Automatic detection and cutting method of copper wire in heating wire based on open line machine

Abstract

The application provides an automatic detection and cutting method for short-circuit copper wires in a heating wire based on an opening machine. According to the preset copper wire length on the heating wire, the spacing between the copper wires, and the spacing between the first induction switch and the cutter, the conveying length of the heating wire on the opening machine is accurately judged under the cooperation of the first induction switch and the second induction switch. Then, different length cutting units are obtained by cutting with the cutter, and the lengths of different connection sections in the different length cutting units are different. The different length connection sections are connected with the connector terminal, and then connected with different electrical appliances to meet the connection requirements. Or the lengths of different connection sections in the same length cutting unit are the same or different, which meets the connection requirements of the same or different length connection sections connected with the connector terminal and connected with the different positions of the electrical appliances. Such cutting efficiency is high, the error caused by manual cutting is reduced, and time and labor are saved.

Description

Technical Field

[0001] This invention relates to the field of heating wire technology, and specifically to a method for automatically detecting and cutting copper wires in heating wires based on a wire-cutting machine. Background Technology

[0002] Heating wire, also known as electric heating wire, is a type of conductor that generates heat through the heating effect of electric current when energized. It has a wide range of applications, covering multiple dimensions such as energy saving, safety, comfort, environmental protection, and intelligence. Heating wire can be wound to form a heating tape and installed in household appliances such as refrigerators. In order to facilitate the electrical connection between the heating tape and the appliance, a section of the heating wire is usually reserved on the outside of the heating tape to form a connecting section. Copper wire is installed on the connecting section to realize the external circuit connection.

[0003] Existing technology, such as Chinese Patent Application No. CN202411957828.6, published on February 25, 2025, discloses a method for manufacturing a heating device, including: an insulating core, a heating wire, and an outer insulator, wherein the outer insulator covers the insulating core, and the heating wire is disposed between the insulating core and the outer insulator; S2: measuring and cutting the heating wire; S3: stripping the outer insulator at the end of the heating wire to expose the inner heating wire and the insulating core; S4: providing a wire, stripping the insulation layer at the end of the wire to expose the inner conductor; S5: providing a tension spring, the tension spring including a straight end and a hook end, and providing a terminal; inserting the heating wire, the conductor, the straight end, the insulating core, and the outer insulator into the terminal respectively for crimping and fixing.

[0004] The above-mentioned literature describes manually cutting the outer side of the heating wire, but this method cannot accurately determine the position of the copper wire, resulting in low efficiency in the entire production process. Existing technologies also use X-ray machines to examine the connecting section, identify the copper wire inside the heating wire connection, mark the outer side of the heating wire, and then manually cut off the excess connecting section at the marked point. This method is time-consuming and labor-intensive, and errors are prone to occur during manual cutting, resulting in different lengths of the remaining connecting section after cutting, which in turn affects subsequent use. Summary of the Invention

[0005] The purpose of this invention is to provide an automatic detection and cutting method for copper wires in heating wires based on a wire cutting machine, which can improve cutting efficiency, reduce errors, and save time and effort.

[0006] This invention provides the following technical solution: an automatic detection and cutting method for copper wires in heating wires based on a wire-cutting machine, wherein the length of the copper wires in the heating wire to be cut is preset as L1, the spacing between different copper wires is preset as L2, and the spacing between the first induction switch of the wire-cutting machine and the cutter is preset as L3, and the sum of L1 and L2 is greater than L3. The heating wire is cut by the wire-cutting machine, including the following steps: S1. The first inductive switch detects the heating wire being transported. When the beginning of the junction between a copper wire and the heating wire is detected, the first inductive switch sends a signal to the control module and begins recording the length of the heating wire being transported. S2. When the length of the heating wire changes from 0 to L3+L1 / n, the control module controls the heating wire to stop feeding and then controls the cutter to move in a direction perpendicular to the feeding of the heating wire and cut the heating wire, forming a first connecting segment with copper wire attached and a length of (L1-L1 / n) at one end of the cutting unit on the heating wire. S3. Set the heating wire conveying length in step S1 to zero, and control the heating wire to continue conveying. When the second induction switch located below the cutter detects the beginning of the junction between another copper wire and the heating wire, record the heating wire conveying length as (L1 - L1 / n) + L2. S4. Continue to feed the heating wire. When the heating wire feeding length is recorded again as L1 / m and the sum of the heating wire feeding length (L1 - L1 / n) + L2 in step S3 reaches the preset cutting unit length L, stop feeding the heating wire and control the cutter to cut the heating wire. A second connecting section with copper wire and a length of L1 / m is formed at the other end of the cutting unit on the heating wire. S5. Repeat steps S1 to S4 to cut the next cutting unit on the heating line.

[0007] The above settings, through the cooperation of the first and second inductive switches, can accurately determine the conveying length of the heating wire on the wire cutting machine based on the preset copper wire length on the heating wire, the spacing between the copper wires, and the distance between the first inductive switch and the cutter. This allows for the cutting of different length cutting units according to different needs, with different connecting segments within each cutting unit having different lengths. This satisfies the requirement that connecting segments of different lengths can be connected to the connector terminals and then to different electrical appliances. Alternatively, it can cut different connecting segments of the same length cutting unit with the same or different lengths to meet the requirement that connecting segments of the same or different lengths can be connected to the connector terminals and then to different positions of the electrical appliances. This cutting method is highly efficient, reduces errors caused by manual cutting, and saves time and labor.

[0008] Furthermore, the heating wire includes a heating wire, a core, and copper wire. The heating wire is spirally wound around the outside of the core. The copper wire has two or more sections and is disposed between the heating wire and the core. The copper wire is arranged in a circle around the core and is parallel to the core.

[0009] The above settings facilitate the detection of the beginning and end of the junction between the copper wire and the heating wire by the first and second induction switches on the wire opening machine, so as to record the length of the heating wire being transported.

[0010] Furthermore, one end of the wire-opening machine is provided with a transition component, which includes a fixed plate and two or more transition wheels and limit blocks. The transition wheels are offset vertically along the width direction of the fixed plate. The limit blocks are respectively provided on both sides of the transition wheels. The limit blocks are provided with limit holes and the limit holes of the two limit blocks are coaxially arranged. The first inductive switch is provided on the limit block and located on one side of the transition wheel.

[0011] The above settings can straighten and smooth the heating wires that have passed through the misaligned transition wheel, avoiding affecting the calculation of the subsequent heating wire conveying length.

[0012] Furthermore, the opening machine is provided with a first positioning component on one side of the transition component. The first positioning component includes a positioning tube, two or more positioning blocks and a first pressing wheel. The first pressing wheels are arranged side by side in the vertical direction and there is a gap between the first pressing wheels that matches the heating wire. The positioning blocks are respectively arranged on both sides of the first pressing wheel and the positioning holes and limiting holes on the positioning blocks are coaxially arranged.

[0013] The above settings ensure that after the heating wire passes through the transition component, it can accurately enter the positioning component through the positioning hole of the positioning hole, and be straightened again by the action of the first pressure wheel.

[0014] Furthermore, the positioning tube is disposed on the positioning block and coaxially arranged with the positioning hole, and the positioning tube has a hollow structure.

[0015] The above settings facilitate the precise delivery of the straightened heating wire along the positioning tube to the cutter, preventing the heating wire from bending and affecting the accurate cutting of the heating wire.

[0016] Furthermore, the cutter is mounted on the wire-opening machine and located on one side of the positioning tube, and the cutter is moved up and down along an axis perpendicular to the positioning tube.

[0017] The above settings enable the cutter to precisely cut the heating wire when it is delivered to the cutting position.

[0018] Furthermore, a second positioning component is provided on one side of the cutter. The second positioning component includes two second pressure rollers, which are arranged side by side in a vertical direction and have a gap between them that matches the heating wire. A feeding plate is provided on one side of the second pressure rollers.

[0019] The above settings enable the cutting unit to straighten the heating wires of the cutting unit again by the second pressure roller before the second cutting, so that the cutting unit after the second cutting meets the requirement of not bending, and the heating wires of the cutting unit formed after cutting are collected on the unloading tray.

[0020] Furthermore, in step S3, when the second inductive switch detects the end of the junction between a copper wire and the heating wire in the heating wire, the heating wire transmission length is (L1 - L1 / n).

[0021] The above settings ensure that the first connecting section of the cutting unit has the required length of copper wire, so that after the first connecting section of the cutting unit is connected to the connector terminal, it can be connected to the electrical appliance.

[0022] Furthermore, in step S4, the formula for calculating the preset cutting unit length L is as follows: L = (L1 - L1 / n) + L2 + L1 / m, Furthermore, for different connection segment lengths in different cutting units, n > m, n = m, or n < m can be set.

[0023] The above settings can cut cutting units of different preset lengths, and make the connecting segments in different cutting units have different lengths, thereby meeting the needs of connecting to different electrical appliances after connecting to the plug-in terminals.

[0024] Furthermore, the length of the first connecting segment (L1 - L1 / n) is greater than the length of the second connecting segment L1 / m, or the length of the first connecting segment (L1 - L1 / n) is equal to the length of the second connecting segment L1 / m, or the length of the first connecting segment (L1 - L1 / n) is less than the length of the second connecting segment L1 / m.

[0025] The above settings allow the lengths of the first and second connecting segments in a cutting unit of the same length to be different, thereby meeting the different connection requirements of different connecting segments and plug terminals to different positions of electrical appliances. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the wire-opening machine of the present invention.

[0027] Figure 2 This is a flowchart of the process of the present invention.

[0028] Figure 3This is a schematic diagram of the heating wire structure in this invention.

[0029] Figure 4 This is a front view of the wire-opening machine of the present invention. Detailed Implementation

[0030] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0031] Example 1.

[0032] like Figure 1 , 3 As shown in Figure 4, this invention provides an automatic detection and cutting method for short-circuited copper wires in heating wires based on a wire-cutting machine. The method is implemented by a wire-cutting machine 7. The heating wire to be cut includes a heating wire 1, a core 2, and a copper wire 3. The heating wire 1 is spirally wound around the outside of the core 2, and an insulating layer 4 is wrapped around the outside of the heating wire 1. The copper wire 3 has two or more segments and is positioned between the heating wire 1 and the core 2. The copper wire 3 is arranged in a circular pattern around the core 2 and is parallel to the core 2. This facilitates the detection of the beginning 5 and the end 6 of the junction between the copper wire 3 and the heating wire 1 by the first induction switch 17 and the second induction switch 22 on the wire-cutting machine 7, so as to record the length of the heating wire.

[0033] In this embodiment, as Figure 3 and 4 As shown, the length of the copper wire 3 set in the heating wire is preset to L1, the spacing between different copper wires 3 is preset to L2, and the spacing between the first induction switch 17 of the wire cutter 7 and the cutter is preset to L3. The sum of L1 and L2 is greater than L3, L1 < L3, L2 < L3, and L1 < L2, so as to ensure that the corresponding heating wire conveying length can be cut within the area of ​​the copper wire 3 length by calculating, thereby ensuring that the connecting sections at both ends of the cutting unit 8 after cutting contain copper wire 3.

[0034] like Figure 1 and 4 As shown, one end of the wire opening machine 7 is provided with a transition component. The transition component includes a fixed plate 11 and two or more transition wheels 9 and limit blocks 10. The transition wheels 9 are offset vertically along the width direction of the fixed plate 11. The limit blocks 10 are respectively provided on both sides of the transition wheels 9. The limit blocks 10 are provided with limit holes 12 and the limit holes 12 of the two limit blocks 10 are coaxially arranged. The first induction switch 17 is provided on the limit block 10 and located on one side of the transition wheel 9, so as to straighten and smooth the heating wire that has passed through the offset transition wheel 9, and avoid affecting the calculation of the subsequent heating wire conveying length.

[0035] like Figure 1 and 4As shown, a first positioning component is provided on the wire opening machine 7 and located on one side of the transition component. The first positioning component includes a positioning tube 13, two or more positioning blocks 14, and two or more first pressing rollers 15. The two or more first pressing rollers 15 are arranged side by side in a vertical direction, and there is a gap between the first pressing rollers 15 that matches the heating wire. The positioning blocks 14 are respectively arranged on both sides of the first pressing rollers 15, and the positioning holes 16 provided on the positioning blocks 14 are coaxially arranged with the limiting holes 12, so as to ensure that after the heating wire passes through the transition component, it can accurately enter the positioning component through the positioning holes 16 of the positioning blocks 14, and be straightened again under the action of the first pressing rollers 15. In one embodiment, refer to Figure 4 A horn-shaped guide 18 is provided on the positioning block 14 near the transition component. One end of the guide 18 is aligned with the positioning hole 16, and the other end of the guide 18 is aligned with the limiting hole 12, so that the heating wire detected by the first inductive switch 17 can accurately enter the first positioning component through the guide 18.

[0036] like Figure 1 and 4 As shown, the positioning tube 13 is set on the positioning block 14 near the second positioning component and is coaxial with the positioning hole 16. The positioning tube 13 has a hollow structure, which facilitates the straightened heating wire to be accurately conveyed to the cutter along the positioning tube 13, avoiding bending of the heating wire and affecting the accurate cutting of the heating wire.

[0037] like Figure 1 and 4 As shown, the cutter is set inside the cutting box 19 on the wire opening machine 7 and located on one side of the positioning tube 13. In this embodiment, the cutter can be driven by a cylinder fixed inside the cutting box 19 and moved up and down along the axis perpendicular to the positioning tube 13 under the guidance of the guide rail inside the cutting box 19. The distance of the cutter's up and down movement is controlled by the extension and retraction of the cylinder. In this way, when the heating wire is delivered to the cutting position, the cutter can accurately cut the heating wire.

[0038] like Figure 1 and 4 As shown, a second positioning component is provided on one side of the cutter. The second positioning component includes two second pressure rollers 20. The two second pressure rollers 20 are arranged side by side in the vertical direction, and there is a gap between the second pressure rollers 20 that matches the heating wire. A feeding tray 21 is provided on one side of the second pressure rollers 20, so that before the second cutting, the heating wire of the cutting unit 8 can be straightened again by the second pressure rollers 20, so that the cutting unit 8 after the second cutting meets the requirement of not bending, and the heating wire formed after cutting is collected on the feeding tray 21.

[0039] like Figure 2As shown, the heating wire is cut by the wire cutter 7, which is equipped with a control module. The control module uses a driver chip from the prior art. The first induction switch 17, the second induction switch 22, the up-and-down movement of the cutter, and the external conveying equipment for conveying the heating wire are all connected to the control module. An automatic detection and cutting method for short-circuited copper wires in heating wires based on a wire-cutting machine, specifically including the following steps: S1. The first inductive switch 17 detects the conveyed heating wire. When the starting end 5 of the junction between a copper wire 3 and the heating wire 1 is detected, the first inductive switch 17 sends a signal to the control module and records the conveyed length of the heating wire.

[0040] S2. When the length of the heating wire changes from 0 to L3+L1 / n, the control module controls the external conveying equipment for the heating wire and stops the heating wire from being conveyed. Then, it controls the cutter to move in a direction perpendicular to the conveying direction of the heating wire and cut the heating wire, forming a first connecting segment with copper wire 3 attached and a length of (L1-L1 / n) at one end of the cutting unit 8 on the heating wire. In this embodiment, the heating wire has reached a straight state after passing through the transition component. Since the heating wire is composed of aramid yarn as the core 2, heating wire 1 spirally wound on the outside of the core 2, and copper wire 3 set between the heating wire 1 and the core 2, the heating wire itself has a certain degree of hardness. After the heating wire is cut, during the continued conveying process, it can avoid bending deformation between the positioning tube 13 and the second pressure wheel 20 due to its own gravity, which would hinder the conveying of the heating wire.

[0041] S3. The heating wire conveying length in step S1 is reset to zero. The control module controls the external conveying equipment for conveying the heating wire and makes the heating wire continue to be conveyed. When the second induction switch 22 detects the end 6 of the junction between a copper wire 3 and a heating wire 1 in the heating wire, the heating wire conveying length is recorded and the heating wire continues to be conveyed. When the second induction switch 22 located below the cutter detects the beginning 5 of the junction between another copper wire 3 and a heating wire 1 in the heating wire, the heating wire conveying length is recorded again. At this time, the heating wire conveying length is (L1 - L1 / n) + L2. In this embodiment, the second induction switch 22 is fixed at the bottom of the cutting box 19 and is offset from the cutter. That is, the movement of the cutter up and down does not affect the detection of the junction between the copper wire 3 and the heating wire 1 by the second induction switch 22.

[0042] S4. Continue feeding the heating wire. When the feeding length of the heating wire is recorded again as L1 / m, and the sum of the feeding length of the heating wire in step S3 (L1 - L1 / n) + L2 reaches the preset cutting unit 8 length L, that is... L = (L1 - L1 / n) + L2 + L1 / m, Stop feeding the heating wire and control the cutter to cut the heating wire, forming a second connecting section with copper wire 3 attached and a length of L1 / m at the other end of the cutting unit 8 on the heating wire; In this embodiment, for different lengths of connecting segments in different cutting units 8, n > m, n = m, or n < m are set, and the values ​​of n and m are both integers greater than 1. When n = m = 2, the length of the copper wire 3 of the first connecting segment in the cutting unit 8 after cutting is exactly half of the preset copper wire 3 length, and the lengths of the first connecting segments and the second connecting segments at both ends of the cutting unit 8 are equal, that is, the length of the first connecting segment (L1 - L1 / n) is equal to the length of the second connecting segment L1 / m. When the values ​​of n and m are different, that is, n ≠ m, then L gets different values, which can cut cutting units 8 of different lengths and make the lengths of connecting segments in different cutting units 8 different, thereby meeting the requirement that connecting segments of different lengths are connected to the plug terminals and then connected to different electrical appliances.

[0043] In another embodiment, when the values ​​of n and m are different and the length of each cut unit 8 after cutting is the same, the length of the first connecting segment (L1-L1 / n) in the cut unit 8 is greater than the length of the second connecting segment L1 / m or the length of the first connecting segment (L1-L1 / n) is less than the length of the second connecting segment L1 / m. This allows the length of the first connecting segment and the length of the second connecting segment in the cut unit 8 of the same length to be different, thereby meeting the different connection requirements of different length connecting segments and plug terminals to electrical appliances.

[0044] S5. Repeat steps S1 to S4 to cut the next cutting unit 8 on the heating line.

[0045] The working principle of this invention is as follows: Based on the preset length of the copper wire 3 on the heating wire, the spacing between the copper wires 3, and the spacing between the first induction switch 17 and the cutter, the conveying length of the heating wire on the wire cutting machine 7 is accurately determined with the cooperation of the first induction switch 17 and the second induction switch 22. Then, after cutting by the cutter, different length cutting units 8 are obtained, and the lengths of different connecting segments in the different length cutting units 8 are different, so as to meet the needs of connecting different length connecting segments with the plug terminals and then connecting to different electrical appliances. Alternatively, the lengths of different connecting segments in the same length cutting unit 8 may be the same or different, so as to meet the needs of connecting the same or different length connecting segments with the plug terminals and connecting to different positions of electrical appliances. This cutting efficiency is high, while reducing the error caused by manual cutting, and saving time and effort.

[0046] Example 2.

[0047] The difference between this embodiment and embodiment 1 is that in another embodiment, in step S4, when the values ​​of n and m are different and the length of each cut unit 8 after cutting is the same, the length of the first connecting segment (L1-L1 / n) in the cut unit 8 is greater than the length of the second connecting segment L1 / m or the length of the first connecting segment (L1-L1 / n) is less than the length of the second connecting segment L1 / m. This allows the length of the first connecting segment and the length of the second connecting segment in the cut unit 8 of the same length to be different, thereby meeting the different connection requirements of different length connecting segments and plug terminals to electrical appliances.

Claims

1. A method for automatically detecting and cutting short-circuited copper wires in a heating wire based on a wire-cutting machine, wherein the length of the copper wire in the heating wire to be cut is preset as L1, the spacing between different copper wires is preset as L2, the spacing between the first induction switch of the wire-cutting machine and the cutter is preset as L3, and the sum of L1 and L2 is greater than L3, and the heating wire is cut by the wire-cutting machine, characterized in that: Includes the following steps: S1. The first inductive switch detects the heating wire being transported. When the beginning of the junction between a copper wire and the heating wire is detected, the first inductive switch sends a signal to the control module and records the length of the heating wire being transported. S2. When the length of the heating wire changes from 0 to L3+L1 / n, the control module controls the heating wire to stop feeding and then controls the cutter to move in a direction perpendicular to the feeding of the heating wire and cut the heating wire, forming a first connecting segment with copper wire attached and a length of (L1-L1 / n) at one end of the cutting unit on the heating wire. S3. Set the heating wire conveying length in step S1 to zero, and control the heating wire to continue conveying. When the second induction switch located below the cutter detects the beginning of the junction between another copper wire and the heating wire, record the heating wire conveying length as (L1 - L1 / n) + L2. S4. Continue to feed the heating wire. When the heating wire feeding length is recorded again as L1 / m and the sum of the heating wire feeding length (L1 - L1 / n) + L2 in step S3 reaches the preset cutting unit length L, stop feeding the heating wire and control the cutter to cut the heating wire. A second connecting section with copper wire and a length of L1 / m is formed at the other end of the cutting unit on the heating wire. S5. Repeat steps S1 to S4 to cut the next cutting unit on the heating line.

2. The method for automatic detection and cutting of short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 1, characterized in that: The heating wire includes a heating wire, a core, and copper wire. The heating wire is spirally wound around the outside of the core. The copper wire has two or more sections and is positioned between the heating wire and the core. The copper wire is arranged in a circle around the core and is parallel to the core.

3. The method for automatically detecting and cutting short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 1, characterized in that: One end of the wire-opening machine is provided with a transition component, which includes a fixed plate and two or more transition wheels and limit blocks. The transition wheels are offset vertically along the width direction of the fixed plate. The limit blocks are respectively provided on both sides of the transition wheels. The limit blocks are provided with limit holes and the limit holes of the two limit blocks are coaxially arranged. The first inductive switch is provided on the limit block and located on one side of the transition wheel.

4. The method for automatic detection and cutting of short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 1, characterized in that: The opening machine is provided with a first positioning component on one side of the transition component. The first positioning component includes a positioning tube, two or more positioning blocks and a first pressing wheel. The first pressing wheels are arranged side by side in the vertical direction and there is a gap between the first pressing wheels that matches the heating wire. The positioning blocks are respectively arranged on both sides of the first pressing wheel and the positioning holes and limiting holes on the positioning blocks are coaxial.

5. The method for automatically detecting and cutting short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 4, characterized in that: The positioning tube is mounted on the positioning block and is coaxial with the positioning hole. The positioning tube has a hollow structure.

6. The method for automatic detection and cutting of short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 1, characterized in that: The cutter is mounted on the wire-opening machine and located on one side of the positioning tube. The cutter moves up and down along the axis perpendicular to the positioning tube.

7. The method for automatic detection and cutting of short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 1, characterized in that: The cutter is provided with a second positioning component on one side. The second positioning component includes two second pressure rollers. The two second pressure rollers are arranged side by side in the vertical direction, and there is a gap between the second pressure rollers that matches the heating wire. A feeding plate is provided on one side of the second pressure rollers.

8. The method for automatic detection and cutting of short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 1, characterized in that: In step S3, when the second inductive switch detects the end of the junction between a copper wire and the heating wire in the heating wire, the heating wire transmission length is (L1 - L1 / n).

9. The method for automatically detecting and cutting short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 1, characterized in that: In step S4, the formula for calculating the preset cutting unit length L is as follows: L = (L1 - L1 / n) + L2 + L1 / m, Furthermore, for different connection segment lengths in different cutting units, n > m, n = m, or n < m can be set.

10. The method for automatically detecting and cutting short-circuited copper wires in heating wires based on a wire-cutting machine according to claim 1, characterized in that: The length of the first connecting segment (L1 - L1 / n) is greater than the length of the second connecting segment L1 / m, or the length of the first connecting segment (L1 - L1 / n) is equal to the length of the second connecting segment L1 / m, or the length of the first connecting segment (L1 - L1 / n) is less than the length of the second connecting segment L1 / m.

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