Electromagnetic wire painting and curing energy-saving integrated process
By using online monitoring and progressive power adjustment, the problems of uneven curing and insufficient maintenance in the UV curing process were solved, achieving efficient and stable production of electromagnetic wires and optimized energy consumption.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-29
- Publication Date
- 2026-04-07
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
Existing UV curing processes in electromagnetic wire production suffer from uneven curing, inability to monitor and compensate in real time, and lack of predictive maintenance, leading to unstable product quality and energy waste.
The system employs an online curing degree monitoring unit to provide real-time feedback, adjusts the UV lamp power in a progressive manner, and optimizes process parameters using machine learning to achieve dynamic compensation and predictive maintenance, thus forming a closed-loop control.
It achieves efficient and stable curing of electromagnetic wires, reduces energy consumption, improves product quality stability and equipment reliability, and reduces reliance on manual experience.
Smart Images
Figure CN121806753A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of electromagnetic wire processing technology, and in particular to an energy-saving integrated process for electromagnetic wire coating and curing. Background Technology
[0002] UV curing technology, as an efficient and environmentally friendly post-coating process, has been widely used in the field of electromagnetic wire insulating varnish coating. Compared with the traditional hot air circulation curing process, UV curing has significant advantages such as low energy consumption, fast curing speed, no solvent evaporation, and small footprint, representing the development direction of green manufacturing.
[0003] However, in actual continuous production lines, existing UV curing processes still face several technical bottlenecks that urgently need to be addressed: First, the curing effect of electromagnetic wire coatings is affected by various factors, including the output stability of the UV light source, coating thickness, production line speed, and material formulation. Fluctuations in these factors can easily lead to uneven or insufficient curing. Second, existing UV curing systems typically employ fixed power output or simple open-loop control. When a certain area experiences curing deviations due to lamp performance degradation or uneven coating thickness, the system cannot detect and effectively compensate for these deviations in real time. Problems are often only discovered at the end of production through sampling inspections, resulting in batches of defective products and significant waste of materials and energy. Finally, the maintenance of core components such as UV lamps relies on periodic replacement and manual judgment based on experience, lacking a predictive maintenance mechanism based on actual performance data. This can lead to increased costs due to premature replacement or a continued impact on product quality and energy efficiency due to failure to replace degraded lamps in a timely manner.
[0004] Therefore, developing an integrated energy-saving process for electromagnetic wire coating and curing that enables real-time monitoring, dynamic compensation, and intelligent diagnosis is of great significance for improving product quality stability, reducing production energy consumption, achieving predictive maintenance, and promoting technological progress in the industry. Summary of the Invention
[0005] To achieve the above objectives, this invention proposes an energy-saving integrated process for electromagnetic wire coating and curing, comprising the following steps:
[0006] Step 1: System initialization and parameter setting. Based on the input insulating varnish type, the target varnish film thickness d of the conductor, and the planned production speed v, a process formula containing multiple UV curing zone reference power arrays and desired curing degree threshold arrays is generated.
[0007] Step 2: Start production and baseline operation, so that the electromagnetic wire coated with wet paint passes through multiple UV curing zones in sequence, all UV lamps operate at the reference power, and the online curing degree monitoring unit located at the exit of each curing zone measures and feeds back the real-time curing degree.
[0008] Step 3: Deviation identification and initial compensation triggering. When the measured degree of curing of the i-th curing zone is detected to be lower than its expected degree of curing threshold, the deviation and initial compensation coefficient are calculated, and then only the UV lamp power of the (i+1)-th curing zone is increased to the adjusted power.
[0009] Step 4: Verification of compensation effect and decision-making for secondary compensation. After the (i+1)th curing zone with increased power, the real-time curing degree is monitored again.
[0010] Step 5: Iterative monitoring and process optimization. Based on the latest measured degree of curing, repeat the cycle of compensation decision and power adjustment until the material passes through the last curing zone.
[0011] Step 6: Final inspection and system health diagnosis. The product quality is determined based on the measured curing degree of the final curing zone, and the system health status is diagnosed based on the curing degree deviation sequence of each zone.
[0012] Step 7: Process Adaptation and Learning. When the production line speed is automatically adjusted, or when fluctuations in the paint film thickness are detected by an online thickness gauge, the control center can dynamically adjust the expected threshold of each zone in real time.
[0013] In one example, the process formulation determines a multi-zone reference power array that enables the product to meet standards under ideal conditions, based on a preset material curing kinetics model and experimental data. and an array of expected curing degree thresholds in an increasing distribution .
[0014] In one example, during the initial compensation trigger, when the real-time curing degree of the i-th curing zone... Continuously below its threshold Time calculation deviation With the initial compensation coefficient and will The power of the curing zone is from the reference power. Upgraded to ,in This is the safety gain coefficient.
[0015] In one example, in the secondary compensation decision, if the power is increased after the first... Measured degree of curing in the curing zone Still below its threshold And its absolute value of deviation Less than the absolute value of the previous deviation Then, a secondary allocation is initiated to calculate the enhancement coefficient. And at the same time improve the first The and the first The power of each curing zone.
[0016] In one example, in the secondary compensation decision, if the power is increased after the first... Measured degree of curing in the curing zone Still below its threshold And its absolute value of deviation Greater than or equal to the absolute value of the previous deviation Then emergency mode will be activated, and the first one will be activated. The power of all subsequent curing zones will be increased by an absolute percentage. .
[0017] In one example, if the curing degree of the final cured area is lower than the preset qualified standard during the system health diagnosis, and the analysis of the deviation sequence of each cured area reveals at least one continuous cured area sequence, wherein the deviation of each cured area is less than the preset severe negative deviation threshold, then the overall performance of the UV light source system is deemed unqualified, and a system maintenance alarm is issued.
[0018] In one example, the online curing degree monitoring unit uses an infrared spectrometer to calculate the real-time curing degree by analyzing the attenuation of characteristic peaks of specific carbon-carbon double bonds in the paint film.
[0019] The energy-saving integrated process of electromagnetic wire coating and curing proposed in this invention can bring the following beneficial effects:
[0020] 1. This invention utilizes online sensors at the outlets of each curing zone to provide real-time feedback on the actual curing degree. When insufficient curing is detected in a certain area, a compensation mechanism is triggered to precisely adjust the UV power of subsequent areas in a progressive manner. While ensuring that the final quality fully meets the standards, it avoids the energy waste caused by preventive over-curing or quality problems in traditional processes. Through intelligent analysis of deviation data from multiple areas, it can accurately diagnose the performance degradation of a single lamp or the overall efficiency decline, realizing the transformation from passive maintenance to predictive maintenance, significantly improving equipment reliability and service life, and reducing overall production costs.
[0021] 2. This invention can dynamically adjust the expected threshold and reference power of each curing zone based on real-time detected changes in parameters such as line speed and film thickness, ensuring process stability. More importantly, the system automatically accumulates historical data and continuously optimizes the internal process model and compensation strategy through machine learning, making decisions more accurate and energy consumption more optimized. This not only reduces the dependence on operational experience and improves product changeover efficiency and first-pass yield, but also enables the curing system to continuously evolve. Attached Figure Description
[0022] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this invention, illustrate exemplary embodiments of the invention and are used to explain the invention, but do not constitute an undue limitation of the invention. In the drawings:
[0023] Figure 1 This is a schematic diagram of the process flow for an energy-saving integrated process of electromagnetic wire coating and curing. Detailed Implementation
[0024] To more clearly illustrate the overall concept of the present invention, a detailed description will be provided below with reference to the accompanying drawings and examples.
[0025] In the description of this invention, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this 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. Therefore, they should not be construed as limitations on this invention.
[0026] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.
[0027] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.
[0028] In this invention, unless otherwise expressly specified and limited, the first feature "on" or "below" the second feature may be in direct contact with the first and second features, or indirect contact through an intermediate medium. In the description of this specification, references to terms such as "an embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.
[0029] like Figure 1 As shown, this invention proposes an energy-saving integrated process for electromagnetic wire coating and curing, comprising the following steps:
[0030] The first step is system initialization and parameter setting. Before production begins, operators input production order parameters through the human-machine interface or automatically load them into the intelligent control center. Required parameters include: insulating varnish type, target varnish film thickness d of the conductor, and planned production speed v. Based on these parameters, the control center retrieves the corresponding process formula from its internal process database or generates it through model calculation. This formula contains two key data points:
[0031] First, the reference power array for the five UV curing zones:
[0032] ,
[0033] The percentages here are relative to the maximum rated power of each lamp. This array represents the minimum energy consumption configuration to ensure the product meets specifications under ideal conditions.
[0034] Second, the expected cure threshold array for the five UV curing zones:
[0035]
[0036] These thresholds were set based on material curing kinetics models and extensive experimental data. They represent the minimum curing conversion rate that the material should achieve after passing through this zone. The thresholds are distributed in an increasing manner, with the final zone threshold... Nearly fully cured.
[0037] The second step is to start production and establish a baseline. The production line is started, and the electromagnetic wires coated with wet paint pass through the five UV curing zones in sequence at a set speed. In the initial stage, all UV lamps operate at the level set according to the baseline power array.
[0038] The online curing degree monitoring units located at the exit of each zone begin operation. For example, the first monitoring unit uses an infrared spectroscopy probe to quickly scan the surface of the coating film when the material leaves the first curing zone. By analyzing the attenuation of characteristic peaks of specific carbon-carbon double bonds, the real-time curing degree is calculated. And transmit it to the control center.
[0039] Ideally, the measured data should be , , , , The entire process requires no compensation, and the system operates at its lowest energy consumption baseline.
[0040] The third step is deviation identification and initial compensation triggering. It is assumed that after a period of operation, the effective radiation intensity of the UV lamps in the first curing zone decreases due to performance degradation. At this time, the first detection unit measures... The value remains below ,For example: After confirmation by the intelligent control center in multiple consecutive sampling cycles If the curing effect in the first curing zone is deemed substandard, the control center will immediately calculate the deviation. , An initial compensation coefficient is calculated based on a preset algorithm. , Subsequently, the system initiates the first stage of the "waterfall-style forward compensation" mechanism—"initial allocation." The control center does not change the power of the first curing zone (as its function has ended), but instead sends a command to the UV lamp driver power supply of the second curing zone, increasing its power from the baseline to [a higher value]. ,in It is a safety gain coefficient, for example, 1.3, calculated as follows: The system sets the power of the second curing zone to 76%.
[0041] The fourth step is to verify the compensation effect and make a secondary compensation decision. After the material is cured in the second curing zone with increased power, it enters the second detection unit, where the new degree of curing is measured. There are two possibilities at this point. The first is that the compensation is effective but not fully met, and the measured... Although still lower However, compared to the potentially lower value without compensation, there has been an improvement. Calculate the new bias. The absolute value is less than This indicates that the compensation direction is correct but the intensity is insufficient. Based on this, the control center initiated a second level of compensation. The algorithm believes that the compensation intensity in the subsequent two areas needs to be strengthened simultaneously, and it calculates a new enhancement coefficient. (For example =1.8). Then simultaneously adjust the power of the third and fourth curing zones:
[0042] , .
[0043] The second scenario is that the compensation is ineffective, and the test results are... The power output is even lower than the baseline expectation, indicating that the problem may be more serious than anticipated, or that the lamps in the second curing zone themselves suffer from severe attenuation. In this case, the control center will skip secondary allocation and directly enter the third-level mode. This involves significantly increasing the power of the second, third, and fourth curing zones, as well as all subsequent zones, for example, by uniformly increasing the power output. Absolute power value: , , to ensure the final quality and at the same time trigger a high-level alarm, indicating that there may be multiple lamp failures.
[0044] Step 5, iterative monitoring and process optimization. In the first case, the material continues to move forward. The third detection unit will monitor the degree of curing after enhanced curing , if it indicates that the compensation is successful, and the system can restore or adjust the power of the fourth curing zone and the fifth curing zone to a suitable level (possibly still slightly higher than the benchmark) to complete the subsequent curing. If it still does not meet the standard, continue to enhance the compensation of more subsequent areas logically.
[0045] This cycle of monitoring, decision-making, compensation, and then monitoring continues until the material passes through the last curing zone. Each step of the decision-making depends on the latest measured data, forming a dynamic closed loop.
[0046] Step 6, final inspection and system health diagnosis. When the material leaves the fifth curing zone, the fifth detection unit gives the final degree of curing , if is greater than the preset qualified standard, it is determined that the product of this section is qualified, and the control center stores information such as power adjustment records, deviation data, compensation trigger points, etc. of all zones in the production process into the historical database. These data can be used for machine learning to optimize the benchmark power and compensation coefficient under similar working conditions in the future. If is less than the preset qualified standard, it is determined that the product is unqualified. At this time, the control center starts the diagnostic program, which will analyze the entire deviation sequence from to . Specifically, for the diagnosis of single lamp attenuation, if the sequence shows that only is low and all subsequent compensations meet the standard, and finally also meets the standard, then only mark that the performance of the UV lamp in the first curing zone has decreased. If the sequence shows that the degree of curing in continuously multiple zones is continuously significantly low and even after strong compensation, still does not meet the standard, then the system diagnoses that the overall performance of the UV light source system has severely decayed, and the control center will generate a clear alarm message.
[0047] Step 7, process adaptability and learning. This system also has the ability of self-adaptation. When the production line speed is automatically adjusted or the film thickness is found to fluctuate through an online thickness gauge, the control center can dynamically adjust the expected thresholds of each zone in real time. For example, when the speed increases from to , each threshold will be adjusted proportionally according to the residence time: , where is the correction coefficient, The big data accumulated by the system for post-deviation compensation can be used to train models, making compensation decisions more accurate and efficient, and forming a self-optimizing intelligent production system.
[0048] The system architecture based on the above technology includes the following modules:
[0049] The multi-segment UV curing module consists of N independent UV curing units arranged sequentially along the production line. Each unit includes an independently adjustable UV light source module, a drive power supply, a cooling subsystem, and a spectral filter. Optical isolation sections are provided between the units to reduce spectral interference.
[0050] The distributed online monitoring module is equipped with a non-contact curing degree monitoring unit at the outlet of each UV curing unit. It uses infrared spectroscopy, Raman spectroscopy or photothermal detection technology to measure and output the quantitative value of the curing conversion rate of the material in that area in real time. At the same time, it integrates the production line speed sensor and online film thickness gauge to obtain process parameters in real time.
[0051] The intelligent control center module includes a process database submodule, a real-time calculation engine, and a decision algorithm submodule. The process database stores the baseline power array and the expected curing degree threshold array for different materials, thicknesses, and speeds. The real-time calculation engine receives monitoring data and calculates deviations and compensation coefficients. The decision algorithm submodule executes a waterfall-style forward compensation strategy to achieve dynamic power allocation.
[0052] The power dynamic adjustment module receives instructions from the intelligent control center and quickly and accurately adjusts the power of each UV curing unit through a high-frequency adjustable drive power supply. It supports both continuous dimming and pulse power modulation modes to ensure the real-time performance and accuracy of the compensation response.
[0053] The system health diagnosis and early warning module establishes a UV lamp performance degradation model based on historical compensation data and deviation sequence analysis. When it detects that the curing degree of multiple consecutive zones is not up to standard or the compensation demand is continuously abnormal, it automatically generates a lamp performance evaluation report and triggers a graded early warning.
[0054] The process adaptive learning module uses machine learning algorithms to train on historical production data, optimize the expected threshold settings, compensation coefficient calculation models, and baseline power configurations for various process parameters, and achieve continuous self-optimization of the system.
[0055] The human-computer interaction and data management module provides a graphical user interface for process recipe input, real-time production data visualization, historical query and report generation, and also enables the storage, management and remote access of production data and equipment status data.
[0056] The integrated control and communication module adopts industrial Ethernet or real-time bus technology to achieve high-speed data exchange and synchronous control between modules, supports data interface with the upper-level production management system, and realizes automatic transmission of production orders, process parameters and quality data.
[0057] The various embodiments in this specification are described in a progressive manner. Similar or identical parts between embodiments can be referred to interchangeably. Each embodiment focuses on describing the differences from other embodiments. In particular, the system embodiments are basically similar to the method embodiments, so the description is relatively simple; relevant parts can be referred to the descriptions in the method embodiments.
[0058] The above description is merely an embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principle of the present invention should be included within the scope of the claims of the present invention.
Claims
1. An energy-saving integrated process for coating and curing electromagnetic wires, characterized in that: Includes the following steps: Step 1: System initialization and parameter setting. Based on the input insulating varnish type, the target varnish film thickness d of the conductor, and the planned production speed v, a process formula containing multiple UV curing zone reference power arrays and desired curing degree threshold arrays is generated. Step 2: Start production and baseline operation, so that the electromagnetic wire coated with wet paint passes through multiple UV curing zones in sequence, all UV lamps operate at the reference power, and the online curing degree monitoring unit located at the exit of each curing zone measures and feeds back the real-time curing degree. Step 3: Deviation identification and initial compensation triggering. When the measured degree of curing of the i-th curing zone is detected to be lower than its expected degree of curing threshold, the deviation and initial compensation coefficient are calculated, and then only the UV lamp power of the (i+1)-th curing zone is increased to the adjusted power. Step 4: Verification of compensation effect and decision-making for secondary compensation. After the (i+1)th curing zone with increased power, the real-time curing degree is monitored again. Step 5: Iterative monitoring and process optimization. Based on the latest measured degree of curing, repeat the cycle of compensation decision and power adjustment until the material passes through the last curing zone. Step 6: Final inspection and system health diagnosis. The product quality is determined based on the measured curing degree of the final curing zone, and the system health status is diagnosed based on the curing degree deviation sequence of each zone. Step 7: Process Adaptation and Learning. When the production line speed is automatically adjusted, or when fluctuations in the paint film thickness are detected by an online thickness gauge, the control center can dynamically adjust the expected threshold of each zone in real time.
2. The energy-saving integrated process for coating and curing electromagnetic wires according to claim 1, characterized in that: The process formulation, based on a pre-set material curing kinetics model and experimental data, determines a multi-zone reference power array that enables the product to meet standards under ideal conditions. and an array of expected curing degree thresholds in an increasing distribution .
3. The energy-saving integrated process for coating and curing electromagnetic wires according to claim 1, characterized in that: In the initial compensation trigger, when the real-time curing degree of the i-th curing zone... Continuously below its threshold Time calculation deviation With the initial compensation coefficient and will The power of the curing zone is from the reference power. Upgraded to ,in This is the safety gain coefficient.
4. The energy-saving integrated process for electromagnetic wire coating and curing according to claim 3, characterized in that: In the aforementioned secondary compensation decision, if the power is increased after the first... Measured degree of curing in the curing zone Still below its threshold And its absolute value of deviation Less than the absolute value of the previous deviation Then, a secondary allocation is initiated to calculate the enhancement coefficient. And at the same time improve the first The and the first The power of each curing zone.
5. The energy-saving integrated process for electromagnetic wire coating and curing according to claim 3, characterized in that: In the aforementioned secondary compensation decision, if the power is increased after the first... Measured degree of curing in the curing zone Still below its threshold And its absolute value of deviation Greater than or equal to the absolute value of the previous deviation Then emergency mode will be activated, and the first one will be activated. The power of all subsequent curing zones will be increased by an absolute percentage. .
6. The energy-saving integrated process for coating and curing electromagnetic wires according to claim 1, characterized in that: If, during the system health diagnosis, the curing degree of the final curing zone is lower than the preset qualified standard, and the analysis of the deviation sequence of each curing zone reveals at least one continuous curing zone sequence, wherein the deviation of each curing zone is less than the preset severe negative deviation threshold, then the overall performance of the UV light source system is deemed unqualified, and a system maintenance alarm is issued.
7. The energy-saving integrated process for electromagnetic wire coating and curing according to claim 1, characterized in that: The online curing degree monitoring unit uses an infrared spectrometer to calculate the real-time curing degree by analyzing the attenuation of specific carbon-carbon double bond characteristic peaks in the paint film.