Apparatus for manufacturing enameled wire and method for manufacturing enameled wire

Abstract

Provided is a device for manufacturing an enameled wire and a method for manufacturing an enameled wire, which can suppress damage to the surface of a conductor or attachment of fine copper powder to the surface of the conductor during wire drawing. The device for manufacturing an enameled wire includes a mechanism for passing a conductor through a wire drawing die. The device for manufacturing an enameled wire includes a vibration sensor provided to the wire drawing die or a member fixed to the wire drawing die, and a change portion configured to change at least one of the position of the wire drawing die and the orientation of the wire drawing die.

Description

Technical Field

[0001] This disclosure relates to an apparatus for manufacturing enameled wire and a method for manufacturing enameled wire. Background Technology

[0002] Enameled wire comprises a conductor and an enameled coating. The conductor is primarily composed of copper. The enameled coating covers the surface of the conductor. Patent Document 1 describes a method for manufacturing enameled wire. In this method, a coarse conductor with a circular cross-section is repeatedly drawn and annealed to produce a conductor with a circular cross-section and a desired diameter, or a conductor with a rectangular cross-section and desired longitudinal and transverse dimensions. Next, a coating is applied to the surface of the conductor to form a coating film. The coating contains polyimide and polyamide-imide. Then, the enameled coating film is formed by firing.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2015-36149 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] During wire drawing, the surface of the conductor may be damaged or fine copper powder may adhere to it. If damage or copper powder is present on the conductor surface, it can easily lead to problems such as poor appearance, foaming starting from the damage, dimensional defects, conductor curling, and reduced voltage withstand characteristics due to damaged protrusions.

[0008] In one aspect of this disclosure, an apparatus and method for manufacturing enameled wire are preferably provided, which can suppress damage to the surface of the conductor or the adhesion of fine copper powder to the surface of the conductor during wire drawing.

[0009] Methods for solving problems

[0010] One aspect of this disclosure is an apparatus for manufacturing enameled wire, comprising a mechanism for passing a conductor through a drawing die. The apparatus includes a vibration sensor and a changing unit; the vibration sensor is disposed on the drawing die or on a component fixed to the drawing die; the changing unit is configured to change at least one of the position and orientation of the drawing die.

[0011] As an aspect of this disclosure, the enameled wire manufacturing apparatus can suppress damage to the surface of the conductor or the adhesion of fine copper powder to the surface of the conductor during wire drawing.

[0012] Another aspect of this disclosure is a method for manufacturing enameled wire, which includes a step of passing a conductor through a drawing die. In the method for manufacturing enameled wire, based on data from a vibration sensor disposed on the drawing die or disposed on a component fixed to the drawing die, at least one of the position and orientation of the drawing die is changed.

[0013] According to the method for manufacturing enameled wire, which is another aspect of this disclosure, damage to the surface of the conductor or the adhesion of fine copper powder to the surface of the conductor can be suppressed during wire drawing. Attached Figure Description

[0014] Figure 1 This is an explanatory diagram showing the structure of an apparatus for manufacturing enameled wire.

[0015] Figure 2 It is a cross-sectional view showing the cross-sectional shape of a rolled conductor.

[0016] Figure 3 It is a cross-sectional view showing the cross-sectional shape of a flat conductor.

[0017] Figure 4 This is an explanatory diagram showing the structure of a flat wire drawing machine.

[0018] Figure 5 This is an explanatory diagram showing the display section that shows the data sent from the vibration sensor.

[0019] Figure 6 This is an explanatory diagram showing how to change the position of a flat wire drawing die in the right, left, up, and down directions.

[0020] Figure 7 This is an explanatory diagram showing the rotation and pitch angles of a flat wire drawing die centered on the first rotation axis.

[0021] Figure 8 This is an explanatory diagram showing the rotation and yaw angle of a flat wire drawing die centered on the second rotation axis.

[0022] Figure 9 This is an explanatory diagram showing the rotation and rolling angles of a flat wire drawing die centered on the third rotation axis.

[0023] Explanation of reference numerals in the attached figures

[0024] 1…Enameled wire manufacturing equipment, 3…Winding tube, 5…Circular wire drawing machine, 7…Flat rolling mill, 9…Annealing furnace, 11…Flat wire drawing machine, 13…Annealing furnace, 15…Coating machine, 17…Sintering furnace, 19…Winding machine, 22A, 22B…Short side, 23…Conductor, 23A…Rolled conductor, 23B…Flat conductor, 24A, 24B…Edge, 25…Enameled wire, 26A, 26B…End face, 31…Flat wire drawing die, 3 2… Mold holder, 33… Vibration sensor, 34… Display unit, 34A… Monitor, 34B… Computer, 35… Machining hole, 36… Change unit, 41… First rotating axis, 42… Second rotating axis, 43… Third rotating axis, 51… First reference line, 52… Second reference line, 53… Third reference line, V_X… Vibration data on the X-axis, V_Y… Vibration data on the Y-axis, V_Z… Vibration data on the Z-axis. Detailed Implementation

[0025] The exemplary embodiments of this disclosure will be described with reference to the accompanying drawings.

[0026] <First Implementation Method>

[0027] 1. Overall structure of the enameled wire manufacturing apparatus 1

[0028] based on Figures 1-3 The overall structure of the enameled wire manufacturing apparatus 1 will be described. For example... Figure 1 As shown, the enameled wire manufacturing apparatus 1 includes a winding tube 3, a circular wire drawing machine 5, a flat rolling mill 7, an annealing furnace 9, a flat wire drawing machine 11, an annealing furnace 13, a coating machine 15, a sintering furnace 17, and a winding machine 19. A wire-shaped conductor 23 is wound on the winding tube 3.

[0029] When the enameled wire manufacturing apparatus 1 is used to implement the enameled wire manufacturing method, the conductor 23 is led out from the winding tube 3 and travels along a path that sequentially passes through the circular drawing machine 5, the flat rolling mill 7, the annealing furnace 9, the flat drawing machine 11, the annealing furnace 13, the coating machine 15, and the sintering furnace 17, and is wound onto the winding machine 19. The conductor 23 passes through the section including the coating machine 15 and the sintering furnace 17 multiple times.

[0030] The conductor 23 is made of, for example, copper or a copper alloy. The cross-sectional shape of the conductor 23 is circular before the flat rolling process described later. It should be noted that the cross-section of the conductor 23 refers to the section orthogonal to the length direction of the conductor 23.

[0031] The circular wire drawing machine 5 draws the conductor 23, which has a circular cross-sectional shape, into wires. The flat rolling mill 7 flattens the traveling conductor 23. The flattened conductor 23 is then designated as rolled conductor 23A. Figure 2As shown, the cross-sectional shape of the rolled conductor 23A is formed by two parallel sides 24A and 24B and two arc-shaped end faces 26A and 26B. In the cross-section, sides 24A and 24B are straight lines. The lengths of sides 24A and 24B in the cross-section are greater than the lengths of end faces 26A and 26B. The rolled conductor 23A is annealed in the annealing furnace 9.

[0032] The flat wire drawing machine 11 performs flat wire drawing on the traveling rolled conductor 23A. Flat wire drawing is a process of drawing the rolled conductor 23A into wires. The conductor 23 that has undergone flat wire drawing is designated as flat conductor 23B. The configuration of the flat wire drawing machine 11 will be described later.

[0033] like Figure 3 As shown, the flat conductor 23B has a rectangular cross-sectional shape. The long sides of the rectangle are sides 24A and 24B. The short sides 22A and 22B of the rectangle are the sides from the end faces 26A and 26B of the rolled conductor 23A.

[0034] like Figure 1 As shown, in the flat wire drawing machine 11, the direction of travel of the conductor 23 is set as the travel direction TR. The opposite direction of the travel direction TR is set as the upstream direction US. The annealing furnace 13 anneals the flat conductor 23B. The coating machine 15 forms a coating film of predetermined thickness on the surface of the flat conductor 23B by applying enameled coating to the surface of the flat conductor 23B.

[0035] The sintering furnace 17 heats the traveling flat conductor 23B, on which a coating of enameled paint of a predetermined thickness has been formed using the coating machine 15, to form a film. For example... Figure 1 As shown, the process of applying enameled coating using a coating machine 15 and forming a film using a sintering furnace 17 is repeated. The result is the production of an enameled wire 25 with a predetermined film thickness. The enameled wire 25 is then wound onto a winding machine 19.

[0036] The method for forming the coating is described below. An enameled wire coating is applied to the surface of the flat conductor 23B. The enameled wire coating is, for example, a coating containing resin and solvent. Next, the solvent in the enameled wire coating applied to the surface of the flat conductor 23B is evaporated, and the resin in the enameled wire coating is cured. After solvent evaporation and resin curing, an enameled wire 25 is formed.

[0037] 2. Composition of the flat wire drawing machine 11

[0038] based on Figures 4-9 Explain the composition of the flat wire drawing machine 11. For example... Figure 4 As shown, the flat wire drawing machine 11 includes a flat wire drawing die 31, a die holder 32, a vibration sensor 33, a display unit 34, and a change unit 36.

[0039] The flat wire drawing die 31 has a flat machining hole 35. The conductor 23 travels along the travel direction TR while passing through the machining hole 35. Before passing through the machining hole 35, the conductor 23 is a rolled conductor 23A. After passing through the machining hole 35, the conductor 23 is a flat conductor 23B.

[0040] It should be noted that the flat wire drawing machine 11 corresponds to the mechanism that passes the rolled conductor 23A through the flat wire drawing die 31. Furthermore, the process of the conductor 23 passing through the flat wire drawing machine 11 corresponds to the process of passing the rolled conductor 23A through the flat wire drawing die 31.

[0041] The mold holder 32 holds the flat wire drawing mold 31. The mold holder 32 corresponds to the component fixed to the flat wire drawing mold 31. In this embodiment, a vibration sensor 33 is provided on the mold holder 32. The vibration sensor 33 detects the vibration of the flat wire drawing mold 31 and the mold holder 32, and sends the data to the display unit 34. The transmitted data represents the vibration of the flat wire drawing mold 31 and the mold holder 32. The data transmission method can be wireless or wired.

[0042] Vibration sensor 33 detects vibrations along the X, Y, and Z axes respectively. Therefore, vibration sensor 33 detects vibrations along three axes. The X-axis is parallel to the axis of the machined hole 35. The Y-axis is parallel to the right-hand direction R and the left-hand direction L.

[0043] The right direction R is the rightward direction when viewing the flat wire drawing die 31 from a viewpoint located on the travel direction TR side. The left direction L is the leftward direction when viewing the flat wire drawing die 31 from a viewpoint located on the travel direction TR side. The right direction R and the left direction L correspond to the horizontal direction. The Z-axis is an axis parallel to the upward direction U and the downward direction D. The upward direction U is a vertical and upward direction. The downward direction D is the opposite direction of the upward direction U. The upward direction U and the downward direction D correspond to the vertical direction.

[0044] Display unit 34 displays data sent from vibration sensor 33. For example, such as Figure 5 As shown, the display unit 34 displays the vibration data V_X on the X-axis, the vibration data V_Y on the Y-axis, and the vibration data V_Z on the Z-axis in graphical form, respectively. Figure 5 In the graph shown, the horizontal axis represents time, and the vertical axis represents acceleration. For example... Figure 4 As shown, the display unit 34 consists of a monitor 34A and a computer 34B. Data is displayed on the monitor 34A.

[0045] The changing part 36 is a mechanism for changing the position and orientation of the flat wire drawing die 31. For example... Figure 6As shown, the changing part 36 can move the flat wire drawing die 31 to the right (R) or left (L) to change the position of the flat wire drawing die 31 in the horizontal direction.

[0046] like Figure 6 As shown, the changing part 36 can move the flat wire drawing die 31 in the upward direction U or the downward direction D, changing the position of the flat wire drawing die 31 in the vertical direction. Figure 7 As shown, the changing part 36 can rotate the flat wire drawing die 31 around the first rotation axis 41, changing the orientation of the flat wire drawing die 31. The first rotation axis 41 is parallel to the right direction R and the left direction L. When viewed from a viewpoint located in the left direction L, the first rotation axis 41 is located at the center of the flat wire drawing die 31, at a position consistent with the machining hole 35.

[0047] When the flat wire drawing die 31 is rotated around the first rotation axis 41, the pitch angle θ changes. Viewed from a point located to the left (L), the pitch angle θ is the angle between the first reference line 51 fixed to the flat wire drawing die 31 and the conductor 23. The first reference line 51 is parallel to the axis of the machining hole 35.

[0048] like Figure 8 As shown, the changing part 36 can rotate the flat wire drawing die 31 around the second rotation axis 42, changing the orientation of the flat wire drawing die 31. The second rotation axis 42 is parallel to the upper direction U and the lower direction D. When viewed from the upper U viewpoint, the second rotation axis 42 is located at the center of the flat wire drawing die 31, at a position consistent with the machining hole 35.

[0049] When the flat wire drawing die 31 is rotated about the second rotation axis 42, the yaw angle δ changes. When viewed from a viewpoint located in the upward direction U, the yaw angle δ is the angle between the first reference line 51 fixed to the flat wire drawing die 31 and the conductor 23.

[0050] like Figure 9 As shown, the changing unit 36 ​​can rotate the flat wire drawing die 31 around the third rotation axis 43, changing the direction of the flat wire drawing die 31. The third rotation axis 43 is parallel to the axis of the machining hole 35. When viewed from a viewpoint located in the travel direction TR, the third rotation axis 43 is located at the same position as the machining hole 35.

[0051] If the flat wire drawing die 31 is rotated around the third rotation axis 43, the roll angle γ changes. The roll angle γ is the angle between the second reference line 52 fixed to the flat wire drawing die 31 and the third reference line 53 fixed to the conductor 23, as viewed from a viewpoint located in the travel direction TR. The second reference line 52 is orthogonal to the axis of the machining hole 35. The third reference line 53 is orthogonal to the edges 24A and 24B.

[0052] 3. Adjustment of the position and orientation of the flat wire drawing die 31

[0053] During the manufacturing process of enameled wire, vibration sensor 33 detects the vibration of flat wire drawing die 31 and die holder 32, and sends the data to display unit 34. Display unit 34 displays the data sent from vibration sensor 33. The data displayed on display unit 34 indicates the magnitude of vibration of flat wire drawing die 31 on the X-axis, Y-axis, and Z-axis.

[0054] The operator or a control unit (not shown) uses the change unit 36 ​​to change at least one of the position and orientation of the flat wire drawing die 31 based on the data displayed on the display unit 34. For example, the control unit controls the change unit 36 ​​based on the data from the vibration sensor 33 to reduce the vibration of the wire drawing die 31. For example, by alternately repeating the steps of changing the position or orientation of the flat wire drawing die 31 by a predetermined amount in a predetermined direction and confirming the data displayed on the display unit 34, the position and orientation of the flat wire drawing die 31 are adjusted to minimize the vibration of the flat wire drawing die 31 on the X-axis, Y-axis, and Z-axis.

[0055] The position and orientation of the flat wire drawing die 31 can be adjusted before the enameled wire manufacturing process begins, or during the implementation of the enameled wire manufacturing process. For example, during the implementation of the enameled wire manufacturing process, the position and orientation of the flat wire drawing die 31 can be adjusted periodically and repeatedly.

[0056] 4. The effects of the enameled wire manufacturing apparatus 1 and the enameled wire manufacturing method

[0057] (1A) The vibration of the flat wire drawing die 31 increases when the rolled conductor 23A is in contact with the flat wire drawing die 31 on one side. In this one-sided contact state, the surface of the rolled conductor 23A is easily damaged. Furthermore, in this one-sided contact state, fine copper powder is generated due to wear of the rolled conductor 23A and easily adheres to its surface. The one-sided contact state refers to a state where a portion of the inner surface of the machined hole 35 has stronger contact with the rolled conductor 23A compared to other portions.

[0058] If the enameled wire manufacturing apparatus 1 and the enameled wire manufacturing method are used, the position and orientation of the flat wire drawing die 31 can be adjusted to minimize the vibration of the flat wire drawing die 31 on the X, Y, and Z axes. The state of minimal vibration of the flat wire drawing die 31 is the state in which the rolled conductor 23A does not contact one side of the flat wire drawing die 31, and the state in which it is difficult to form damage or fine copper powder on the surface of the rolled conductor 23A.

[0059] Therefore, if the enameled wire manufacturing apparatus 1 and the enameled wire manufacturing method are used, it is possible to suppress the formation of damaged, fine copper powder on the surface of the rolled conductor 23A.

[0060] (1B) The vibration sensor 33 can detect vibrations on all three axes. If the enameled wire manufacturing apparatus 1 and the enameled wire manufacturing method are used, the position and orientation of the flat wire drawing die 31 can be adjusted to reduce vibrations on all three axes. As a result, it is possible to further suppress the formation of damaging, fine copper powder on the surface of the rolled conductor 23A.

[0061] (1C) If the enameled wire manufacturing apparatus 1 and the enameled wire manufacturing method are used, the horizontal position, vertical position, pitch angle θ, yaw angle δ, and roll angle γ of the flat wire drawing die 31 can be changed. Therefore, the vibration of the flat wire drawing die 31 can be further reduced. As a result, the formation of damaging, fine copper powder on the surface of the rolled conductor 23A can be further suppressed.

[0062] (1D) As described above, if the enameled wire manufacturing apparatus 1 and the enameled wire manufacturing method are used, the position and orientation of the flat wire drawing die 31 can be adjusted to minimize the vibration of the flat wire drawing die 31 on the X-axis, Y-axis and Z-axis. The state in which the vibration of the flat wire drawing die 31 is small is the state in which the rolled conductor 23A does not contact the flat wire drawing die 31 on one side, and the state in which the wear of the flat wire drawing die 31 is uniform.

[0063] Therefore, by using the enameled wire manufacturing apparatus 1 and the enameled wire manufacturing method, the life of the flat wire drawing die 31 can be extended, and the reprocessing of the flat wire drawing die 31 can be made easier.

[0064] <Other Implementation Methods>

[0065] The embodiments of this disclosure have been described above, but this disclosure is not limited to the above embodiments and can be implemented in various ways.

[0066] (1) Vibration sensor 33 can also be set in flat wire drawing die 31.

[0067] (2) The modification unit 36 ​​may also change only one of the positions and orientations of the flat wire drawing die 31. The modification unit 36 ​​may also not change a portion of the horizontal position, vertical position, pitch angle θ, yaw angle δ, and roll angle γ of the flat wire drawing die 31.

[0068] (3) The display unit 34 can also display the composite vibration wave of vibrations on two or more axes. In this case, the user can understand the magnitude of the composite vibration on two axes. For example, the display unit 34 displays the composite vibration wave of vibrations on two axes. For example, the display unit 34 displays the composite vibration wave of vibrations on three axes.

[0069] (4) The conductor 23 drawn by the flat drawing die 31 can also be a round wire. In this case, the change part 36 may not change the roll angle γ.

[0070] (5) The directions of the X-axis, Y-axis and Z-axis can be mutually orthogonal, or they can be different from the directions of the first embodiment.

[0071] (6) The component that provides the vibration sensor 33 can also be a component other than the mold holder 32, which is a component fixed to the flat wire drawing mold 31.

[0072] (7) Vibration sensor 33 can also detect the vibration of one axis. One axis is, for example, any one of the X-axis, Y-axis, and Z-axis. Vibration sensor 33 can also detect the vibration of two axes. Two axes are, for example, the X-axis and Y-axis, the Y-axis and Z-axis, or the Z-axis and X-axis.

[0073] (8) The method by which the display unit 34 displays data may also be different from that in the first embodiment. For example, the magnitude or acceleration of the vibration may be displayed digitally. Alternatively, a graph showing changes in size or length may be displayed based on the magnitude or acceleration of the vibration.

[0074] (9) The direction in which the flat wire drawing die 31 is moved by the changing part 36 can be neither horizontal nor vertical. The directions of the first rotating axis 41, the second rotating axis 42 and the third rotating axis 43 can also be different from those in the first embodiment.

[0075] (10) The flat wire drawing machine 11 may also not have a display unit 34. In this case, for example, the control unit (not shown) controls the change unit 36 ​​based on the data of the vibration sensor 33, thereby changing at least one of the position and orientation of the flat wire drawing die 31 to reduce the vibration of the flat wire drawing die 31.

[0076] (11) Multiple constituent elements may share the functions of one constituent element in each of the above embodiments, or one constituent element may perform the functions of multiple constituent elements. Additionally, a portion of the configuration in each of the above embodiments may be omitted. Furthermore, at least a portion of the configuration in each of the above embodiments may be added to, substituted for, or otherwise modified relative to the configurations of other above embodiments.

[0077] (12) In addition to the enameled wire manufacturing apparatus 1 described above, this disclosure can also be implemented in various ways, such as a system that uses the enameled wire manufacturing apparatus 1 as a component, a vibration detection method, a vibration display method, and a method for adjusting the position and orientation of the drawing die.

[0078] [The technical concepts disclosed in this specification]

[0079] [Project 1]

[0080] An apparatus for manufacturing enameled wire includes a mechanism for passing a conductor through a drawing die, and further includes: a vibration sensor disposed on the drawing die or on a component fixed to the drawing die, and a changing part configured to change at least one of the position and orientation of the drawing die.

[0081] [Project 2]

[0082] According to the enameled wire manufacturing apparatus of Project 1, the vibration sensor is configured to detect vibration on a 1st axis, a 2nd axis, or a 3rd axis.

[0083] [Project 3]

[0084] The enameled wire manufacturing apparatus according to item 1 or 2 further includes a display unit configured to display data from the aforementioned vibration sensor.

[0085] [Project 4]

[0086] According to the enameled wire manufacturing apparatus of Project 3, the display unit is configured to display a composite vibration wave of vibrations with two or more axes.

[0087] [Project 5]

[0088] The enameled wire manufacturing apparatus according to any one of items 1 to 4, wherein the aforementioned modification unit is configured to modify one or more of the horizontal position, vertical position, pitch angle, yaw angle, and roll angle of the drawing die.

[0089] [Project 6]

[0090] The enameled wire manufacturing apparatus according to any one of items 1 to 5 further includes a control unit configured to control the alteration unit based on data from the vibration sensor, so as to reduce the vibration of the drawing die.

[0091] [Project 7]

[0092] A method for manufacturing enameled wire includes a step of passing a conductor through a drawing die, wherein, based on data from a vibration sensor disposed on the drawing die or disposed on a component fixed to the drawing die, at least one of the position and orientation of the drawing die is changed.

[0093] [Project 8]

[0094] The manufacturing method of enameled wire according to Project 7, wherein the above data is shown.

[0095] [Project 9]

[0096] According to the method for manufacturing enameled wire described in item 7 or 8, at least one of the position and orientation of the drawing die is changed based on the data from the vibration sensor to reduce the vibration of the drawing die.

Claims

1. An apparatus for manufacturing enameled wire, comprising a mechanism for passing a conductor through a drawing die, and comprising: A vibration sensor, disposed on the wire drawing die or on a component fixed to the wire drawing die; and The alteration unit is configured to alter at least one of the position and orientation of the wire drawing die.

2. The enameled wire manufacturing apparatus according to claim 1, wherein, The vibration sensor is configured to detect vibrations on one, two, or three axes.

3. The enameled wire manufacturing apparatus according to claim 1 or 2, further comprising a display unit configured to display data from the vibration sensor.

4. The enameled wire manufacturing apparatus according to claim 3, wherein, The display unit is configured to display a composite vibration wave of vibrations with two or more axes.

5. The apparatus for manufacturing enameled wire according to claim 1 or 2, wherein, The modification unit is configured to change one or more of the horizontal position, vertical position, pitch angle, yaw angle, and roll angle of the wire drawing die.

6. The enameled wire manufacturing apparatus according to claim 1 or 2, further comprising a control unit configured to control the alteration unit based on data from the vibration sensor, so as to reduce the vibration of the drawing die.

7. A method for manufacturing enameled wire, comprising the step of passing a conductor through a drawing die, wherein, based on data from a vibration sensor disposed on the drawing die or disposed on a component fixed to the drawing die, at least one of the position and orientation of the drawing die is changed.

8. The method for manufacturing enameled wire according to claim 7, wherein, The data is displayed.

9. The method for manufacturing enameled wire according to claim 7 or 8, wherein, Based on the data from the vibration sensor, at least one of the position and orientation of the wire drawing die is changed to reduce the vibration of the wire drawing die.

Images