Amorphous alloy bare wire continuous production equipment based on temperature and force field coordinated regulation and control

Abstract

The invention discloses amorphous alloy bare wire continuous production equipment based on temperature and force field coordinated regulation and control, which comprises a vacuum unit, and is characterized in that a production unit is vacuumized for multiple times before working; the production unit comprises a first pipe, a second pipe and a nozzle which are sequentially arranged, the first pipe is used for receiving the materials of the feeding unit and conveying the materials to the second pipe, and the materials are driven by the pressure supply unit to enter the nozzle in the second pipe; the cooling unit is used for cooling the product sprayed by the nozzle through water circulation; and the take-up unit is used for collecting the product cooled by the cooling unit. Through cooperative control of all the units and combination of a control unit-sensor-actuator closed-loop system, full-process automation and intelligent control is achieved, dependence on experience of operators is reduced, single-process, full-automatic and ultra-long-time continuous stable production is achieved, and the production efficiency is improved. The inherent defects of discontinuous process, environmental pollution, poor stability, dependence on manpower and the like in the traditional method are fundamentally overcome.

Description

Technical Field

[0001] This invention relates to the field of amorphous alloy material preparation, specifically to a continuous production equipment for amorphous alloy bare wire based on the coordinated control of temperature and force field. Background Technology

[0002] Amorphous alloy (also known as metallic glass) wires, due to their excellent mechanical properties, corrosion resistance, and soft magnetic characteristics, show broad application prospects in sensors, structural reinforcement, and functional devices. However, their industrial fabrication has long faced severe technical bottlenecks. Currently, mainstream fabrication methods have the following inherent defects: Glass coating method: The process is lengthy and requires acid washing to remove the glass layer, which not only increases costs and time, but also brings the risk of environmental pollution and surface chemical damage, resulting in a low product qualification rate.

[0003] Inner circular water spinning method: The equipment is precise and expensive, the process window is narrow, it is sensitive to operating conditions, the yield is generally low, and it is difficult to scale up.

[0004] Melt drawing method: poor process stability, and fluctuations in the melting zone during high-speed wire drawing result in poor wire diameter uniformity.

[0005] Furthermore, other technical solutions have also failed to completely solve the problem: Patent CN201410018478.7 uses hollow quartz tubes and resistance heating, focusing on superplastic stretching rather than melt extrusion. It does not solve the problem of high-temperature thermal management of quartz nozzles, and the material supply is batch-based, making continuous operation impossible.

[0006] Patent CN202111295275.9 uses a glass coating method and laser annealing, which can achieve continuous wire drawing, but still requires subsequent acid washing, and does not solve the problem of geometric stability of quartz nozzles under long-term high temperature.

[0007] Patent CN03117758.1 uses a water-cooled rotary spinning wheel to avoid the influence of gravity, but it does not use a quartz nozzle for precision extrusion, making it unsuitable for high-precision bare yarn production.

[0008] Patent CN201810105020.3 uses constant pressure injection and copper roller cooling, but its nozzle material and thermal management strategy are unclear, and the furnace capacity is limited, requiring interruption of the process to add material, making it impossible to achieve long-term continuous production.

[0009] In summary, existing technologies have failed to simultaneously and fundamentally solve the three core problems of long-term shape stability of quartz nozzles at high temperatures, automatic and continuous replenishment of raw materials, and large-scale stable production of high-precision bare filaments. Therefore, there is an urgent need in this field for a novel comprehensive solution. Summary of the Invention

[0010] This invention addresses the problems in the prior art by disclosing a continuous production equipment for amorphous alloy bare wire based on the coordinated control of temperature and force field. Through the coordinated control of each unit and the closed-loop system of control unit-sensor-actuator, this invention achieves full-process automation and intelligent control, reduces the dependence on operator experience, and realizes continuous and stable production of a single process, fully automatic, and for an extended period of time. It fundamentally solves the inherent defects of traditional methods, such as discontinuous process, environmental pollution, poor stability, and dependence on manual labor.

[0011] This invention is achieved through the following technical solution: This invention first provides a continuous production equipment for amorphous alloy bare wire based on the coordinated control of temperature and force field, including... The vacuum unit is evacuated multiple times before the production unit begins operation; The production unit includes a first pipe, a second pipe, and a nozzle arranged in sequence. The first pipe is used to receive the material from the feeding unit and transport the material to the second pipe. The material is driven into the nozzle by the pressure supply unit in the second pipe. The cooling unit is used to cool the product sprayed from the nozzles by circulating water. The take-up unit is used to collect the product after it has been cooled by the cooling unit.

[0012] The control unit is used to control the entire material production process, alarm for abnormal situations, and execute set operations.

[0013] As a further option, the controller of the control unit is a PLC or an industrial PC.

[0014] As a further solution, the pressure supply unit includes a gas storage cylinder, which is connected to a gas storage tank via a first pipeline. The gas storage tank is connected to a transition chamber via a second pipeline. A first pressure gauge is installed on the first pipeline, and a second pressure gauge and a first solenoid valve are installed on the second pipeline. The first solenoid valve, the first pressure gauge, and the second pressure gauge are respectively connected to the controller to transmit the collected gas pressure in the pipeline to the controller in real time. As a further option, the gas cylinder is used to store inert gas; As a further option, the inert gas is argon.

[0015] As a further embodiment, the feeding unit includes a mixer and a screw feeder on one side. The screw feeder is used to transport the material in the mixer to the production unit. The outlet of the screw feeder is welded with an output pipe, and a second solenoid valve for controlling whether the material is being transported is installed inside the output pipe. The motor of the screw feeder and the signal of the second solenoid valve are connected to the controller.

[0016] As a further embodiment, the production unit includes a quartz tube comprising a sealed-connected tube 1 and a tube 2, which are arranged at an angle. The upper side of tube 1 is sealed to the output pipe of the screw feeder, and their axes coincide. A coil 1 for preheating the material is sleeved on the outside of tube 1, but the two do not contact each other. Both tubes 1 and 2 are sealed to the lower part of the transition chamber. A coil 2 for reheating the material is sleeved on the outside of tube 2, but the two do not contact each other. The material is preheated in tube 1, turning the solid state into a liquid state. It is then reheated in tube 2, maintaining the liquid state and forming the product. As a further option, both coil 1 and coil 2 are medium-high frequency induction heating coils, and both are connected to the controller. As a further option, the angle between tube 1 and tube 2 is between 5° and 15°. As a further option, the coefficient of thermal expansion of the material below the output pipe and transition cavity of the screw feeder is close to that of the quartz tube. As a further option, the material of the output tube and the material below the transition cavity are both Kovar alloy or nickel-based alloy; As a further option, tube number one is a hollow cylindrical structure, and tube number two includes an upper part and a lower part of an integral structure. The upper part is a hollow cylinder, and the lower part is an inverted cone shape with a nozzle at the bottom. As a further improvement, the cone angle of the inverted cone is in the range of 45°-90°; As a further improvement, the cone angle of the inverted cone is 60°; As a further improvement, the nozzle is a hollow cylinder with an inner diameter ranging from 50 to 300 μm; As a further step, a micron-sized silicon nitride (Si3N4) or yttrium oxide-stabilized zirconium oxide (YSZ) protective coating is prepared on the inner wall of the nozzle by low temperature or plasma-enhanced chemical vapor deposition. As a further improvement, the coating thickness is 3-10 μm; As a further step, coil number two is sleeved in the middle of tube number two, reducing or eliminating induction heating in the area near the nozzle, and actively establishing an axial temperature gradient from the heat source layout.

[0017] As a further improvement, the cooling unit includes a water-cooled jacket located below the nozzle, and a water tank is installed below the water-cooled jacket. The water tank is connected to the water inlet of the water-cooled jacket via an industrial water chiller. The water outlet of the water-cooled jacket is used to spray water onto the product to cool it down. A flow meter and a water pressure gauge, which are respectively connected to the controller signal, are also installed on the water outlet pipe of the industrial water chiller. As a further improvement, the water-cooling jacket is a concentric sleeve structure formed by an inner layer and an outer layer. The concentric sleeve water-cooling jacket is arranged perpendicular to the discharge direction. The water outlet of the water-cooling jacket is located on the inner wall of the inner layer. The distance H between the top of the water-cooling jacket and the nozzle outlet is determined by the empirical formula H = k·d, where k is an empirical coefficient with a value ranging from 10 to 20, which needs to be adjusted according to the thermal conductivity of the alloy and the characteristics of the cooling medium; d is the nozzle outlet diameter in μm. As a further improvement, the inner wall of the inner layer of the water-cooled jacket is provided with a double-headed or triple-headed spiral flow channel, and micro-turbulence plates are added to the inner wall of the flow channel. As a further improvement, the height of the spoilers is 0.5-1mm and the spacing is 2-5mm; As a further improvement, the inner wall of the water-cooling jacket is uniformly drilled with a laser, and the inner diameter of the hole is 0.2-0.5mm. As a further improvement, the upper part of the water-cooling jacket integrates a microporous jet structure and a negative pressure suction ring gap; As a further improvement, the pore size of the micropores is ≤200μm, and the vacuum degree of the negative pressure suction annulus is -20kPa; As a further improvement, the inner wall of the water cooling jacket is made of C18150 chromium zirconium copper alloy, which is mirror polished and has a surface roughness Ra<0.05μm.

[0018] As a further improvement, the vacuum unit is a vacuum pump.

[0019] As a further improvement, the take-up unit includes a guide groove and a first roller, a second roller, and a take-up device installed at its tail. The guide groove is located below the water-cooling jacket and is used to guide the product ejected from the nozzle between the first roller and the second roller. The distance between the first roller and the second roller can be adjusted according to the outer diameter of the product. A take-up device is provided on one side of the second roller.

[0020] As a further improvement, the control unit also includes an edge detection sensor, a liquid level sensor, a camera, and a temperature sensor, which are respectively connected to the controller signal. The edge detection sensor is used to measure the outer diameter of the product, the camera is used to collect product information at the same time, the liquid level sensor is installed on one side of the second tube to monitor the height of the material in the second tube, and the temperature sensor is used to measure the temperature of the material in the second tube.

[0021] As a further improvement, the temperature sensor includes a non-contact infrared thermometer and a high-temperature resistant K-type or S-type armored thermocouple. The non-contact infrared thermometer is installed above the second tube and is coaxially arranged with the second tube. The high-temperature resistant K-type or S-type armored thermocouple is used to measure the temperature of the outer wall of the nozzle in contact.

[0022] The features and beneficial effects of this invention are as follows: (1) This invention realizes full-process automation and intelligent control, reduces the dependence on operator experience, and has good production reproducibility. Through modular design, key component reinforcement and continuous feeding system, the mean time between failures of the equipment is effectively improved, realizing continuous and stable production of a single process, fully automatic, and ultra-long duration (>24 hours). It fundamentally solves the inherent defects of traditional methods such as discontinuous process, environmental pollution, poor stability and dependence on manual labor, and provides a solid guarantee for realizing large-scale industrial production.

[0023] (2) The amorphous bare filaments prepared by the equipment of the present invention are significantly superior to all three traditional methods in terms of filament diameter consistency, surface smoothness, amorphous structure integrity and mechanical properties, which proves the absolute advantage of the present invention in achieving high precision and high quality products.

[0024] (3) The vacuum unit and inert gas supply unit set up in this application, as well as the control system that forms a closed loop of controller-sensor-actuator, improve working efficiency and ensure the safety of equipment operation. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of the production equipment described in an embodiment of the present invention; Figure 2 for Figure 1 Enlarged view of section A in the middle; Figure 3 This is a schematic diagram of the control principle of the controller for the temperature sensor according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the control principle of the controller for the feeding unit according to an embodiment of the present invention.

[0027] Explanation of reference numerals in the attached figures: 1-Gas cylinder; 2-Gas tank; 3-Industrial water chiller; 4-Mixer; 5-Screw feeder; 6-Coil No. 1; 7-Temperature sensor; 8-Vacuum unit; 9-Transition chamber; 10-Quartz tube; 101-Tube No. 1; 102-Tube No. 2; 103-Nozzle; 11-Coil No. 2; 12-Camera; 13-Water cooling jacket; 14-Guide groove; 15-Roller No. 1; 16-Roller No. 2; 17-Take-up device; 18-Water tank; 19-Pressure gauge No. 1; 20-Pressure gauge No. 2; 21-Flow meter; 22-Water pressure gauge. Detailed Implementation

[0028] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below, and embodiments of the present invention will be provided, but this does not limit the scope of the present invention.

[0029] In the description of this invention, 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 orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention 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 a limitation of the invention. 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, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0030] In the description of this invention, it should be noted that, unless otherwise explicitly 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 of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0031] Continuous production equipment for amorphous alloy bare wire based on coordinated temperature and force field control, such as Figures 1 to 4 As shown, including The vacuum unit performs multiple vacuuming operations before the production unit begins operation (e.g., evacuating to 5 × 10⁻⁶). -3 (Pa) to completely remove oxygen and moisture, ensuring the safety of equipment use; The production unit includes a first pipe, a second pipe, and a nozzle arranged in sequence. The first pipe is used to receive the material from the feeding unit and transport the material to the second pipe. The material is driven into the nozzle by the pressure supply unit in the second pipe. The cooling unit is used to cool the product sprayed from the nozzles by circulating water. The take-up unit is used to collect the product after it has been cooled by the cooling unit.

[0032] This solution achieves fully automated and intelligent control of the entire process, reducing reliance on operator experience and ensuring excellent production repeatability. Through modular design, key component reinforcement, and a continuous feeding system, the mean time between failures (MTBF) is effectively improved, guaranteeing continuous industrial production exceeding 24 hours. This solution is applicable to various amorphous alloy systems, from easy-to-form to difficult-to-form (such as Zr-based, Pd-based, Cu-based, Fe-based, and Co-based alloys). For Fe-based, Zr-based, and Co-based alloys, long-term stable production with wire diameter fluctuations of less than ±2.0 μm can be achieved.

[0033] The continuous production equipment for amorphous alloy bare wire based on temperature and force field coordinated regulation also includes a control unit. The control unit is used to control the entire material production process, alarm for abnormal situations, and execute set operations to ensure production safety.

[0034] In one embodiment, the controller of the control unit is a PLC or an industrial PC.

[0035] The pressure supply unit includes a gas cylinder 1, a gas tank 2, a first pressure gauge 19, and a second pressure gauge 20. The gas cylinder 1 is connected to the gas tank 2 via a first pipeline, and the gas tank 2 is connected to the transition chamber 9 via a second pipeline. The first pressure gauge 19 is installed on the first pipeline, and the second pressure gauge 20 and a first solenoid valve are installed on the second pipeline. The first solenoid valve, the first pressure gauge 19, and the second pressure gauge 20 are respectively connected to the controller to transmit the collected gas pressure in the pipeline to the controller in real time. Gas cylinder 1 is used to store inert gas, preferably argon. Since the pressure of the argon in cylinder 1 changes with usage, directly using cylinder 1 to supply gas can lead to insufficient supply later due to pressure fluctuations. To ensure the stability of the gas supply to transition chamber 9, a gas storage tank 2 is provided. When cylinder 1 is opened, gas storage tank 2 is filled with gas first, and then gas storage tank 2 supplies gas to transition chamber 9. When the pressure in cylinder 1 decreases and the gas supply decreases, gas storage tank 2 uses its stored gas to promptly supply gas to transition chamber 9, ensuring that the gas supply to transition chamber 9 is not affected. Simultaneously, the controller uses the pressure values ​​of pressure gauge 19 and pressure gauge 20 to determine whether the gas supply meets normal conditions and whether cylinder 1 needs to be replaced.

[0036] In some embodiments, the feeding unit includes a mixer 4 and a screw feeder 5. The screw feeder 5 is used to convey the material in the mixer 4 to the production unit. The outlet of the screw feeder 5 is welded with an output pipe. A second solenoid valve for controlling whether the material is conveyed is installed inside the output pipe. The motor of the screw feeder 5 and the second solenoid valve are connected to the controller.

[0037] In some embodiments, the production unit includes a first coil 6, a quartz tube 10, and a second coil 11. The quartz tube 10 includes a first tube 101 and a second tube 102 that are detachably connected (threaded or snap-fit, and equipped with a high-temperature resistant sealing ring for effective sealing). The first tube 101 and the second tube 102 are arranged at an angle. The upper side of the first tube 101 is sealed to the output pipe of the screw feeder 5 (threaded connection), and the axes of the two coincide, so that the material is directly fed into the first tube 101 after exiting the screw feeder 5, and there will be no sedimentation due to the difference in inner diameter. The first coil 6 for preheating the material is sleeved on the outside of the first tube 101, and the two do not contact each other. The first tube 101 and the second tube 102 are both sealed to the lower part of the transition cavity 9 (threaded or snap-fit, and equipped with a high-temperature resistant sealing ring for effective sealing). The second coil 11 for reheating the material is sleeved on the outside of the second tube 102, and the two do not contact each other. The material is preheated in tube 101 to liquefy it from a solid state, and then reheated in tube 102 to maintain the liquid state and form the product. Quartz tube 10, as an independent functional component, has its upper part connected to the lower end of transition cavity 9 via a planar sealing structure (threaded connection or snap-fit). A high-temperature resistant sealing ring is used between them for effective sealing. Since the heating area of ​​coil 11 is located in the lower part of tube 102, the connection interface between quartz tube 10 and transition cavity 9 is in a non-heated area. The mild temperature environment in this area ensures that the sealing material can work stably for a long time, guaranteeing connection reliability and facilitating periodic replacement and maintenance of the quartz tube. In this embodiment, the snap-fit ​​clamps are all made of high-temperature resistant alloy.

[0038] In some embodiments, coil 6 and coil 11 are both medium- and high-frequency induction heating coils, and both are signal-connected to the controller.

[0039] In some embodiments, the angle between tube 101 and tube 102 is between 5° and 15°. This angle ensures that the material flows from tube 101 into tube 102 at a speed that is neither too fast nor too slow. During the process of the material flowing from tube 101 into tube 102, it needs to be preheated by coil 6 to change the state of the material from solid to liquid. When the angle is too large, the material flows too fast due to gravity, and the material cannot be fully added before entering tube 102, which does not meet the process requirements. When the angle is too small, although the material can be fully heated, the speed is too slow, which affects the working efficiency. Therefore, the above-mentioned angle is selected.

[0040] In some embodiments, in order to ensure sealing quality, the coefficient of thermal expansion of the material below the output pipe and transition cavity 9 of the screw feeder 5 is close to that of the quartz tube; preferably, the material below the output pipe and transition cavity 9 is Kovar alloy or nickel-based alloy.

[0041] In some embodiments, tube 101 is a hollow cylindrical structure, and tube 102 includes an upper part and a lower part of an integral structure. The upper part is a hollow cylinder, the lower part is an inverted cone, and a nozzle 103 is provided at the bottom.

[0042] In some embodiments, the cone angle of the inverted cone ranges from 45° to 90°, preferably 60°. The nozzle 103 is a hollow cylinder with an inner diameter ranging from 50 to 300 μm, preferably 80 to 200 μm. This structure reduces melt flow resistance by more than 40%, effectively avoiding temperature fluctuations caused by melt stagnation in the second tube 102.

[0043] In some embodiments, to improve the creep resistance, chemical corrosion resistance, and service life of the nozzle 103 at high temperatures, a micron-sized silicon nitride (Si3N4) or yttrium oxide-stabilized zirconium oxide (YSZ) protective coating can be prepared on its inner wall using low-temperature or plasma-enhanced chemical vapor deposition. Preferably, the coating thickness is 3-10 μm; this coating has high density, high melting point, and excellent high-temperature stability, and can form a strong bond with the quartz substrate, effectively blocking melt erosion and wetting. This strengthening measure aims to extend the single continuous service life of the nozzle to more than 24 hours, providing a guarantee for continuous industrial production.

[0044] In some embodiments, the second coil 11 is sleeved in the middle of the second tube 102, mainly providing energy, reducing or eliminating induction heating in the area near the nozzle 103, thereby actively establishing an axial temperature gradient from the heat source layout.

[0045] In some embodiments, the cooling unit includes an industrial water chiller 3, a water cooling jacket 13, a water tank 18, a flow meter 21, and a water pressure gauge 22. The water cooling jacket 13 is installed directly below the nozzle 103 of the quartz tube 10. The water tank 18 is also installed below the water cooling jacket 13. The bottom of the water tank 18 is connected to the liquid inlet of the industrial water chiller 3 through an inlet pipe. The liquid outlet of the industrial water chiller 3 is connected to the water inlet of the water cooling jacket 13 through an outlet pipe. The water outlet of the water cooling jacket 13 is used to spray water onto the product to cool it down. The flow meter 21 and the water pressure gauge 22 are also installed on the outlet pipe and are respectively connected to the controller signal. The flow meter 21 and the water pressure gauge 22 transmit the collected data to the controller in real time. When the value of the flow meter 21 or the water pressure gauge 22 exceeds the set threshold, the controller alarms through an alarm. When either the flow meter 21 or the water pressure gauge 22 exceeds the safety value, the controller controls the entire equipment to stop immediately to ensure the production safety of the equipment. A backup plan can also be adopted.

[0046] In some embodiments, the water-cooled jacket 13 is a concentric sleeve-type water-cooled jacket formed by an inner layer and an outer layer, and its arrangement direction is perpendicular to the discharge direction. The water outlet of the water-cooled jacket 13 is located on the inner wall of the inner layer. The distance H between the top of the water-cooled jacket 13 and the outlet of the nozzle 103 is determined by the empirical formula H = k·d, where k is an empirical coefficient with a value range of 10-20, which needs to be adjusted according to the thermal conductivity of the alloy and the characteristics of the cooling medium; d is the nozzle outlet diameter in μm, and the actual adjustment range is 1-15mm to ensure efficient heat exchange between the cooling medium and the melt jet.

[0047] In some embodiments, the inner wall of the inner layer of the water-cooled jacket 13 is provided with a double-headed or triple-headed spiral flow channel, and micro-turbulence vanes are added to the inner wall of the flow channel. Preferably, the height of the turbulence vanes is 0.5-1 mm and the spacing is 2-5 mm. The coolant (deionized water) flows at high speed along the spiral path, forming strong turbulence, which effectively destroys the thermal boundary layer and increases the heat transfer coefficient by more than 3 times.

[0048] In some embodiments, the inner wall of the water-cooling jacket 13 is uniformly drilled with a laser, and the holes are the water outlets. The inner diameter of the holes is 0.2-0.5 mm, so that the coolant is sprayed vertically and uniformly onto the surface of the melt jet.

[0049] In some embodiments, to address the Leidenfrost vapor film effect that may occur when the nozzle 103 ejects the filament at high speed (>15m / s), a microporous jet structure (pore diameter ≤200μm) and a negative pressure suction annular gap (vacuum degree -20kPa) are integrated on the upper part of the water cooling jacket 13. The vapor film is broken through the combined effect of physical impact and air pressure difference, ensuring cooling uniformity.

[0050] In some embodiments, the inner wall of the water-cooling jacket 13 is made of C18150 chromium zirconium copper alloy and is mirror-polished (surface roughness Ra<0.05μm) to reduce flow resistance and suppress bubble adhesion, thereby maintaining cooling stability.

[0051] The working principle of the cooling unit is as follows: When the product is ejected from nozzle 103, it passes through the center of water-cooling jacket 13. Deionized water in water-cooling jacket 13 sprays onto the product to cool it. The water falls into water tank 18 below due to gravity. Because the water and product are in high-temperature contact, some impurities are generated during cooling, and these impurities also fall into water tank 18. Water tank 18 also serves to remove impurities, preventing them from entering the industrial water chiller 3. Therefore, the connection between water tank 18 and the inlet pipe is located below water tank 18, not at the bottom. This lower location prevents impurities from flowing into the industrial water chiller 3 and allows the returning water to be quickly transported to the industrial water chiller 3 through the inlet pipe. The industrial water chiller 3 cools the high-temperature water again and then sends it to the inlet of water-cooling jacket 13 through the outlet pipe. The outlet of water-cooling jacket 13 is used to spray water onto the product to cool it. This cycle repeats continuously. The controller uses flow meter 21 and water pressure gauge 22 to monitor the cooling unit's operation in real time. If any abnormality is detected, an alarm will be triggered to alert the operator. This structure enables the cooling unit to achieve a cooling efficiency of ≥ 10... 5 A cooling rate of K / s satisfies the amorphous transformation requirements of Zr-based, Fe-based, Co-based and other multi-element alloy systems, ensuring rapid solidification of the melt and the formation of a complete amorphous structure.

[0052] Vacuum unit 8 is a vacuum pump. Before the equipment officially starts working, the vacuum pump is used to evacuate the equipment multiple times to ensure the safety of the equipment operation. The vacuum pump signal is connected to the controller.

[0053] The take-up unit includes a guide groove 14 and a first roller 15, a second roller 16 and a take-up device 17 installed at its tail. The guide groove 14 is located below the water-cooling jacket 13 and is used to guide the product sprayed from the nozzle 103 between the first roller 15 and the second roller 16. The distance between the first roller 15 and the second roller 16 is adjustable according to the outer diameter of the product. A take-up device is provided on one side of the second roller 16. The take-up device 17 is a metal cable take-up device in the prior art.

[0054] After the product is sprayed from the nozzle 103 and cooled by the cooling unit, one end enters the guide groove 14 until it enters the vicinity of the first roller 15 and the second roller 16. Since the first roller 15 and the second roller 16 rotate outward, when the end of the product comes into contact with one of the rollers, it will enter between the first roller 15 and the second roller 16 under the action of force to prevent the product from tilting. The product is guided by the first roller 15 and the second roller 16 and then connected to the take-up device 17 for take-up.

[0055] In some embodiments, the control unit further includes an edge detection sensor, a liquid level sensor, a camera 12, and a temperature sensor, all connected to the controller signal. The edge detection sensor and camera 12 are both installed between the quartz tube 10 and the water-cooling jacket 13. The edge detection sensor (which can also be replaced with a diameter gauge) is used to measure the outer diameter of the product. When the outer diameter exceeds a set threshold, the controller will sound an alarm, and the staff will take appropriate measures. The camera 12 is used to simultaneously collect video information of the product. When an alarm is triggered, the staff can trace the previous production status of the product based on the camera 12. The liquid level sensor is installed on one side of the second tube 102 and is used to monitor the height of the material in the second tube 102. Preferably, the liquid level sensor is a non-contact liquid level sensor. When the liquid level sensor detects that the liquid level in the second tube 102 has dropped to a set threshold, it will remind the staff to add material through an alarm. When the liquid level sensor detects that the liquid level in the second tube 102 is higher than the set value, it will control the mixer 4 and the screw feeder 5 to stop working. The temperature sensor is used to measure the temperature of the material in the second tube.

[0056] In some embodiments, the camera 12 is a 1000fps high-speed CMOS camera (pixel size 3μm×3μm). Surface defect recognition rate >99% (five types of defects including necking, burrs, and scratches); defect classification response time <50ms (95% confidence level); when the controller determines that three consecutive defect points are detected in the camera 12, an audible and visual alarm is automatically triggered.

[0057] In one embodiment, the temperature sensor includes a non-contact infrared thermometer 7 and a high-temperature resistant K-type or S-type armored thermocouple. The non-contact infrared thermometer 7 is mounted above and coaxially with the second tube 102. The high-temperature resistant K-type or S-type armored thermocouple measures the temperature of the nozzle outer wall (Tnozzle) in contact. Based on the feedback from these two temperatures, the central controller independently and precisely adjusts the cooling intensity of the second coil and the cooling unit to ensure that Tmelt is at the target superheat (50-150 K above the liquidus) while keeping Tnozzle stably controlled below the softening point of the quartz glass (e.g., for long-term operation, target Tnozzle < 1150°C), fundamentally guaranteeing the geometric stability of the nozzle and production safety.

[0058] In one embodiment, to ensure the accuracy of the test, the distance between the non-contact infrared thermometer 7 and the second tube 102 is 20-50mm.

[0059] The controller of this application can monitor key parameters such as cooling water flow rate (monitoring accuracy ±0.1L / min), pipeline pressure (monitoring accuracy ±1kPa), and quartz tube temperature (monitoring accuracy ±1℃) in real time.

[0060] Based on the impact of different threshold states on the equipment, the monitoring values ​​are classified as follows: Level 1 alarm: When the above parameters (such as cooling water flow rate, pipeline pressure, quartz tube temperature, etc.) exceed the warning threshold, an audible and visual alarm is triggered and pushed to the mobile terminal; Secondary protection: When the above parameters exceed their set minimum safety threshold (for example, the cooling water flow rate is lower than the minimum required value to ensure the cooling rate), the set operation is automatically executed or the emergency plan is activated or an emergency stop is initiated.

[0061] The control unit also includes a digital twin and data archive module. This module uses software to map the key operating states of the physical equipment in real time (such as temperature field, stress field, cooling rate, and other parameters), and records sensor data, control commands, and visual images throughout the entire process, forming a traceable "production black box." This module can reconstruct all state parameters in the 30 seconds before a failure occurs, analyze data to uncover the relationship between process parameters and product quality, and predict equipment failures based on machine learning algorithms (such as LSTM neural networks), achieving an early warning time of more than 1 hour.

[0062] Both the mixer 4 and the screw feeder 5 are existing structures that can be connected to the controller signal.

[0063] The working principle of the continuous production equipment for amorphous alloy bare wire based on temperature and force field coordinated control is as follows: The controller controls the first and second solenoid valves to close and the vacuum pump 8 to open for vacuuming. After several cycles, the vacuum pump 8 is closed, and then high-purity inert gas (such as argon) is introduced to the set pressure. The first and second solenoid valves are opened. The material is put into the mixer 4. After mixing, the mixer 4 discharges the material to the screw feeder 5. The screw feeder 5 conveys the material to the quartz tube 10. After the set time is reached (this time is determined through multiple experiments, at which point all or most of the material has entered the second tube 102), the second solenoid valve is closed and the first solenoid valve is opened to supply pressure to the equipment. The air pressure causes the material in the second tube to be sprayed out from the nozzle 103 and enter the water cooling jacket 13. After being cooled in the water cooling jacket 13, the material passes through the guide groove 14, the first roller 15 and the second roller 16 and is then taken in by the take-up device 17. This application fundamentally eliminates the traditional coating and peeling steps, simplifying multiple processes into a single continuous process. Under typical conditions, the process flow is shortened by more than 50%, which helps to improve efficiency and achieve green manufacturing. The amorphous alloy bare wire produced by this equipment has no mechanical drawing damage or acid etching pits, and the surface roughness Ra can reach below 0.05 μm. The wire diameter fluctuation can be controlled within ±1.5 μm (for 50 μm wire). The high-speed uniform cooling system ensures high amorphousness throughout the entire length of the wire. The X-ray diffraction (XRD) pattern shows typical amorphous "bun peaks" without sharp crystallization peaks.

[0064] To clearly demonstrate the core inventive points and technical advantages of this invention in the coordinated control of temperature and force fields, the following uses Co as an example. 68 Fe5Si 15 B 12 Taking amorphous alloys as an example, wires were prepared using the equipment of the present invention (example) and three traditional equipment (comparative examples 1-3), and the key processes and the performance of the final products were systematically compared. Example

[0065] (1) Raw material and equipment configuration Raw material: Pre-alloyed Co 68 Fe5Si 15 B 12 Master alloy ingot, purity ≥99.99%.

[0066] Equipment: The equipment described in this application.

[0067] Core component parameters: The nozzle of the quartz tube has an inner diameter of 100 μm. To improve its resistance to creep and corrosion, a dense 5 μm thick Y2O3 coating was prepared on its inner wall using plasma-enhanced chemical vapor deposition at 780°C.

[0068] Coil 1 and Coil 2: 30kW medium-frequency induction heating coils, with a zoned design where the upper zone (Coil 1) accounts for 70% of the power and the lower zone (Coil 2) accounts for 30% of the power, actively establishing an axial temperature gradient from the heat source layout.

[0069] Cooling unit: The cooling water flow rate is precisely controlled at 5.0 ± 0.1 L / min, and the water temperature is constant at 20 ± 0.5°C; the top of the water cooling jacket 13 is 5mm away from the outlet of the nozzle 103.

[0070] Reel-in unit: Enables rapid reel-in.

[0071] (2) Process and parameters S1. Load 200g of master alloy ingot into mixer 4, and evacuate the system to 5×10⁻⁶. -3 After Pa, high-purity argon gas is introduced to 0.12 MPa to establish a protective atmosphere.

[0072] Subsequently, the process driving gas pressure of transition chamber 9 was set according to the model P = k·F / d² (where k is the characteristic coefficient, F is the tension, and d is the diameter). For Co... 68 Fe5Si 15 B 12 The alloy's property coefficient k is recommended by the database to be 3.27 × 10⁻⁶. -2Pa·m² / N. With a target wire diameter d = 100 μm and a target tension F = 5.5 cN, the initial air pressure P is set to 0.18 MPa.

[0073] S2. Start coils one and two to raise the alloy melt temperature (Tmelt) to 1260°C (the liquidus of this alloy is about 1180°C, and the superheat is 80K).

[0074] S3. Synchronously start and precisely control the industrial water chiller to stabilize the nozzle outer wall temperature (Tnozzle) at 1060°C (this temperature is far below the softening point of quartz glass and below the 1150°C safety threshold set for long-term operation). This creates a steep axial temperature gradient of ΔT = 200°C, ensuring the stability of the nozzle geometry at long-term high temperatures (ellipticity <0.8%). Simultaneously, the water cooling jacket is located 5mm below the nozzle outlet, with a ≥1.5×10... 5 A cooling rate of K / s rapidly cools the filament. A closed-loop temperature control system operates throughout the process, ensuring that Tmelt and Tnozzle fluctuations are less than ±3°C and ±2°C, respectively.

[0075] S4. Traction and Rewinding: The linear speed of rollers 1 and 2 is set to 15 m / s. The target tension is set to 5.5 cN, with real-time fluctuations controlled within ±0.15 cN.

[0076] S5. Continuous Operation and Reliability Verification: The equipment operated continuously and stably for 24 hours via automatic feeding from the feeding unit. To verify system reliability, an abnormal operating condition was simulated where the cooling water flow rate dropped to 7.5 L / min (below the safety threshold). The intelligent monitoring and control system triggered secondary protection within 50ms: cutting off the induction heating power supply and activating the emergency cooling device, successfully preventing nozzle overheating damage and equipment failure, demonstrating the robustness of the invention under high-load continuous operation.

[0077] (3) Product performance and results Wire diameter consistency: For continuously produced wire, samples were taken every kilometer, and 100 points were measured using a laser diameter gauge. The average wire diameter was 100.2 μm, the standard deviation σ = 0.45 μm, and the wire diameter fluctuation range was 100.2 ± 1.3 μm (< ±1.5 μm).

[0078] Surface morphology: Scanning electron microscopy (SEM) showed that the surface was smooth, without scratches or necking. The surface roughness Ra was measured to be 0.036 μm using white light interferometry.

[0079] Microstructure: The X-ray diffraction (XRD) pattern shows typical broad and diffuse "bun peaks" without any observable sharp crystallization peaks, indicating that the wire is completely amorphous.

[0080] Mechanical properties: The average breaking strength reached 4150 MPa through single-filament tensile testing.

[0081] Production stability: 24-hour continuous production, wire qualification rate (meeting diameter ±1.5μm, Ra<0.05μm, completely amorphous) ≥ 98.5%.

[0082] Comparative Example 1: Traditional Glass Encapsulation Method (1) Technological process Co is encased in borosilicate glass tubes. 68 Fe5Si 15 B 12 The alloy core is drawn into wire at 1220 °C in an induction heating furnace. After drawing, the wire is immersed in a 15% hydrofluoric acid (HF) solution for 40 minutes to remove the glass cladding.

[0083] (2) Product performance and results Wire diameter consistency: Due to fluctuations during the glass tube drawing process and uneven etching during acid pickling, the wire diameter fluctuates greatly, with an average wire diameter of 108 μm and a fluctuation range of 108 ± 9 μm.

[0084] Surface morphology: SEM images showed numerous acid-etched pits and microcracks on the surface. The root cause is that the HF acid not only dissolved the glass but also caused anisotropic corrosion on the amorphous alloy surface. Surface roughness Ra = 0.28 μm.

[0085] Microstructure: The XRD pattern shows weak crystalline diffraction peaks on top of the amorphous diffuse peaks. This is because during the coating and wire drawing process, the thermal stress between the alloy core and the glass tube causes uneven local cooling rates, which fail to exceed the critical cooling rate for amorphous formation.

[0086] Production issues: The process is lengthy, involving coating and pickling, making continuous production impossible; each batch requires shutdown for processing. Pickling causes environmental pollution and safety hazards.

[0087] Pass rate: Due to surface damage and crystallization issues, the pass rate is only ~68%.

[0088] Comparative Example 2: Traditional Inner Circular Water Spinning Method (1) Technological process The alloy melt is sprayed at 1240°C onto the surface of a copper roller cooled by high-speed rotating (8500 rpm) cold water (5°C), forming a strip that is then spun out into filaments.

[0089] (2) Product performance and results Wire diameter uniformity: Due to the inherent "air cushion effect" and dynamic vibration when the melt jet comes into contact with the high-speed roller surface, the contact point between the melt and the cooling roller is unstable, resulting in extremely uneven wire diameter. The average wire diameter is 95μm, with a fluctuation range of 95 ± 11μm.

[0090] Surface morphology: SEM observation revealed axial microcracks and wrinkles on the surface. Surface roughness Ra = 0.21 μm.

[0091] Microstructure: XRD shows that amorphous and nanocrystalline phases coexist, with partial crystallization.

[0092] Production issues: The equipment requires extremely high precision. Even slight vibrations during operation can cause wire breakage or loss of diameter control, requiring frequent shutdowns for calibration. Continuous operation time cannot exceed 3 hours.

[0093] Pass rate: approximately 60%.

[0094] Comparative Example 3: Traditional Melt Extraction Method (1) Technological process The melt (1250°C) at the bottom of the alloy melt crucible is brought into direct contact with a high-speed rotating (20 m / s) cold copper wheel, and a wire is formed by pulling force.

[0095] (2) Product performance and results Wire diameter consistency: The shape and solidification point of the melting zone are extremely unstable, leading to frequent necking and bulging of the wire. The average wire diameter is 104 μm, with a fluctuation range of 104 ± 13 μm.

[0096] Surface morphology: SEM showed obvious necking defects and oxide burrs. Surface roughness Ra = 0.32 μm.

[0097] Microstructure: The XRD pattern shows strong diffraction peaks of (Co, Fe)23B6 crystals, indicating severe crystallization.

[0098] Production problems: The process stability is extremely poor. Usually, after 1.5 hours of operation, the wire diameter goes out of control and normal production cannot be maintained.

[0099] Pass rate: as low as approximately 45%.

[0100] The comparison summary table is as follows:

[0101] Through the above targeting Co 68 Fe5Si 15 B 12 A detailed comparison of the examples of amorphous alloys with Comparative Examples 1-3 clearly leads to the following conclusions: In terms of core product performance, the amorphous bare filaments prepared by the equipment of this invention are significantly superior to all three traditional methods in terms of filament diameter consistency, surface smoothness, amorphous structure integrity and mechanical properties, proving the absolute advantage of this invention in achieving high-precision and high-quality products.

[0102] In terms of production process and efficiency, this invention achieves continuous and stable production with a single process, full automation, and ultra-long duration (>24 hours), fundamentally solving the inherent defects of traditional methods such as discontinuous process, environmental pollution, poor stability, and reliance on manual labor, and providing a solid guarantee for achieving large-scale industrial production.

[0103] It should be noted that 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 continuous production device for amorphous alloy bare wire based on temperature and force field synergistic regulation, characterized in that: The application relates to a production device for producing a product, comprising a vacuum unit, a production unit, a cooling unit, a take-up unit and a control unit. ​ The vacuum unit is used for vacuumizing multiple times before the production unit works. The production unit comprises a first pipe, a second pipe and a nozzle arranged in sequence, the first pipe is used for receiving materials from a feeding unit and conveying the materials to the second pipe, and the materials are driven into the nozzle by a pressure supply unit in the second pipe. The cooling unit is used for cooling the product sprayed from the nozzle through water circulation. The take-up unit is used for collecting the product cooled by the cooling unit. The control unit is used for controlling the whole process of material production, alarming and executing setting operation for abnormal conditions.

2. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 1, characterized in that: The controller of the control unit is a PLC or an industrial PC.

3. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 2, characterized in that: The pressure supply unit comprises a gas cylinder, a gas storage tank and a transition cavity, the gas cylinder is connected to the gas storage tank through a first pipe, the gas storage tank is connected to the transition cavity through a second pipe, a first gas pressure gauge is arranged on the first pipe, a second gas pressure gauge and a first electromagnetic valve are arranged on the second pipe, the first electromagnetic valve, the first gas pressure gauge and the second gas pressure gauge are signal-connected to the controller, and the collected gas pressure in the pipes is transmitted to the controller in real time. Preferably, the gas cylinder is used for storing inert gas. Preferably, the inert gas is argon.

4. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 2, characterized in that: The feeding unit comprises a mixer and a spiral feeder arranged on one side of the mixer, the spiral feeder is used for conveying the materials in the mixer to the production unit, the outlet of the spiral feeder is welded with an output pipe, a second electromagnetic valve for controlling whether the materials are conveyed is arranged in the output pipe, and the motor of the spiral feeder and the second electromagnetic valve are signal-connected to the controller.

5. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 2, characterized in that: The production unit comprises a quartz pipe, the quartz pipe comprises a first pipe and a second pipe which are sealingly connected, the first pipe and the second pipe are arranged at an angle, the upper side of the first pipe is sealingly connected with the output pipe of the spiral feeder, and the axes of the two are coincident, the first pipe is externally sleeved with a first coil for preheating the materials and the two do not contact, the first pipe and the second pipe are sealingly connected with the lower part of the transition cavity, the second pipe is externally sleeved with a second coil for reheating the materials and the two do not contact, the materials are preheated in the first pipe to be heated from solid state to liquid state, the materials are reheated in the second pipe to be kept in liquid state and form the product. Preferably, the first coil and the second coil are both middle-high frequency induction heating coils, and both are signal-connected to the controller. Preferably, the angle between the first pipe and the second pipe ranges from 5 DEG to 15 DEG. Preferably, the expansion coefficients of the materials of the output pipe of the spiral feeder and the lower part of the transition cavity are close to the expansion coefficient of the quartz pipe. Preferably, the materials of the output pipe and the lower part of the transition cavity are both Kovar alloy or nickel-based alloy. Preferably, the first pipe is a hollow cylindrical structure, the second pipe comprises an upper part and a lower part which are in an integral structure, the upper part is a hollow cylinder, the lower part is a reverse cone, and the bottom of the reverse cone is provided with the nozzle. Preferably, the angle of the reverse cone ranges from 45 DEG to 90 DEG. Preferably, the angle of the reverse cone is 60 DEG. Preferably, the nozzle is a hollow cylinder, and the inner diameter ranges from 50 to 300 mu m. Preferably, a micron-level silicon nitride or yttrium-stabilized zirconium oxide protective coating is prepared on the inner wall of the nozzle through low-temperature or plasma-enhanced chemical vapor deposition. Preferably, the thickness of the coating is 3-10 mu m. The second coil is preferably sleeved on the middle part of the second pipe to reduce or completely eliminate induction heating in the area close to the nozzle, thereby actively establishing an axial temperature gradient from the heat source.

6. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 5, characterized in that: The cooling unit comprises a water cooling jacket below the nozzle, and a water tank is further installed below the water cooling jacket. The water tank is connected to the water inlet of the water cooling jacket through an industrial water chiller, and the water outlet of the water cooling jacket is used to spray water on the product to cool the product. A flow meter and a water pressure gauge are further installed on the water outlet pipe of the industrial water chiller and are respectively connected to the controller. The water cooling jacket is preferably a concentric sleeve structure composed of an inner layer and an outer layer, and the arrangement direction is perpendicular to the discharging direction. The water outlet of the water cooling jacket is located on the inner wall of the inner layer, and the distance H between the top end of the water cooling jacket and the nozzle outlet is determined by an empirical formula H = k·d, wherein k is an empirical coefficient with a value range of 10-20, which needs to be adjusted according to the thermal conductivity of the alloy and the characteristics of the cooling medium; and d is the diameter of the nozzle outlet, in units of μm. The inner wall of the inner layer of the water cooling jacket is preferably provided with a double-head or triple-head spiral flow channel, and a micro-turbulence fin is additionally arranged on the inner wall of the flow channel. The height of the turbulence fin is preferably 0.5-1 mm, and the spacing is 2-5 mm. The inner wall of the inner layer of the water cooling jacket is preferably uniformly drilled by laser, and the inner diameter of the hole is 0.2-0.5 mm. The upper part of the water cooling jacket is preferably integrated with a micro-pore jet structure and a negative pressure suction annulus. The pore diameter of the micro-pore is ≤200 μm, and the vacuum degree of the negative pressure suction annulus is -20 kPa. The inner wall of the water cooling jacket is preferably made of C18150 chromium-zirconium-copper alloy and is mirror-polished to have a surface roughness Ra<0.05 μm.

7. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 1, characterized in that: The vacuum unit is a vacuum pump.

8. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 5, characterized in that: The take-up unit comprises a guide groove, a first roller and a second roller installed at the tail of the guide groove, and a take-up device. The guide groove is located below the water cooling jacket and is used to guide the product sprayed by the nozzle into the space between the first roller and the second roller. The distance between the first roller and the second roller can be adjusted according to the outer diameter of the product, and the side of the second roller is provided with the take-up device.

9. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 5, characterized in that: The control unit further comprises an edge detection sensor, a liquid level sensor, a camera, and a temperature sensor, which are respectively connected to the controller. The edge detection sensor is used to measure the outer diameter of the product, the camera is used to simultaneously collect information of the product, the liquid level sensor is installed on one side of the second pipe and is used to monitor the height of the material in the second pipe, and the temperature sensor is used to measure the temperature of the material in the second pipe.

10. The temperature and force field synergistically regulated amorphous alloy bare wire continuous production equipment according to claim 9, characterized in that: The temperature sensor comprises a non-contact infrared temperature measuring instrument and a high-temperature-resistant K-type or S-type armored thermocouple. The non-contact infrared temperature measuring instrument is installed above the second pipe and is coaxially arranged with the second pipe, and the high-temperature-resistant K-type or S-type armored thermocouple is used to contactively measure the temperature of the outer wall of the nozzle.

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