric push rod. A second micro electric push rod is fixedly connected to the side wall of the horizontal rectangular cylinder. A connecting square rod is fixedly connected to the moving end of the second micro electric push rod. An opening slot for the movement of the connecting square rod is opened on the lower surface of the horizontal rectangular cylinder. An adjustment hole is opened at the top of the heat insulation shell, and a heat insulation soft ring is fixedly connected to the wall of the adjustment hole. The inner wall of the heat insulation soft ring is fixedly connected to the outer wall of the connecting square rod. An adjustment ring matching the steel wire core is fixedly connected to the bottom end of the connecting square rod. The inner diameter of the adjustment ring is 0.2-0.5 mm larger than the outer diameter of the steel wire core.

[0012] In the aforementioned low-loss aluminum-clad steel single-wire continuous extrusion coating device, the steel wire core centering detection mechanism includes a fixing ring fixedly connected to the side end of the extension frame. Four multi-channel eddy current sensors are uniformly embedded in the outer wall of the fixing ring. A surface drying cylinder is fixedly connected to the outer wall of the extension frame. The air outlet end of the second conduit is fixedly connected to the bottom end of the surface drying cylinder. Multiple drainage holes are opened on the side walls at both ends of the surface drying cylinder.

[0013] In the aforementioned low-loss aluminum-clad steel single-line continuous extrusion coating device, the marking mechanism includes a marking liquid storage cylinder fixedly connected to the outer wall of the extension frame. The inlet of the marking liquid storage cylinder is threadedly connected to a sealing plug. The top of the marking liquid storage cylinder is fixedly connected to an air guide pipe. The air inlet of the air guide pipe is fixedly connected to the wall of a second guide pipe. The bottom side of the marking liquid storage cylinder is fixedly connected to a material conveying pipe. The outlet of the material conveying pipe is fixedly connected to a normally closed solenoid valve. The outer wall of the normally closed solenoid valve is fixedly connected to the outer wall of a fixing ring.

[0014] Compared with existing technologies, the advantages of a low-loss aluminum-clad steel single-line continuous extrusion coating process and its equipment are as follows: 1. Through the pre-extrusion and cooling mechanisms, when a low-loss aluminum-clad steel single-line undergoes continuous extrusion cladding production, the appropriate specifications of steel wire core and fine aluminum rods are first selected according to the specifications of the aluminum-clad steel single-line to be extruded and clad. Then, the steel wire core and fine aluminum rods are pre-treated. The four pre-treated fine aluminum rods are processed through the pre-extrusion mechanism. During the pre-extrusion process, the four fine aluminum rods can be easily pre-extruded into aluminum rods with an arc-shaped cross-section. Moreover, using four fine aluminum rods instead of traditional large-diameter aluminum rods for extrusion cladding of the steel wire core results in a smaller diameter (single rod). With a diameter of 3-5mm, the radial heat conduction path is short, resulting in more uniform heating. The temperature difference between the surface and the center is ≤10℃, allowing for rapid flow within the extrusion coating die. This reduces the stagnant area of ​​the aluminum layer material, ensuring a more uniform distribution of the aluminum layer material within the extrusion coating die cavity. Furthermore, the four strands of fine aluminum rods dispersedly coating the steel wire core, reducing resistance during extrusion coating and increasing the extrusion coating speed. This enhances the production speed of low-loss aluminum-clad steel single-line production. Simultaneously, the cooling mechanism ensures the reliability of the extrusion coating die and pre-extrusion mechanism.

[0015] 2. Through the set wire core centering detection mechanism and wire core centering control mechanism, the low-loss aluminum-clad steel single wire discharged from the extrusion coating die is cooled by the cooling water tank and then enters the straightening machine for straightening. After straightening, the low-loss aluminum-clad steel single wire passes through the fixing ring and is located at the center of four multi-channel eddy current sensors for wire core centering detection. If the centering detection fails, the PLC controller controls the wire core centering control mechanism to adjust the position of the wire core, so that the wire core is centered and qualified in subsequent production processes. This design enables the low-loss aluminum-clad steel single wire continuous extrusion coating device to have the function of online wire core centering detection, ensuring that the aluminum layer material is evenly distributed on the outside of the wire core, and effectively improving the quality of low-loss aluminum-clad steel single wire continuous extrusion coating production.

[0016] 3. Through the set marking mechanism, when the centering of the steel wire core detected by the multi-channel eddy current sensor is unqualified, the PLC controller also controls the marking mechanism to spray marking liquid onto the surface of the low-loss aluminum-clad steel single wire where the steel wire core centering is unqualified. The marking facilitates the quick location by subsequent repair personnel, thereby facilitating the repair of the unqualified part of the low-loss aluminum-clad steel single wire. When the centering of the steel wire core is qualified, the PLC controller controls the marking mechanism to stop working. This design enables the low-loss aluminum-clad steel single wire continuous extrusion coating device to have the function of accurately marking the position of unqualified steel wire core centering, improving the convenience of repair of the unqualified position of the low-loss aluminum-clad steel single wire. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a low-loss aluminum-clad steel single-line continuous extrusion coating process provided by the present invention; Figure 2This is a schematic diagram of the structure of a low-loss aluminum-clad steel single-line continuous extrusion coating device provided by the present invention; Figure 3 yes Figure 2 A schematic diagram of the structure in partial cross-section; Figure 4 yes Figure 2 A three-dimensional structural diagram of the J-shaped square tube section; Figure 5 yes Figure 2 A three-dimensional structural diagram of the central control mechanism for the steel wire core; Figure 6 yes Figure 2 A side view of the middle fixing ring section; Figure 7 yes Figure 2 A three-dimensional structural diagram of the marking mechanism.

[0018] In the diagram: 1. Insulated outer shell; 2. Cooling water tank; 3. Straightening machine; 4. Support frame; 5. Cooling mechanism; 51. Air supply box; 52. Air pump; 53. Activated carbon filter canister; 54. One-way valve; 55. Baffle plate; 56. Pressure relief valve; 57. Vertical plate; 58. Vortex tube; 59. Hot zone; 510. Cold zone; 511. Air inlet zone; 512. First conduit; 513. Air outlet pipe; 514. Second conduit; 6. Pre-extrusion mechanism; 61. Heat-conducting cylinder; 62. Electric heating tube; 63. J-shaped square tube; 64. Metal bearing; 65. Pre-extrusion cylinder; 66. Arc-shaped extrusion groove; 67. Sealing cover; 7. Steel wire core centering control mechanism 71. U-shaped frame; 72. First miniature electric push rod; 73. Horizontal rectangular cylinder; 74. Second miniature electric push rod; 75. Connecting square rod; 76. Opening slot; 77. Heat insulation soft ring; 78. Adjustment ring; 8. Steel wire core centering detection mechanism; 81. Fixing ring; 82. Multi-channel eddy current sensor; 83. Surface drying cylinder; 84. Drain hole; 9. Marking mechanism; 91. Marking liquid storage cylinder; 92. Sealing plug; 93. Air guide pipe; 94. Material conveying pipe; 95. Normally closed solenoid valve; 10. Horizontal plate; 11. PLC controller; 12. Extension cylinder; 13. Extrusion coating mold; 14. Annular cooling cavity; 15. Extension frame. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] like Figure 1As shown, a low-loss aluminum-clad steel single-line continuous extrusion coating process includes the following steps: S1. Raw material selection and pretreatment: First, select the appropriate steel wire core and thin aluminum rod according to the specifications of the aluminum-clad steel single wire to be extruded and coated. Then, unfold the steel wire core and thin aluminum rod through the wire feeding equipment. Next, the steel wire core and thin aluminum rod are subjected to surface impurity removal, acid pickling to remove oxide layer, water washing and cleaning, surface drying and heat treatment in sequence. S2. Pre-extrusion of thin aluminum rods: The thin aluminum rods pre-treated in step S1 are fed into the pre-extrusion process, so that the circular cross-section thin aluminum rods are pre-extruded into arc cross-section aluminum rods. S3. Steel wire core centering control: The steel wire core pre-treated in step S1 is sent into the centering adjustment process so that the steel wire core is in the center of the low-loss aluminum-clad steel single-wire continuous extrusion coating. S4. Aluminum-clad steel single-wire wrapping: The arc-shaped aluminum rod and steel wire core processed in steps S2 and S3 are simultaneously fed into extrusion wrapping mold 13 for continuous extrusion wrapping. S5. Cooling and straightening: The low-loss aluminum-clad steel single wire processed in step S4 is sequentially fed into the cooling water tank 2 for cooling and straightening machine 3 for straightening. S6. Wire core centering test: Online non-contact wire core centering test is performed on the low-loss aluminum-clad steel single wire that has been straightened in step S5. S7. Feedback adjustment and marking: If the steel wire core centering is not qualified in step S6, then the steel wire core centering control process in step S3 is re-controlled. At the same time, marking liquid is sprayed on the low-loss aluminum-clad steel single line to mark the position of the unqualified steel wire core. S8. Wire winding: The low-loss aluminum-clad steel single wires output in steps S6 and S7 are all wound up by a winding machine. The low-loss aluminum-clad steel single wires that pass the inspection in step S6 are sent to the warehouse for storage after winding up. The low-loss aluminum-clad steel single wires that fail the inspection in step S7 are sent to the rework station for rework after winding up.

[0021] In step S1, there is one steel wire core and four thin aluminum rods, which are arranged in a ring on the outside of the steel wire core.

[0022] like Figures 2-7As shown, a low-loss aluminum-clad steel single-line continuous extrusion coating device is applied to the aforementioned low-loss aluminum-clad steel single-line continuous extrusion coating process. The device includes a heat-insulating shell 1, a cooling water tank 2, and a straightening machine 3, arranged linearly. A support frame 4 is fixedly connected to the bottom of the heat-insulating shell 1, and a horizontal plate 10 is fixedly connected to the bottom of the support frame 4. A PLC controller 11 and a cooling mechanism 5 are fixedly connected to the upper surface of the horizontal plate 10. The cooling mechanism 5 includes an air supply box 51 fixedly connected to the upper surface of the horizontal plate 10, and an air pump 52 fixedly connected to the lower surface of the horizontal plate 10. An activated carbon filter canister 53 is fixedly connected to the air inlet of the air pump 52, and a one-way valve 54 is fixedly connected to the air outlet of the air pump 52. The outlet of the one-way valve 54 passes through the upper surface of the horizontal plate 10 and is fixedly connected to the bottom of the air supply box 51. The internal structure is fixedly connected to a partition 55. The top of the partition 55 is fixedly connected to a pressure relief valve 56. The upper surface of the partition 55 and the inner wall of the top of the air supply box 51 are fixedly connected to two vertical plates 57. The two vertical plates 57 are jointly embedded with multiple vortex tubes 58. The two vertical plates 57 divide the air at the top of the air supply box 51 into a hot zone 59, a cold zone 510 and an air intake zone 511. The outlet end of the pressure relief valve 56 is located inside the air intake zone 511. The outer wall of the air supply box 51 in the cold zone 510 is fixedly connected to a first conduit 512. The outlet end of the first conduit 512 passes through the bottom end of the extrusion coating mold 13 and is connected to the annular cooling cavity 14. The top of the extrusion coating mold 13 is fixedly connected to an outlet pipe 513. The air intake end of the outlet pipe 513 is connected to the annular cooling cavity 14. The outer wall of the air supply box 51 in the hot zone 59 is fixedly connected to a second conduit 514.

[0023] An extension cylinder 12 is fixedly embedded on one side of the heat insulation shell 1, and an extrusion coating mold 13 is fixedly embedded on the other side of the heat insulation shell 1 by bolts. An annular cooling cavity 14 is opened inside the extrusion coating mold 13. A pre-extrusion mechanism 6 is fixedly connected to the inner wall of the heat insulation shell 1. The pre-extrusion mechanism 6 includes a heat-conducting cylinder 61 fixedly connected to the inner wall of the heat insulation shell 1. A plurality of electric heating tubes 62 in contact with the outer wall of the heat-conducting cylinder 61 are fixedly connected to the side wall of the heat insulation shell 1. Four J-shaped square tubes 63 arranged in a ring are fixedly embedded in the inner wall of the heat-conducting cylinder 61. The inner ends of the J-shaped square tubes 63 are fixedly... Two sets of symmetrically distributed metal bearings 64 are fixedly embedded. The inner walls of the two metal bearings 64 in each set are fixedly connected to a pre-extrusion cylinder 65. The outer walls of the two pre-extrusion cylinders 65 are provided with mutually cooperating arc-shaped extrusion grooves 66. The ends of the four J-shaped square tubes 63 all penetrate the outer wall of the heat insulation shell 1. The outer walls of the air outlet ends of the four J-shaped square tubes 63 are fixedly fitted with a sealing cover 67. The inner wall of the sealing cover 67 is fixedly connected to the outer wall of the heat insulation shell 1. The air inlet ends of the four J-shaped square tubes 63 are all located inside the sealing cover 67. The air outlet end of the air outlet pipe 513 is fixedly connected to the side end of the sealing cover 67.

[0024] A steel wire core centering control mechanism 7 is fixedly connected to the upper surface of the heat insulation shell 1. The steel wire core centering control mechanism 7 includes a U-shaped frame 71 fixedly connected to the outer wall of the heat insulation shell 1. A first micro electric push rod 72 is fixedly embedded at the top of the U-shaped frame 71. A horizontal rectangular tube 73 is fixedly connected to the moving end of the first micro electric push rod 72. A second micro electric push rod 74 is fixedly connected to the side wall of the horizontal rectangular tube 73. A connecting square rod 75 is fixedly connected to the moving end of the second micro electric push rod 74. An opening slot 76 for moving the connecting square rod 75 is opened on the lower surface of the horizontal rectangular tube 73. An adjustment hole is opened at the top of the heat insulation shell 1. A heat insulation soft ring 77 is fixedly connected to the wall of the adjustment hole. The inner wall of the heat insulation soft ring 77 is fixedly connected to the outer wall of the connecting square rod 75. An adjustment ring 78 matching the steel wire core is fixedly connected to the bottom end of the connecting square rod 75. The inner diameter of the adjustment ring 78 is 0.3 mm larger than the outer diameter of the steel wire core.

[0025] An extension frame 15 is fixedly connected to the outer wall of the outlet end of the straightening machine 3. A wire core centering detection mechanism 8 is fixedly connected to the side of the extension frame 15 away from the straightening machine 3. The wire core centering detection mechanism 8 includes a fixing ring 81 fixedly connected to the side end of the extension frame 15. Four multi-channel eddy current sensors 82 are uniformly embedded in the outer wall of the fixing ring 81. A surface drying cylinder 83 is fixedly connected to the outer wall of the extension frame 15. The air outlet end of the second conduit 514 is fixedly connected to the bottom end of the surface drying cylinder 83. Multiple exhaust holes 84 are opened on the side walls of both ends of the surface drying cylinder 83.

[0026] A marking mechanism 9 is fixedly connected to the outer wall of the extension frame 15. The marking mechanism 9 includes a marking liquid storage cylinder 91 fixedly connected to the outer wall of the extension frame 15. A sealing plug 92 is threadedly connected to the inlet of the marking liquid storage cylinder 91. A gas guide pipe 93 is fixedly connected to the top of the marking liquid storage cylinder 91. The gas inlet end of the gas guide pipe 93 is fixedly connected to the wall of the second conduit 514. A conveying pipe 94 is fixedly connected to the bottom side of the marking liquid storage cylinder 91. A normally closed solenoid valve 95 is fixedly connected to the outlet of the conveying pipe 94. The outer wall of the normally closed solenoid valve 95 is fixedly connected to the outer wall of the fixing ring 81.

[0027] The air pump 52, the first miniature electric actuator 72, the second miniature electric actuator 74, the normally closed solenoid valve 95, and the electric heating tube 62 are all electrically connected to the output terminal of the PLC controller 11 via wires. The multi-channel eddy current sensor 82 is electrically connected to the input terminal of the PLC controller 11 via wires. The above-mentioned electrical components and electrical connections are all existing technologies and will not be described in detail here.

[0028] The operating principle of this invention is described as follows: When a low-loss aluminum-clad steel single-wire is continuously extruded and coated, firstly, steel wire cores and fine aluminum rods of appropriate specifications are selected according to the specifications of the aluminum-clad steel single-wire to be extruded and coated. Then, the steel wire cores and fine aluminum rods are unfolded by a wire feeding device. Next, the steel wire cores and fine aluminum rods are subjected to surface impurity removal, acid pickling to remove the oxide layer, water washing, surface drying, and heat treatment in sequence. The number of steel wire cores is one strand, and the number of fine aluminum rods is four strands. The four strands of fine aluminum rods are evenly arranged in a ring on the outside of the steel wire core. With the steel wire core as the center, the wires are evenly arranged in a ring at 90° equidistant intervals. The distance between the center of each thin aluminum rod and the center of the steel wire core is consistent to ensure that the aluminum layer is subjected to balanced circumferential force during cladding. Then, the pre-treated thin aluminum rods are passed through the pre-extrusion mechanism 6 and the extrusion cladding mold 13. The pre-treated steel wire core is passed through the steel wire core centering control mechanism 7 and the extrusion cladding mold 13. Then, the extruded and clad low-loss aluminum-clad steel single wire is passed through the cooling water tank 2, the straightening machine 3 and the steel wire core centering detection mechanism 8. Finally, the extruded and clad low-loss aluminum-clad steel single wire is collected by the winding machine. Four strands of thin aluminum rods are used instead of traditional thick-diameter aluminum rods for extrusion coating of the steel wire core. These thin aluminum rods have a smaller diameter (3-5mm per rod), a shorter radial heat conduction path, and more uniform heating. The temperature difference between the surface and the center is ≤10℃, ensuring that the temperature in the center area of ​​the thin aluminum rod reaches the optimal plastic deformation temperature of 400-500℃, guaranteeing sufficient softening of the thin aluminum rod. Then, as the four strands of thin aluminum rod pass through the pre-extrusion mechanism 6, they can be easily pre-extruded into an arc-shaped cross-section. Specifically, each thin aluminum rod passes individually through the corresponding J-shaped square tube 63, simultaneously passing between the two pre-extrusion cylinders 65 at that J-shaped square tube 63. The friction generated during the conveying of the thin aluminum rods allows them to... Two pre-extrusion cylinders 65 rotate in opposite directions, and then the circular cross-section thin aluminum rod is extruded into an arc-shaped cross-section aluminum rod using the arc-shaped extrusion groove 66. The arc curvature of the arc-shaped aluminum rod matches the outer curvature of the steel wire core, making the thin aluminum rod and the steel wire core fit more tightly, reducing air residue during extrusion, and reducing the thickness of the thin aluminum rod. This allows the thin aluminum rod to flow faster at the extrusion coating die 13 in the later stage, reducing the stagnation area of ​​the aluminum layer material. The aluminum layer material of the thin aluminum rod is more evenly distributed in the cavity of the extrusion coating die 13. Moreover, the four strands of thin aluminum rod dispersedly wrap the steel wire core, which can reduce the resistance during the extrusion coating of the thin aluminum rod and increase the extrusion coating speed, thereby improving the production speed of the low-loss aluminum-clad steel single line. Meanwhile, the PLC controller 11 also controls the air pump 52 to operate. The air pump 52 draws in outside air through the activated carbon filter canister 53. The outside air is purified by the activated carbon filter canister 53, and the purified air is injected into the bottom of the air supply box 51 through the one-way valve 54. As the amount of clean air gradually increases, a high-pressure air zone is formed at the bottom of the air supply box 51, eventually reaching the preset pressure range of the pressure relief valve 56. At this time, the pressure relief valve 56 opens, and the high-pressure clean air is injected into the vortex tube 58 of the air intake zone 511. After entering the vortex tube 58, the high-pressure clean air rotates at high speed inside the tube, forming a strong vortex. In the field, the core airflow near the pipe axis has a low temperature due to the low efficiency of converting rotational kinetic energy into heat energy (cold end output), while the peripheral airflow near the pipe wall has a high temperature due to intense friction (hot end output), achieving instantaneous separation of hot and cold air. Hot air (80℃~90℃) is discharged from the hot end of the vortex tube 58 and enters the hot zone 59, while low-temperature air (-5℃~10℃) is discharged from the cold end of the vortex tube 58 and enters the cold zone 510. The low-temperature air in the cold zone 510 is then injected into the annular cooling cavity 14 of the extrusion coating mold 13 through the first conduit 512, reducing the surface temperature of the extrusion coating mold 13. This not only reduces the thermal deformation of the extrusion cladding die 13, but also reduces wear caused by the thermal expansion of the die, ensuring the production quality of the low-loss aluminum-clad steel single line. The cooled air is then injected into the sealing cover 67 through the exhaust pipe 513. The cooled air in the sealing cover 67 enters multiple J-shaped square tubes 63. The cooling air in the J-shaped square tubes 63 cools down the metal bearing 64 and the pre-extrusion cylinder 65, ensuring the safe operation of the pre-extrusion mechanism 6. Finally, the cooled air is discharged through the outlet end of the sealing cover 67 through the J-shaped square tubes 63. The hot air in the hot zone 59 is discharged through the second conduit. During the low-loss aluminum-clad steel single-line continuous extrusion coating process, the PLC controller 11 also controls the electric heating tube 62 to start. The electric heating tube 62 raises the internal temperature of the heat insulation shell 1 through the heat conduction cylinder 61, avoiding the interference of normal production due to the excessively low internal temperature of the heat insulation shell 1. This design optimizes the traditional low-loss aluminum-clad steel single-line continuous extrusion coating process by using four thin aluminum rods and pre-extrusion. It not only improves the uniformity of the aluminum layer material distribution during extrusion coating, but also reduces the resistance of the aluminum layer material extrusion coating, effectively improving the quality and efficiency of low-loss aluminum-clad steel single-line continuous extrusion coating.

[0029] The low-loss aluminum-clad steel wire discharged from the extrusion coating mold 13 is cooled by the cooling water tank 2 and then straightened by the straightening machine 3. After straightening, the low-loss aluminum-clad steel wire passes through the surface drying cylinder 83, which receives hot air from inside the second conduit 514. The hot air dries the surface of the low-loss aluminum-clad steel wire inside the surface drying cylinder 83 to prevent water stains from interfering with subsequent testing. The hot air (80℃~90℃) forms a flowing airflow inside the surface drying cylinder 83, quickly evaporating residual moisture on the surface of the aluminum-clad steel wire, preventing water stains from causing attenuation or distortion of the eddy current sensor detection signal, and ensuring the accuracy of centering detection. After drying, the low-loss aluminum-clad steel single wire passes through the fixing ring 81 and is positioned at the center of four multi-channel eddy current sensors 82. The multi-channel eddy current sensors 82 emit high-frequency eddy current signals into the aluminum-clad steel single wire. These signals penetrate the aluminum layer and interact with the steel wire core. Differences in the aluminum layer thickness lead to variations in the attenuation amplitude and phase shift of the eddy current signals. The four evenly distributed multi-channel eddy current sensors 82 synchronously acquire signals from each direction and feed them back to the PLC controller 11. The PLC controller 11 compares the four sets of signals with preset aluminum layer thickness reference parameters. By calculating the difference in attenuation amplitude between the four sensor signals and considering the aluminum layer thickness, the PLC controller determines the appropriate parameters. The conductivity parameter of the layer material (≥37.7 MS / m) is used to infer the actual thickness of the aluminum layer at the corresponding position, with a calculation accuracy of ±0.01 mm and a centering judgment error of ≤±0.5%. When the difference in the thickness of the aluminum layer material in any two opposite directions exceeds the industry allowable range (usually ≤8%), the centering of the steel wire core is judged to be unqualified. At this time, the PLC controller 11 adjusts the extension and retraction of the first micro electric push rod 72 and the second micro electric push rod 74 based on the signal fed back by the multi-channel eddy current sensor 82. The first micro electric push rod 72 drives the horizontal rectangular cylinder 73 to move longitudinally, which in turn drives the connecting square rod 75 and the control ring 78 to move the cylinder. The steel wire core is raised and lowered. The moving end of the second micro electric push rod 74 drives the connecting square rod 75 to move laterally, thereby driving the steel wire core to move laterally through the control ring 78 and adjusting the position of the steel wire core so that the centering of the steel wire core in the extrusion coating mold 13 meets the standard. This ensures that the centering of the steel wire core meets the standard during the subsequent low-loss aluminum-clad steel single-line production. This design enables the low-loss aluminum-clad steel single-line continuous extrusion coating device to have the function of online centering detection of the steel wire core. In conjunction with the steel wire core centering control mechanism 7, the centering of the steel wire core is adjusted in time to ensure that the aluminum layer material is evenly distributed on the outside of the steel wire core, effectively improving the quality of low-loss aluminum-clad steel single-line continuous extrusion coating production. When the centering of the steel wire core detected by the multi-channel eddy current sensor 82 fails to meet the standard, the PLC controller 11 also controls the normally closed solenoid valve 95 to be energized and opened. Since some hot air inside the second conduit 514 is injected into the marking liquid storage cylinder 91 through the air guide pipe 93, and the marking liquid storage cylinder 91 is a sealed structure, a high-pressure zone can be formed at the top of the marking liquid storage cylinder 91, increasing the power for subsequent marking liquid spraying. At the moment the normally closed solenoid valve 95 opens, the outlet end of the conveying pipe 94 connects to the outside, providing a pressure relief channel for the marking liquid storage cylinder 91. Simultaneously, as hot air continues to be injected into the high-pressure zone at the top of the marking liquid storage cylinder 91, the hot air pushes the marking liquid inside the marking liquid storage cylinder 91... The marking liquid enters the feed pipe 94, and finally, the marking liquid in the feed pipe 94 is sprayed through the normally closed solenoid valve 95 onto the surface of the low-loss aluminum-clad steel single wire where the steel wire core centering is not up to standard. The marking allows subsequent repair personnel to quickly locate the defective area, thus facilitating the repair of the defective area of ​​the low-loss aluminum-clad steel single wire. When the steel wire core centering is up to standard, the PLC controller 11 controls the normally closed solenoid valve 95 to close after de-energization, and the marking liquid spraying stops. This design enables the low-loss aluminum-clad steel single wire continuous extrusion coating device to accurately mark the position of the steel wire core centering failure and facilitates quick location by repair personnel, improving the convenience of repairing the defective position of the low-loss aluminum-clad steel single wire.

[0030] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A low-loss aluminum clad single wire continuous extrusion cladding process characterized by, The process comprises the following steps: S1, raw material selection and pretreatment, according to the aluminum-clad single wire specification to be extruded, select the corresponding specification of steel wire core and thin aluminum rod, after being expanded by the wire laying equipment, sequentially pass through surface impurity removal, pickling to remove oxide layer, water cleaning, surface drying and heating pretreatment; S2, thin aluminum rod pre-extrusion, the thin aluminum rod pretreated in step S1 is sent to the pre-extrusion process, so that the round cross-section thin aluminum rod is pre-extruded into an arc cross-section aluminum rod; S3, steel wire core centering control, the steel wire core pretreated in step S1 is sent to the centering adjustment process, so that the steel wire core is at the center of the low-loss aluminum-clad single wire continuous extrusion coating; S4, aluminum-clad single wire coating, the arc cross-section aluminum rod and the steel wire core treated in steps S2 and S3 are synchronously sent to the extrusion coating die (13) for continuous extrusion coating treatment; S5, cooling and straightening, the low-loss aluminum-clad single wire processed in step S4 is sequentially sent to the cooling water tank (2) for cooling and the straightening machine (3) for straightening; S6, steel wire core centering degree detection, the low-loss aluminum-clad single wire straightened in step S5 is subjected to online non-contact steel wire core centering degree detection; S7, feedback adjustment and marking, if the steel wire core centering degree is detected to be unqualified, the steel wire core centering control process is performed again, and a marking liquid is sprayed to mark the unqualified position; S8, wire rod winding, the low-loss aluminum-clad single wire after detection is wound by the winding machine, the qualified products are stored after winding, and the unqualified products are sent to the repair station for processing.

2. A low loss aluminium clad single wire continuous extrusion cladding process as claimed in claim 1, wherein, The number of steel wire cores in step S1 is one, and the number of thin aluminum rods is four, and the four thin aluminum rods are evenly arranged in a ring shape outside the steel wire core.

3. A low-loss aluminum-clad single-wire continuous extrusion coating device applied to a low-loss aluminum-clad single-wire continuous extrusion coating process as claimed in claim 2, the device comprising a heat-insulating outer shell (1), a cooling water tank (2), and a straightening machine (3), the heat-insulating outer shell (1), the cooling water tank (2), and the straightening machine (3) being arranged in line in sequence, characterized in that, The bottom end of the heat insulation shell (1) is fixedly connected with a support frame (4), the bottom end of the support frame (4) is fixedly connected with a horizontal plate (10), and the upper surface of the horizontal plate (10) is fixedly connected with a PLC controller (11) and a cooling mechanism (5); One side end of the heat insulation shell (1) is fixedly embedded with an extension cylinder (12), and the other side end of the heat insulation shell (1) is fixedly embedded with an extrusion coating die (13) through bolts; The inner wall of the heat insulation shell (1) is fixedly connected with a pre-extrusion mechanism (6); The upper surface of the heat insulation shell (1) is fixedly connected with a steel wire core centering control mechanism (7); The outlet end outer wall of the straightening machine (3) is fixedly connected with an extension frame (15), one side of the extension frame (15) away from the straightening machine (3) is fixedly connected with a steel wire core centering degree detection mechanism (8), and the outer wall of the extension frame (15) is fixedly connected with a marking mechanism (9).

4. A low-loss aluminium-clad single wire continuous extrusion cladding device according to claim 3, characterised in that, The cooling mechanism (5) includes the air supply tank (51) fixedly connected with the upper surface of the horizontal plate (10), the lower surface of the horizontal plate (10) is fixedly connected with the air pump (52), the air inlet end of the air pump (52) is fixedly connected with the activated carbon filter tank (53), the air outlet end of the air pump (52) is fixedly communicated with the one-way valve (54), the air outlet end of the one-way valve (54) penetrates the upper surface of the horizontal plate (10) and is fixedly communicated with the bottom end of the air supply tank (51), the inside of the air supply tank (51) is fixedly connected with the partition plate (55), the top end of the partition plate (55) is fixedly communicated with the pressure relief air guide valve (56), the upper surface of the partition plate (55) and the top end inner wall of the air supply tank (51) are fixedly connected with two vertical plates (57), a plurality of vortex tubes (58) are embedded in the two vertical plates (57) together, the two vertical plates (57) divide the top end air of the air supply tank (51) into a hot area (59), a cold area (510) and an air inlet area (511), the air outlet end of the pressure relief air guide valve (56) is located in the air inlet area (511), the outer wall of the cold area (510) of the air supply tank (51) is fixedly communicated with the first conduit (512), the air outlet end of the first conduit (512) penetrates the bottom end of the extrusion cladding die (13) and is communicated with the annular cooling cavity (14), the top end of the extrusion cladding die (13) is fixedly connected with the air outlet pipe (513), the air inlet end of the air outlet pipe (513) is communicated with the annular cooling cavity (14), and the outer wall of the hot area (59) of the air supply tank (51) is fixedly communicated with the second conduit (514).

5. A low-loss aluminium-clad single wire continuous extrusion cladding device according to claim 4, characterised in that, The pre-extrusion mechanism (6) includes the heat conduction cylinder (61) fixedly connected with the inner wall of the heat insulation shell (1), a plurality of electric heating pipes (62) in contact with the outer wall of the heat conduction cylinder (61) are fixedly connected to the side wall of the heat insulation shell (1), four J-shaped square tubes (63) arranged in a ring shape and uniformly are fixedly embedded in the inner wall of the heat conduction cylinder (61), two groups of symmetrically distributed metal bearings (64) are fixedly embedded in the inner side end of the J-shaped square tube (63), the inner wall of each group of two metal bearings (64) is fixedly connected with the pre-extrusion cylinder (65), the outer wall of the two pre-extrusion cylinders (65) is provided with an arc-shaped extrusion groove (66) matched with each other, the ports of the four J-shaped square tubes (63) penetrate the outer wall of the heat insulation shell (1), and the outer wall of the air outlet end of the four J-shaped square tubes (63) is fixedly sleeved with the sealing cover (67). The inner wall of the sealing cover (67) is fixedly connected with the outer wall of the heat insulation shell (1), the air inlet ends of the four J-shaped square tubes (63) are located inside the sealing cover (67), and the air outlet end of the air outlet pipe (513) is fixedly communicated with the side end of the sealing cover (67).

6. A low-loss aluminium-clad single wire continuous extrusion cladding device according to claim 5, characterised in that, The steel wire core centering control mechanism (7) comprises a U-shaped frame (71) fixedly connected with the outer wall of the heat insulation shell (1), a first micro electric push rod (72) is fixedly embedded at the top end of the U-shaped frame (71), a horizontal rectangular cylinder (73) is fixedly connected to the moving end of the first micro electric push rod (72), a second micro electric push rod (74) is fixedly connected to the side wall of the horizontal rectangular cylinder (73), a connecting square rod (75) is fixedly connected to the moving end of the second micro electric push rod (74), an opening groove (76) for the movement of the connecting square rod (75) is formed in the lower surface of the horizontal rectangular cylinder (73), an adjusting hole is formed in the top end of the heat insulation shell (1), and the hole wall of the adjusting hole is fixedly connected with a heat insulation soft ring (77), the inner wall of the heat insulation soft ring (77) is fixedly connected with the outer wall of the connecting square rod (75), and the bottom end of the connecting square rod (75) is fixedly connected with a control ring (78) matched with the steel wire core, and the inner diameter of the control ring (78) is 0.2-0.5mm larger than the outer diameter of the steel wire core.

7. A low-loss aluminium-clad single wire continuous extrusion cladding device according to claim 6, characterised in that, The steel wire core centering control mechanism (7) comprises a U-shaped frame (71) fixedly connected with the outer wall of the heat insulation shell (1), a first micro electric push rod (72) is fixedly embedded at the top end of the U-shaped frame (71), a horizontal rectangular cylinder (73) is fixedly connected to the moving end of the first micro electric push rod (72), a second micro electric push rod (74) is fixedly connected to the side wall of the horizontal rectangular cylinder (73), a connecting square rod (75) is fixedly connected to the moving end of the second micro electric push rod (74), an opening groove (76) for the movement of the connecting square rod (75) is formed in the lower surface of the horizontal rectangular cylinder (73), an adjusting hole is formed in the top end of the heat insulation shell (1), and the hole wall of the adjusting hole is fixedly connected with a heat insulation soft ring (77), the inner wall of the heat insulation soft ring (77) is fixedly connected with the outer wall of the connecting square rod (75), and the bottom end of the connecting square rod (75) is fixedly connected with a control ring (78) matched with the steel wire core, and the inner diameter of the control ring (78) is 0.2-0.5mm larger than the outer diameter of the steel wire core.

8. A low-loss aluminium-clad single wire continuous extrusion cladding device according to claim 7, characterised in that, The marking mechanism (9) comprises a marking liquid storage cylinder (91) fixedly connected with the outer wall of the extension frame (15), a sealing plug (92) is threadedly connected to the inlet of the marking liquid storage cylinder (91), a gas guide pipe (93) is fixedly communicated with the top end of the marking liquid storage cylinder (91), the gas inlet end of the gas guide pipe (93) is fixedly communicated with the pipe wall of the second conduit (514), a material conveying pipe (94) is fixedly communicated with the side bottom end of the marking liquid storage cylinder (91), a normally closed electromagnetic valve (95) is fixedly communicated with the outlet of the material conveying pipe (94), and the outer wall of the normally closed electromagnetic valve (95) is fixedly connected with the outer wall of the fixed ring (81).

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