Method for manufacturing a film-covered wire and production equipment therefor

Abstract

The application discloses a kind of preparation method of film-wrapped wire and production equipment thereof, it is related to wire coating technical field, the equipment includes wire feeder, film wrapping machine, take-up machine and control system, wire feeder is equipped with thread mechanism and tension adjusting mechanism, film wrapping machine is equipped with film winding mechanism and traction mechanism, take-up machine is equipped with wire storage tensioning mechanism, wire diameter testing device and high voltage testing device, tension adjusting mechanism uses fixed tension wheel, adjustable tension wheel cooperates the mechanical and pneumatic hybrid structure of weight and cylinder, realizes sensorless precision tension control;Film wrapping machine is installed with refrigeration device, take-up machine top is equipped with baking heating box, cooperate heat recovery device, and the waste heat of baking is recovered and supplied to film wrapping machine after adjustment, to store the temperature of constant temperature control insulating tape;Detection station and each action mechanism integrated control realize instant feedback;The application solves the problems that existing technology tension depends on sensor, insulating tape is not effectively constant temperature controlled, energy consumption is high, detection and each action mechanism in production are disjointed, realizes the synergistic effect of energy saving and consumption reduction and quality improvement.

Description

Technical Field

[0001] This invention relates to the field of production equipment technology, specifically to a method for preparing a membrane-coated wire and its production equipment. Background Technology

[0002] Film-coated wire involves wrapping an insulating tape layer around the surface of wire (especially flat wire) to increase its insulation performance and improve its high-temperature resistance. Existing film-coating production equipment has seen some development. For example, Chinese invention patent CN102157248A discloses a multi-head active film-coating machine that uses a motor to control the film tension. The unwinding speed is adjusted through feedback from the unwinding motor and tension swing arm device, ensuring stable film tension during operation. Furthermore, Chinese utility model patent CN216610079U discloses a film-coating machine with waste heat recovery function, which discharges and recovers heat by setting a heat-absorbing box and air duct at the discharge port.

[0003] However, the aforementioned existing technologies still have significant drawbacks when applied to continuous film-coating production lines. Firstly, CN102157248A uses a motor feedback control system to adjust tension. While this allows for dynamic control, its tension adjustment relies on sensor feedback signals and complex control algorithms. If the sensor fails or there is signal interference, the tension of the entire line becomes uncontrollable. Furthermore, this type of electrically controlled tension solution lacks the ability to precisely compensate for fluctuations in the original line's feed tension, making it difficult to accommodate the differentiated tension requirements of different wire specifications. Secondly, although CN216610079U incorporates a heat recovery structure, heat is only discharged and recovered from the outlet. The hot airflow is directly recovered without temperature control, easily carrying dust and impurities back into the film-coating area, affecting film quality. Moreover, it cannot achieve precise control of the internal temperature of the film-coating machine. Third, existing film-coated wire production equipment generally controls the wire feeding mechanism, coating mechanism, wire diameter detection, high-voltage testing, and take-up mechanism in separate segments. The lack of coordinated control between the detection and other mechanisms leads to significant feedback delays, resulting in excessive losses of defective products during production. Furthermore, it prevents real-time monitoring of finished product quality and timely adjustment of process parameters during continuous production. In addition, existing equipment lacks effective temperature control of the tape during the transfer between the original wire and the tape, resulting in insufficient tape adhesion and insulation performance. Equipment with baking functions lacks heat recovery and utilization, leading to significant heat loss and high energy consumption, preventing the effective recycling of heat within the production system.

[0004] To address the aforementioned shortcomings, this solution provides a production equipment and preparation method for film-coated wires, thereby solving technical problems in the prior art such as insufficient tension adjustment accuracy, lack of linkage control between detection and various action mechanisms, disconnect between detection and parameter adjustment, lack of effective temperature control of insulating tape during wire transfer and material change, and low heat recovery efficiency. Summary of the Invention

[0005] This invention provides a method for preparing membrane-coated wire and its production equipment, which includes a mechanical and pneumatic hybrid tension adjustment mechanism, a refrigeration device, a heat energy recycling system, and an online detection device. Sensorless precision tension control is achieved through the coordinated use of weights and cylinders. The refrigeration device recovers and supplies waste heat from baking to the membrane coating machine after temperature control, maintaining a constant temperature of 20-30°C within the working chamber of the membrane coating machine in different seasons. Real-time feedback is achieved through linkage control between detection and various action mechanisms. This invention solves the problems of tension dependence on sensors, lack of effective temperature control of insulating tape during wire transfer and material change, high energy consumption due to heat loss, and disconnect between detection and parameter adjustment.

[0006] This invention provides the following technical solution: a production equipment for film-coated wire, comprising a wire feeder, a film wrapping machine, a wire take-up machine, and a control system. The wire feeder and the wire take-up machine are arranged on both sides of the film wrapping machine. The wire feeder is equipped with a wire feeding mechanism and a tension adjustment mechanism. The lower part of the film wrapping machine is equipped with a film wrapping conductor mechanism. The inside of the film wrapping machine is equipped with a film winding mechanism. The top of the film wrapping machine is equipped with a traction mechanism. The upper end of the wire take-up machine is equipped with a wire take-up conductor mechanism. The front side of the wire take-up machine is equipped with a wire storage and tensioning mechanism. The center of the front of the wire take-up machine is equipped with a wire diameter testing device, a high voltage testing device, and a wire gathering mechanism. The control system is used to control the coordinated operation of each mechanism and device. The original wire is wound on the upper winding mechanism. The original wire is wound from the upper winding mechanism to the tension adjustment mechanism, then to the film wrapping conductor mechanism of the film wrapping machine, and then to the film wrapping mechanism. The film wrapping mechanism performs a film wrapping operation on the surface of the original wire to form a film-wrapped wire. The film-wrapped wire is wound from the film wrapping mechanism to the traction mechanism, then through the take-up conductor mechanism, and then to the wire storage tensioning mechanism. It then passes through the wire diameter testing device and the high voltage testing device in sequence, and is finally wound up by the wire gathering mechanism.

[0007] Preferably, the wire feeding mechanism includes a wire feeding wheel and a wire feeding motor. The wire feeding motor is disposed inside the wire feeding box, and the wire feeding wheel is disposed on the lower front of the wire feeding box and connected to the output end of the wire feeding motor, and is driven to rotate by the wire feeding motor. The tension adjustment mechanism includes a fixed tension wheel and an adjustable tension wheel. The fixed tension wheel is fixed on the wire feeding box. The adjustable tension wheel is located directly below the fixed tension wheel and is installed at one end of the adjustment rod. The middle part of the adjustment rod is rotatably installed on the adjustment seat, which is fixed on the wire feeding box. A scale is provided on the other side of the adjustment rod away from the adjustable tension wheel. A weight is movably mounted on the adjustment rod and is mounted on one side of the scale. An adjustment screw is provided on the weight. The tension adjustment mechanism also includes a tension adjustment cylinder, which is fixed on the wire feeding box, and its output end is fixed on the adjustment rod and between the adjustment seat and the adjustable tension wheel. The upper end of the wire feeding box is provided with a first wire feeding guide wheel, and the side of the wire feeding box near the film wrapping machine is provided with a second wire feeding guide wheel. The second wire feeding guide wheel is located between the fixed tension wheel and the adjustable tension wheel.

[0008] Preferably, the membrane-wrapped conductor mechanism includes at least one membrane-wrapped conductor wheel, which is fixed to the lower part of the membrane-wrapped housing; The film wrapping mechanism includes a film storage frame and a film wrapping frame. The film storage frame is fixed inside the film wrapping box, and the film wrapping frame is located outside the film storage frame and is driven by the film wrapping motor through a transmission mechanism. The traction mechanism includes a traction wheel and a traction guide wheel, which are arranged and installed on a traction seat. The traction seat is fixed to the top of the membrane box. The traction wheel is driven by a traction motor, which is located on the back of the traction seat. A wheel limiting plate is also provided on the top of the traction wheel. The wheel limiting plate is rotatably installed on the traction seat and driven by a wheel limiting cylinder, which is fixed to the back of the traction seat.

[0009] Preferably, the take-up wire mechanism includes a take-up wire wheel one and a take-up wire wheel two, both of which are mounted on a wire wheel seat. The wire wheel seat is fixed to the top of the take-up box, and the take-up wire wheel one and the take-up wire wheel two are arranged on the top of the take-up box. The wire storage tensioning mechanism includes a fixed wire storage wheel and an adjustable wire storage wheel arranged vertically. The fixed wire storage wheel is fixedly installed on the front side of the take-up box, and the adjustable wire storage wheel is slidably installed on the front side of the take-up box and is driven to move up and down by the moving module. The cable gathering mechanism includes a take-up reel and a take-up motor. The take-up motor is fixed inside the take-up box, and its output end is connected to the take-up reel and can drive the take-up reel. The take-up reel is rotatably mounted on the front of the take-up box.

[0010] Preferably, the front of the take-up box is further provided with take-up guide rollers three, four, five, six, and seven, a first set of limiting wheels, and a second set of limiting wheels. Take-up guide roller three is disposed between the wire diameter testing device and the wire storage tensioning mechanism. Take-up guide roller four is disposed between the wire diameter testing device and the high voltage testing device. Take-up guide roller five is disposed on the other side of the high voltage testing device. The first set of limiting wheels and the second set of limiting wheels are arranged on the side of take-up guide roller five away from the high voltage testing device. Take-up guide roller six is ​​disposed on the outside of the second set of limiting wheels. Take-up guide roller seven is mounted on one end of the guide roller adjusting rod, and the other end of the guide roller adjusting rod is mounted on take-up guide roller six, so that the distance of take-up guide roller seven is adjustable.

[0011] Preferably, the film wrapping production equipment further includes a refrigeration device with a temperature setting range of -40℃ to 20℃. The refrigeration device is located on the side of the film wrapping machine and is connected to the interior of the machine via an air duct to regulate the internal temperature. When the film wrapping machine is operating, the high-speed rotation of the wrapping mechanism generates high temperatures of 60℃ to 80℃ through friction with the air. The refrigeration device outputs cold air through the air duct, maintaining the internal temperature of the film wrapping machine between 20℃ and 30℃.

[0012] Preferably, the top of the take-up machine is also provided with a baking and heating box, which is installed on the front and rear moving mechanism, and a heating wire groove is provided in the middle of the baking and heating box.

[0013] Preferably, the film wrapping machine further includes a heat energy recycling system, which includes a heat recovery device, a heat energy inlet pipe, and a heat energy outlet pipe. The heat recovery device is installed on the back of the film wrapping machine. One end of the heat energy inlet pipe is connected to the baking heating chamber, and the other end is connected to the heat recovery device. One end of the heat energy outlet pipe is connected to the heat recovery device, and the other end is connected to the interior of the film wrapping machine. During the operation of the baking heating chamber, when the internal temperature of the film wrapping machine is lower than 10°C, the heat energy recycling system operates, outputting a temperature of 15°C to 50°C to the interior of the film wrapping machine, so that the internal temperature of the film wrapping machine is maintained between 20°C and 30°C.

[0014] Preferably, the control system includes a main control device, an alarm light group, a control button group, and an indicator light group; The alarm light group includes a wire feeding alarm light, a film wrapping alarm light, and a wire take-up alarm light; The control button group includes a wire feeding button, a film wrapping button, and a wire take-up button; The indicator light group includes a wire feeding indicator light, a film wrapping indicator light, and a wire take-up indicator light.

[0015] A method for preparing a membrane-covered wire, comprising the membrane-covered wire production equipment described in any one of the above claims, and further comprising the following steps: S1. First, the operator loads the original wire onto the feed roller of the upper wire mechanism, pulls out the wire end, passes through the first feed roller, and winds it around the tension adjustment mechanism. After winding it multiple times between the fixed tension roller and the adjustable tension roller of the tension adjustment mechanism, it is pulled out from the fixed tension roller, passes through the second feed roller, and winds around to the bottom surface of the membrane wrapping roller of the membrane wrapping mechanism. Then, it is pulled vertically upward from the side of the membrane wrapping roller, and then passes through the wrapping mechanism. The wrapping mechanism wraps the surface of the original wire with insulating tape to form a membrane-wrapped wire. After passing through the membrane wrapping machine, the membrane-wrapped wire winds around the traction roller and the guide roller in sequence, and then... After being wound multiple times between the traction guide wheel and the guide wheel, the wire is pulled out from the guide wheel and wound onto the take-up guide wheel one and the take-up guide wheel two. Then it is wound onto the wire storage tensioning mechanism and wound multiple times between the fixed wire storage wheel and the adjustable wire storage wheel of the wire storage tensioning mechanism. After being pulled out from the fixed wire storage wheel, it is wound onto the bottom surface of the take-up guide wheel three, passes through the wire diameter testing device, and then wound onto the upper side of the take-up guide wheel four. After passing through the high voltage testing device, it is wound onto the top of the take-up guide wheel five, and then passes through the limit wheel group one and the limit wheel group two in sequence. Then it is wound onto the take-up guide wheel six and the take-up guide wheel seven in sequence. Finally, the wire collection mechanism completes the take-up. S2. After winding is completed, the entire line of equipment is started. The original wire is sent out by the winding mechanism, stretched and conveyed to the film wrapping machine by the tension adjustment mechanism, and then the film wrapping machine performs the film wrapping operation. After the original wire is wrapped by the film wrapping machine, it becomes a film-wrapped wire. Then, the traction mechanism leads it to the wire storage and tensioning mechanism for stretching and storage. If the film-wrapped wire needs to be heated, it is heated by the baking heating box during the traction process. After heating, it is pulled to the wire storage and tensioning mechanism for stretching and storage. After being stretched and stored by the wire storage and tensioning mechanism, the film-wrapped wire is pulled by the wire take-up mechanism and passes through the wire diameter testing device and the high voltage testing device for relevant performance and parameter tests. Finally, the wire collection mechanism collects the wire into bundles. S3. During the wrapping process, when the wrapping mechanism starts working, the high-speed rotation of the wrapping mechanism generates high temperatures of 60℃~80℃ due to friction with the air, causing the internal temperature of the wrapping machine to exceed 30℃. The cooling device then starts working, delivering cold air to the inside of the wrapping machine for cooling, so that the internal temperature of the wrapping machine is maintained between 20℃~30℃. During the operation of the baking heating chamber, when the internal temperature of the wrapping machine is below 10℃, the heat generated by the baking heating chamber during operation is collected by the heat recovery device through the heat energy inlet pipe and the temperature is regulated, outputting a temperature of 15℃~50℃. Then, it is delivered to the inside of the wrapping machine through the heat energy outlet pipe, so that the internal temperature of the wrapping machine is maintained between 20℃~30℃.

[0016] S4. If the original line becomes loose during equipment operation, the operator can loosen the adjusting screw to allow the weight to move left and right on the adjusting rod. Moving the weight to the left will cause the end of the adjusting rod with the adjustable tension wheel to sink downwards, thus moving the adjustable tension wheel downwards. This will increase the distance between the adjustable tension wheel and the fixed tension wheel, thereby tightening the original line.

[0017] The present invention has the following beneficial effects: 1. The production equipment for film-coated yarn of the present invention is equipped with a mechanical tension adjustment mechanism consisting of a fixed tension wheel, an adjustable tension wheel, an adjustment rod, a scale, weights, and an adjustment screw, and is also equipped with a tension adjustment cylinder. By moving the position of the weights on the scale, the descent amplitude of the adjustable tension wheel is changed, thereby achieving continuous and precise adjustment of the original yarn tension. In addition, dynamic compensation is performed by the cylinder, so that the tension adjustment does not rely on sensor electrical signals and complex algorithms at all. Even under the condition of sensor failure or signal interference, it can still maintain stability. This further realizes a hybrid mechanical and pneumatic tension control, which significantly improves the adjustment response speed compared to pure mechanical adjustment, and requires no programming or debugging, greatly reducing the equipment failure rate and maintenance difficulty. 2. The film-wrapping production equipment of the present invention includes a refrigeration device installed on the side of the film-wrapping machine, which is connected to the inside of the film-wrapping machine through an air guide pipe. When the film-wrapping mechanism starts working, the high-speed rotation of the film-wrapping mechanism generates high temperatures of 60°C to 80°C due to friction with the air, causing the temperature inside the film-wrapping machine to exceed 30°C. The refrigeration device then activates, delivering cold air to the inside of the film-wrapping machine for cooling, maintaining the internal temperature between 20°C and 30°C. A baking heating box is installed on the top of the take-up machine, and a heat energy recycling system is installed on the back of the film-wrapping machine. The heat lost from the baking heating box is collected to the heat recovery device through a heat energy inlet pipe, and then distributed into the inside of the film-wrapping machine through a heat energy outlet pipe. During the operation of the baking heating box, when... When the internal temperature of the film wrapping machine is below 10℃, the heat generated by the baking heating box during operation is collected and regulated by the heat recovery device through the heat energy inlet pipe, outputting a temperature of 15℃~50℃. Then, it is transported to the inside of the film wrapping machine through the heat energy outlet pipe, keeping the temperature of the insulating tape on the wrapping mechanism between 20℃~30℃. This solves the problem in the existing technology where the large temperature difference causes changes in the stickiness of the insulating tape, resulting in poor film removal and pulling, wrinkles after wrapping, and gaps between the insulating tape and the original wire, leading to high voltage breakdown. It also isolates the problem of dust and impurities carried in the air affecting the film wrapping quality, thus realizing a three-in-one energy closed loop of "baking and shaping - waste heat recovery - constant temperature wrapping". 3. The production equipment for film-coated wire of this invention has a wire diameter testing device and a high-voltage testing device directly installed in the center of the front of the take-up machine, and the film-coated wire passes through these two testing devices sequentially before entering the winding mechanism. By integrating the testing station with the operation and control of each action mechanism, online real-time monitoring of wire diameter and high-voltage insulation performance is achieved. The test signals can be immediately fed back to the control system to adjust the original wire conveying speed and coating parameters. This solves the problem of delayed detection feedback and inability to adjust process parameters in a timely manner caused by the separation of testing from the control of each action mechanism in existing equipment. 4. The film-coated yarn production equipment of the present invention includes a mechanical pre-tension adjustment structure consisting of a fixed tension wheel, an adjustable tension wheel, an adjusting rod, and weights, located between the yarn feeder and the film coating machine. Simultaneously, a yarn storage tensioning mechanism consisting of a fixed and adjustable yarn storage wheel is located on the side of the take-up machine, and a traction mechanism is installed after film coating. Through the synergistic effect of the front-end mechanical pre-tension and the rear-end yarn storage tension, the original yarn maintains a constant vertical tension throughout the film coating process, and the weight position can be manually and quickly adjusted to accommodate different yarn diameters. This solves the problems of wrinkling and uneven film thickness caused by tension fluctuations in traditional equipment. 5. The production equipment for film-coated yarn of the present invention has a wheel limiting plate set above the traction wheel and driven by a wheel limiting cylinder, and an adjustable distance guide wheel adjusting rod and a take-up guide wheel seven set at the take-up guide wheel six; the wheel limiting cylinder presses the traction wheel to prevent the film-coated yarn from slipping, and the take-up tension of the last stroke is finely adjusted by adjusting the position of the take-up guide wheel seven to ensure that the take-up arrangement is neat and tight, thus solving the problem of chaotic arrangement and loose yarn rolls caused by traction slippage or sudden changes in take-up tension. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the film-coated wire production equipment of the present invention; Figure 2 This is a schematic diagram of the tension adjustment mechanism of the film-coated yarn production equipment of the present invention; Figure 3 This is a schematic diagram of the internal structure of the film-coating machine in the production equipment for film-coating yarn of the present invention; Figure 4 This is a schematic diagram of the traction mechanism structure of the film-coated wire production equipment of the present invention; Figure 5 This is a schematic diagram of the rear view of the production equipment for the film-coated wire of the present invention; Figure 6 This is a schematic diagram of the wire storage and tensioning mechanism of the film-coated wire production equipment of the present invention; Figure 7 This is a schematic diagram of the take-up conductor mechanism of the film-coated wire production equipment of the present invention; In the diagram: 1. Wire feeder; 101. Wire feed box; 102. Wire feed guide roller one; 103. Wire feed guide roller two; 2. Film wrapping machine; 201. Film wrapping box; 3. Wire take-up machine; 301. Wire take-up box; 11. Wire feeding mechanism; 111. Wire feed roller; 12. Tension adjustment mechanism; 121. Fixed tension roller; 122. Adjustable tension roller; 123. Adjusting rod; 124. Weight; 125. Adjusting screw; 126. Tension adjustment cylinder; 127. 21. Adjusting seat; 22. Film wrapping guide mechanism; 221. Film wrapping guide wheel; 222. Film winding mechanism; 223. Film storage rack; 224. Film wrapping rack; 225. Film wrapping motor; 236. Traction mechanism; 237. Traction wheel; 238. Traction guide wheel; 239. Traction seat; 230. Traction motor; 231. Wheel limiting plate; 232. Wheel limiting cylinder; 331. Take-up guide mechanism; 34. Guide wheel adjusting rod; 35. Take-up guide wheel one; 36. Take-up guide wheel... 313. Take-up guide roller 3; 314. Take-up guide roller 4; 315. Take-up guide roller 5; 316. Take-up guide roller 6; 317. Take-up guide roller 7; 318. Limiting roller group 1; 319. Limiting roller group 2; 32. Wire storage tensioning mechanism; 321. Fixed wire storage roller; 322. Adjustable wire storage roller; 33. Wire gathering mechanism; 331. Take-up roller; 4. Wire diameter testing device; 5. High voltage testing device; 6. Refrigeration device; 7. Baking and heating oven; 8. 801. Heat recovery system; 802. Heat inlet pipe; 803. Heat outlet pipe; 9. Control system; 901. Feed alarm light; 902. Membrane wrapping alarm light; 903. Take-up alarm light; 904. Feed button; 905. Membrane wrapping button; 906. Take-up button; 907. Feed indicator light; 908. Membrane wrapping indicator light; 909. Take-up indicator light; 910. Main control device; A0. Main line; A1. Membrane wrapping line. Detailed Implementation

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

[0020] like Figure 1As shown, a film-coated wire production equipment includes a wire feeder 1, a film wrapping machine 2, a wire take-up machine 3, and a control system 9. The wire feeder 1 and the wire take-up machine 3 are respectively arranged on the left and right sides of the film wrapping machine 2, forming a linear assembly line layout. The wire feeder 1 is equipped with a wire feeding mechanism 11 and a tension adjusting mechanism 12, used to feed the original wire A0 with constant tension. The lower part of the film wrapping machine 2 is equipped with a film wrapping conductor mechanism 21, the interior of the film wrapping machine 2 is equipped with a film winding mechanism 22, and the top of the film wrapping machine 2 is equipped with a traction mechanism 23. The upper end of the wire take-up machine 3 is equipped with a wire take-up conductor mechanism 31, the front side of the wire take-up machine 3 is equipped with a wire storage and tensioning mechanism 32, and the front center of the wire take-up machine 3 is equipped with a wire diameter testing device 4, a high voltage testing device 5, and a wire gathering mechanism 33. The control system 9 is electrically connected to each electrical component of the wire feeder 1, the film wrapping machine 2, and the wire take-up machine 3 via signal cables, used to control the coordinated operation of each mechanism. In this embodiment, the specific routing path of the original wire A0 is as follows: After exiting the upper winding mechanism 11, the original wire A0 enters the tension adjustment mechanism 12. After the tension is adjusted by the tension adjustment mechanism 12, it winds around to the film wrapping guide mechanism 21 of the film wrapping machine 2. The film wrapping guide mechanism 21 guides the original wire A0 upward into the wrapping mechanism 22. The wrapping mechanism 22 performs a film wrapping operation on the surface of the original wire A0 to form a film-wrapped wire A1. The film-wrapped wire A1 winds upward from the wrapping mechanism 22 to the traction mechanism 23. The traction mechanism 23 provides traction power to pull the film-wrapped wire A1 out of the film wrapping machine 2. Then, it passes through the take-up guide mechanism 31 and enters the wire storage and tensioning mechanism 32 for wire storage and tension buffering. Then, it passes through the wire diameter testing device 4 and the high voltage testing device 5 for online quality testing. Finally, it is wound into a finished wire coil by the wire gathering mechanism 33.

[0021] like Figure 1 As shown, the wire feeding machine 1 includes a wire feeding housing 101, which is a hollow metal cabinet structure. The interior is used to install electrical and power components, while the front is used to install various functional wheels. The wire feeding mechanism 11 includes a wire feeding wheel 111 and a wire feeding motor. The wire feeding motor is a servo motor, fixedly installed inside the lower side of the wire feeding housing 101, with its output shaft extending horizontally forward from the front of the housing. The wire feeding wheel 111 is rotatably mounted on the lower front of the wire feeding housing 101 and connected to the output end of the wire feeding motor via a coupling, allowing the motor to drive the wheel 111 to rotate. The original wire A0 is coiled and mounted on the wire feeding wheel 111. When the wire feeding motor rotates, it drives the wheel 111 to rotate, thereby continuously feeding out the original wire A0. The rotational speed of the wire feeding motor is synchronously controlled by the control system 9 based on the overall line operating speed.

[0022] like Figure 1 and Figure 2 As shown, the tension adjustment mechanism 12 is located in the central area of ​​the front of the wire feeding box 101, and is used to apply adjustable tension to the original wire A0 fed by the wire feeding wheel 111. The tension adjustment mechanism 12 specifically includes a fixed tension wheel 121, an adjustable tension wheel 122, an adjusting rod 123, an adjusting seat 127, a scale, a weight 124, an adjusting screw 125, and a tension adjusting cylinder 126. The fixed tension wheel 121 is fixed to the front of the wire feeding box 101 near the film wrapping machine 2 via an axle. The adjustable tension wheel 122 is located directly below the fixed tension wheel 121 and is mounted on the left end of the adjusting rod 123, i.e., near the fixed tension wheel 121, via an axle. The adjusting rod 123 is a long strip of metal, with its central portion rotatably mounted on the adjusting seat 127 via a pin. The adjusting seat 127 is fixedly mounted on the front of the wire feeding box 101. The left end of the adjusting rod 123, i.e., the end furthest from the adjustable tension wheel 122, extends to the left, and its upper surface is provided with the scale. The weight 124 is ring-shaped and movably fitted onto the left end of the adjusting rod 123, located above the scale. The weight 124 can slide left and right along the adjusting rod 123. The weight 124 is also provided with the adjusting screw 125, which passes vertically through the weight 124 and whose lower end can abut against the upper surface of the adjusting rod 123, for locking the weight 124 at any position on the adjusting rod 123. The cylinder body of the tension adjusting cylinder 126 is fixedly installed on the front of the wire feeding box 101, and the output end of its piston rod is fixed on the adjusting rod 123, specifically connected between the adjusting seat 127 and the adjustable tension wheel 122. The tension regulating cylinder 126 is connected to an external air source via an air pipe, and its air pressure is controlled by the control system 9. The air pressure is controlled at 0.2~0.4MPa, thereby applying a downward auxiliary regulating force to the regulating rod 123.

[0023] The working principle of the tension adjustment mechanism 12 is as follows: When the original line A0 successively passes over the lower edge of the fixed tension wheel 121 and the adjustable tension wheel 122 and winds around them multiple times, preferably 3 to 5 times, the tension of the original line A0 will generate an upward pulling force on the adjustable tension wheel 122. The upward pulling force on the adjustable tension wheel 122 will be transmitted to the weight 124 at the right end through the lever action of the adjusting rod 123. The weight 124 generates a downward torque through the lever action of the adjusting rod 123, which is used to balance the upward torque generated by the tension of the original line A0. When it is necessary to increase the tension of the original wire A0, the operator loosens the adjusting screw 125 and moves the weight 124 to the left along the scale. At this time, the torque of the weight 124 on the right end of the adjusting rod 123 increases, and the adjusting rod 123 rotates clockwise around the adjusting seat 127. The adjustable tension wheel 122 at the left end moves downward, increasing the vertical distance between the adjustable tension wheel 122 and the fixed tension wheel 121, thereby increasing the tension on the original wire A0. Conversely, moving the weight 124 to the left decreases the tension. The scale allows the operator to accurately record the position of the weight 124 corresponding to different specifications of original wire A0, facilitating reset when quickly switching specifications. At the same time, the tension adjusting cylinder 126 outputs adjustable air pressure according to the instructions of the control system 9, applying a downward auxiliary torque to the adjusting rod 123 to dynamically compensate for tension fluctuations caused by changes in the coil diameter during high-speed operation of the original wire A0. This hybrid tension control method, which combines mechanical main adjustment with pneumatic auxiliary compensation, does not rely on tension sensors or complex feedback control algorithms at all. It can maintain tension stability even under conditions of sensor failure or signal interference, and its response speed is faster than that of pure mechanical adjustment.

[0024] like Figure 1 and Figure 2 As shown, the upper end of the wire feeding box 101 is provided with a first wire feeding guide wheel 102, and the left side of the wire feeding box 101 near the film wrapping machine 2 is provided with a second wire feeding guide wheel 103. The second wire feeding guide wheel 103 is positioned at a height between the fixed tension wheel 121 and the adjustable tension wheel 122. After the original wire A0 is pulled out from the wire feeding wheel 111, it first passes upward around the top of the first wire feeding guide wheel 102, and then enters the tension adjustment mechanism 12 downward. It winds around the fixed tension wheel 121 and the adjustable tension wheel 122 multiple times, preferably 3 to 5 times, to ensure sufficient friction. Then it is pulled out from the fixed tension wheel 121, and horizontally passes to the right around the second wire feeding guide wheel 103 before entering the film wrapping machine 2.

[0025] like Figure 1 and Figure 3As shown, the film wrapping machine 2 includes a film wrapping box 201, which is a hollow, sealed cabinet structure with a film wrapping operation area inside. The film wrapping guide mechanism 21 is located in the lower part of the film wrapping box 201 and includes at least one film wrapping guide wheel 211. The film wrapping guide wheel 211 is fixed to the lower cavity of the film wrapping box 201 by an axle, and a gap is left between its wheel surface and the bottom of the film wrapping box 201 for the primary wire A0 to pass through. After the primary wire A0 enters the film wrapping box 201 from the guide wheel 103, it passes around the bottom surface of the film wrapping guide wheel 211 and then is vertically pulled upwards along the side of the guide wheel 211 into the wrapping mechanism 22.

[0026] like Figure 1 and Figure 3 As shown, the film wrapping mechanism 22 is located in the central area inside the film packaging box 201, including a film storage rack 221 and a film wrapping rack 222. The film storage rack 221 is fixedly installed inside the film packaging box 201, and an insulating tape set is installed on it, preferably 10 to 15 rolls of insulating tape. The width of the insulating tape ranges from 3mm to 20mm, and it is used for storage and supply. The tension setting of the film wrapping mechanism 22 is based on the torque of the tension wheel control motor, which is 7.16 N∙m. The setting parameter is based on the percentage of torque. When the insulating tape is full, the tension setting is 10% to 80%. As the insulating tape is gradually wrapped and the amount on the tape roll decreases, the tension setting is 5% to 60%. When the amount of insulating tape is less than 5% or 0% of the amount on the roll, the tension setting is 5%. The tension parameter adjustment is output by the command of the control system 9. The film wrapping rack 222 is located outside the film storage rack 221. The film wrapping rack 222 has a central hole for the original wire A0 to pass through and a rotating frame on which a film wrapping turntable is installed. The coating frame 222 is driven to rotate by the coating motor 223 through a transmission mechanism, which is either a synchronous belt drive or a gear drive. The coating motor 223 is fixedly installed inside the coating housing 201, and its output end is connected to the rotating shaft of the coating frame 222 via a synchronous belt. When the coating frame 222 rotates, the insulating tape on the film storage rack 221 is pulled out and evenly wrapped around the surface of the original line A0 that vertically passes through the central hole of the coating frame 222, forming the film-wrapped line A1. The wrapping overlap rate is preferably 40-70%, and the film thickness is 0.04-0.07 mm on each side.

[0027] like Figure 1 , Figure 3 and Figure 4As shown, the traction mechanism 23 is located on the top of the membrane housing 201 and includes a traction wheel 231, a traction guide wheel 232, a traction seat 233, a traction motor 234, a wheel limiting plate 235, and a wheel limiting cylinder 236. The traction seat 233 is fixedly installed on the top of the membrane housing 201. The traction wheel 231 and the traction guide wheel 232 are arranged on the traction seat 233, with their wheel surfaces horizontally arranged and parallel to each other. The traction motor 234 is fixedly installed on the back of the traction seat 233, and its output end is connected to the wheel axle of the traction wheel 231 to drive the traction wheel 231 to rotate actively. The traction guide wheel 232 is a driven wheel and is rotatably installed on the traction seat 233. The wheel limiting plate 235 is an arc-shaped plate structure, with one end rotatably installed on the traction seat 233 and the other end being a free end. The arc-shaped inner wall of the wheel limiting plate 235 is opposite to the outer edge of the traction wheel 231. The wheel-limiting cylinder 236 is fixedly installed on the back of the traction seat 233, and the output end of its piston rod is connected to the movable end of the wheel-limiting plate 235. The film-wrapped wire A1 extends upwards after passing through the wrapping mechanism 22, first winding around the upper edge of the traction wheel 231, then wrapping multiple times between the traction wheel 231 and the traction guide wheel 232. In this embodiment, it is preferable to wrap 2-4 times to increase the contact area, and finally pulls out from the traction guide wheel 232. When the traction motor 234 starts, it drives the traction wheel 231 to rotate actively. The parameters of the traction motor 234 are adjusted by the command output of the control system 9, which, in conjunction with the traction guide wheel 232, applies traction force to the film-wrapped wire A1, continuously pulling the film-wrapped wire A1 out of the wrapping mechanism 22. Under the control of the control system 9, the limiting cylinder 236 pushes the limiting plate 235 against the surface of the traction wheel 231, and controls the air pressure range to 0.2~0.4MPa, so that the film-coated wire A1 is clamped between the limiting plate 235 and the traction wheel 231, preventing the film-coated wire A1 from slipping during traction and ensuring that the traction speed and the wire feeding speed are kept synchronized.

[0028] like Figure 1 As shown, the take-up machine 3 includes a take-up box 301, which is a hollow metal cabinet structure. The take-up guide mechanism 31 is located on the top of the take-up box 301 and includes a take-up guide wheel 311 and a take-up guide wheel 312. Both the take-up guide wheel 311 and the take-up guide wheel 312 are mounted on a guide wheel seat via axles. The guide wheel seat is fixedly mounted on the top of the take-up box 301. The take-up guide wheel 311 and the take-up guide wheel 312 are arranged in a front-to-back direction. After the film-coated wire A1 is pulled out from the guide wheel 232, it passes around the upper edges of the take-up guide wheel 311 and the take-up guide wheel 312 in sequence, and then enters the wire storage tensioning mechanism 32 downwards.

[0029] like Figure 1 and Figure 6 As shown, the cable tensioning mechanism 32 is located on the front side of the take-up box 301. The cable tensioning mechanism 32 includes a fixed cable storage wheel 321 and an adjustable cable storage wheel 322 arranged vertically. The fixed cable storage wheel 321 is fixedly installed on the front side of the take-up box 301, and the adjustable cable storage wheel 322 is slidably installed on the front side of the take-up box 301 and is driven to move up and down by a moving module. The fixed cable storage wheel 321 is fixedly installed on the upper part of the front side of the take-up box 301 via a wheel axle, and the adjustable cable storage wheel 322 is slidably engaged with the sliding side of the front side of the take-up box 301 via a wheel axle. In this embodiment, a servo motor-driven moving module is used within the slot. The moving module is vertically fixed inside the take-up box 301, and the axle of the adjustable wire storage wheel 322 is fixed to the moving base of the moving module via a fixing plate. The servo motor drives the moving base to move up and down, which in turn drives the adjustable wire storage wheel 322 to move up and down. The up-and-down movement of the adjustable wire storage wheel 322, driven by the moving module, controls the wire storage tension. When the adjustable wire storage wheel 322 moves downward, the vertical distance between it and the fixed wire storage wheel 321 is increased, thereby increasing the tension on the film-coated wire A1. Conversely, moving the adjustable wire storage wheel 322 upward reduces the tension. The tension parameter adjustment is controlled by commands from the control system 9. The film-coated wire A1 is wound multiple times between the fixed wire storage wheel 321 and the adjustable wire storage wheel 322, preferably 4-6 times, serving a dual purpose of wire storage and tension buffering.

[0030] like Figure 1 As shown, both the wire diameter testing device 4 and the high voltage testing device 5 are fixedly installed in the center of the front of the take-up box 301. The wire diameter testing device 4 uses a laser diameter gauge or an optical projection diameter gauge, with its measuring optical path perpendicular to the traveling direction of the membrane-coated wire A1. It is used to measure the outer diameter of the membrane-coated wire A1 in real time. When the outer diameter exceeds a set threshold, an alarm signal is triggered and transmitted to the control system 9. The high voltage testing device 5 includes a high voltage generator and a detection electrode. The high voltage generator applies a set high voltage, such as 3kV~6kV, between the membrane-coated wire A1 and the detection electrode to detect whether there are defects such as pinholes or breaks in the insulation layer of the membrane-coated wire A1. When the leakage current exceeds a set threshold, an alarm signal is triggered and transmitted to the control system 9.

[0031] like Figure 1As shown, after the film-coated wire A1 is pulled out from the fixed wire storage wheel 321 of the wire storage tensioning mechanism 32, it passes sequentially through the wire diameter testing device 4 and the high voltage testing device 5, thus simultaneously completing wire diameter size detection and high voltage insulation performance detection during continuous production. The detection signals are fed back to the control system 9 in real time. The control system 9 judges the quality status of the film-coated wire A1. Once dimensional deviation or insulation breakdown is detected, an alarm signal is immediately issued and all equipment is suspended. After the defective products are manually removed, the equipment is restarted and the film coating parameters are adjusted in conjunction with the operation, realizing online closed-loop quality control of "immediate coating, immediate testing, and immediate adjustment".

[0032] like Figure 1 and Figure 7 As shown, the wire gathering mechanism 33 includes a take-up reel 331 and a take-up motor. The take-up motor is fixedly installed inside the take-up housing 301, with its output end extending horizontally out of the front of the take-up housing 301. The take-up reel 331 is rotatably installed on the front of the take-up housing 301 and is connected to the output end of the take-up motor via a coupling. The take-up motor drives the take-up reel 331 to rotate. The parameters of the take-up motor are adjusted by the command output of the control system 9. After passing through the wire diameter testing device 4 and the high voltage testing device 5, the qualified film-coated wire A1 is wound and collected into a bundle by the take-up reel 331.

[0033] like Figure 1 and Figure 7As shown, the front of the take-up box 301 is also provided with take-up guide rollers 313, 314, 315, 316, 317, a first set of limiting rollers 318, and a second set of limiting rollers 319. The third take-up guide roller 313 is disposed between the wire diameter testing device 4 and the wire storage tensioning mechanism 32, and is used to guide the film-coated wire A1 from the wire storage tensioning mechanism 32 to the wire diameter testing device 4. The fourth take-up guide roller 314 is disposed between the wire diameter testing device 4 and the high-voltage testing device 5, and is used to guide the film-coated wire A1 from the wire diameter testing device 4 to the high-voltage testing device 5. The take-up guide roller 315 is located on the other side of the high-voltage testing device 5 and is used to guide the membrane-coated wire A1 out of the high-voltage testing device 5. The first set of limiting rollers 318 and the second set of limiting rollers 319 are arranged on the other side of the take-up guide roller 315 away from the high-voltage testing device 5. Each set of limiting rollers includes two opposing limiting rollers. The gap between the two limiting rollers is used to clamp and guide the membrane-coated wire A1 to prevent the membrane-coated wire A1 from swaying left or right during travel. The sixth take-up guide roller 316 is located outside the second set of limiting rollers 319. The seventh take-up guide roller 317 is mounted on one end of the guide roller adjusting rod 310. The other end of the guide roller adjusting rod 310 is rotatably mounted on the axle of the sixth take-up guide roller 316, so that the distance between the seventh take-up guide roller 317 and the sixth take-up guide roller 316 is adjustable. By adjusting the position of the take-up guide roller 317, the final angle and tension of the film-wrapped wire A1 before entering the take-up roller 331 can be changed, ensuring neat and tight winding.

[0034] like Figure 1 and Figure 5 As shown, the production equipment in this embodiment also includes a refrigeration device 6, a baking and heating chamber 7, and a heat energy recycling system 8. The refrigeration device 6 is located on the side of the film wrapping machine 2 and communicates with the interior of the film wrapping machine 2 via an air duct. The refrigeration device 6 includes a temperature sensor, a temperature controller, and a regulating air valve. The temperature sensor is located inside the film wrapping chamber 201 and is used to detect the internal temperature of the film wrapping machine 2 in real time and transmit the signal to the temperature controller. The temperature controller controls the opening of the regulating air valve based on the difference between the set temperature (-40℃~20℃) and the temperature generated by friction between the film wrapping mechanism and the air during high-speed rotation, thereby controlling the airflow into the film wrapping machine 2 and achieving precise temperature regulation of the interior of the film wrapping machine 2. The parameter adjustment of the refrigeration device 6 is output by the command of the control system 9. In this embodiment, the temperature controller can be a commonly used industrial thermostat.

[0035] like Figure 1 and Figure 5As shown, the baking heating box 7 is located on top of the take-up machine 3, specifically mounted on the front-back moving mechanism. The front-back moving mechanism uses a commonly used front-back moving module; in this embodiment, it is a linear guide rail coupled with a lead screw drive or a synchronous belt drive, driven by a moving motor, which can move the baking heating box 7 in the front-back direction. The parameters of the moving motor are adjusted by commands from the control system 9. The baking heating box 7 has a heating groove in the middle for the film-wrapped wire A1 to pass through. The baking heating box 7 contains an electric heating tube and a temperature sensor. The heating temperature parameters of the baking heating box 7 are adjusted by commands from the control system 9. The main control device 910 of the control system 9 has a temperature setting page with a temperature setting range of 20℃ to 400℃. When the electric heating tube is energized, it generates heat to heat and bake the film-wrapped wire A1 passing through the heating groove, causing the insulating tape wrapped around the surface of the film-wrapped wire A1 to soften and tightly adhere to the wire surface, improving the adhesion and insulation performance of the insulating tape. The forward and backward moving mechanism can adjust the position of the baking heating box 7 according to the specifications and process requirements of the film-coated wire A1, so as to control whether the film-coated wire A1 needs to be heated and baked.

[0036] like Figure 1 and Figure 5 As shown, the heat energy reuse system 8 includes a heat recovery device 801, a heat energy inlet pipe 802, and a heat energy outlet pipe 803. The heat recovery device 801 is installed on the back of the film wrapping machine 2, specifically using a heat recovery rotor or a plate heat exchanger. One end of the heat energy inlet pipe 802 is connected to the hot air outlet of the baking heating chamber 7, and the other end is connected to the inlet end of the heat recovery device 801. One end of the heat energy outlet pipe 803 is connected to the outlet end of the heat recovery device 801, and the other end is connected to the interior of the film wrapping machine 2, specifically connected to the hot air inlet end of the film wrapping machine 2. The temperature parameters of the heat energy reuse system 8 are adjusted by the command output of the control system 9, with a temperature range of 15℃ to 50℃.

[0037] The working principle of the heat energy reuse system 8 is as follows: During the heating and baking process of the film-coating line A1 in the baking heating chamber 7, part of the heat is absorbed by the film-coating line A1, and the other part of the heat is dissipated as hot air from the heat dissipation vent of the baking heating chamber 7. This dissipated hot air is introduced into the heat recovery device 801 through the heat energy inlet pipe 802. The heat exchange core inside the heat recovery device 801 absorbs the heat in the hot air and transfers it to the circulating air flowing through the heat recovery device 801. The clean hot air after heat exchange is directly sent into the interior of the film-coating machine 2 through the heat energy outlet pipe 803.

[0038] The heat energy recycling system 8 monitors the internal temperature of the film wrapping machine 2 in real time through a temperature sensor installed inside the machine. During the operation of the baking heating chamber, when the temperature is below 10°C, the clean hot air supplied by the heat recovery device 801 keeps the internal temperature of the film wrapping machine 2 between 20°C and 30°C. When the wrapping mechanism 22 starts working, the high-speed rotation of the wrapping mechanism generates high temperatures of 60°C to 80°C due to friction with the air, causing the internal temperature of the film wrapping machine 2 to exceed 30°C. The cooling device 6 outputs -40°C to 20°C and automatically adjusts the temperature, delivering cold air to the inside of the film wrapping machine 2 to cool it down, keeping the internal temperature of the film wrapping machine 2 between 20°C and 30°C. The heat recovery device 801 can effectively filter dust and volatiles in the hot air, ensuring that the air supplied to the inside of the film wrapping machine 2 is clean and avoiding any impact on the wrapping quality.

[0039] The thermal energy reuse system 8 and the refrigeration device 6 precisely maintain the internal temperature of the membrane wrapping machine 2 within a constant range of 20~30℃, providing multiple protections for the membrane wrapping machine 2 itself: First, the constant temperature environment prevents non-uniform thermal expansion and contraction of the internal metal components of the membrane wrapping machine 2, including the housing, shaft, bearing housing, and transmission mechanism, caused by frequent and large temperature fluctuations. This ensures that the clearances between components, such as the clearance between bearings and journals and gear meshing clearances, remain stable, effectively eliminating problems such as metal fatigue, structural micro-deformation, and aging and brittleness of seals caused by repeated thermal stress, thus extending the service life of the overall equipment structure. Simultaneously, the constant temperature control ensures that the internal temperature of the membrane wrapping machine 2 is always higher than the ambient dew point temperature, fundamentally preventing water vapor from condensing into liquid water or hardening on the surface of the insulating tape due to sudden temperature drops. This ensures that the performance of the insulating tape remains within a safe range, preventing condensation or hardening on the surface of the insulating tape. This leads to reduced adhesion to the original A0 line and wrinkles caused by tape overlap, resulting in decreased insulation performance. Furthermore, the constant temperature environment keeps the lubricating grease in the bearings and transmission pairs inside the film wrapping machine 2 within its optimal viscosity range. This avoids both excessively high grease viscosity at low temperatures, which would prevent the formation of a complete oil film during startup and exacerbate dry friction wear, and excessively low grease viscosity at high temperatures, which would cause the oil film to thin, reduce load-bearing capacity, and cause grease oxidation and deterioration. This effectively reduces frictional losses in the film wrapping mechanism 22 and its rotating parts. In addition, the clean hot air supplied by the cooling device 6 when the heat energy recycling system 8 is working allows the film wrapping machine 2 to operate in a "passive reception, active compensation" control mode. This mode does not actively adjust the internal temperature of the film wrapping machine 2 when it is within the 20℃~30℃ range, but only activates the cooling function when the temperature exceeds the range. This avoids frequent start-stop cycles for its cooling components, significantly reducing the number of cycles and overload losses of the internal components of the cooling device 6, and significantly extending the service life of the cooling device 6 itself. On the other hand, the adhesion performance of the insulating tape (i.e., the film layer) during the wrapping process is highly sensitive to temperature. During the operation of the baking heating box 7, when the temperature is below 10°C, the molecular chain segments of the insulating tape are not active enough, the film layer is too hard and the extensibility decreases, resulting in the film layer and the wire surface not being fully wetted and bonded, the interface bonding force is weak, and bubbles and delamination are easily generated. At this time, it is necessary to actively raise the temperature through the heat recovery system. When the temperature is between 10°C and 20°C, it can slowly rise to above 20°C by relying on the heat generated by the film wrapping machine itself (the heat generated by the rotation of the wrapping mechanism), without active intervention. When the temperature is above 30°C, the viscous flow state of the wrapping film is excessive, the viscosity of the adhesive layer increases, and the adhesion between the film feeding mechanism and the insulating tape increases, making it difficult to detach, resulting in the film layer being too soft, causing stretching deformation and uneven thickness. After wrapping, the surface of the film layer shows drips and wrinkles.This invention strictly controls the internal temperature of the film wrapping machine within the optimal window of 20℃~30℃, ensuring the wrapping film is in a moderately softened state within this temperature range, with moderate molecular chain segment mobility. This guarantees sufficient extensibility for tight adhesion to the wire surface while maintaining optimal adhesiveness of the insulating tape, achieving optimal interfacial bonding between the film layer and the wire. Experimental verification shows that under temperature control conditions of 20℃~30℃, the peel force of the film-wrapped wire increases from 2.1 N / cm without temperature control to 3.4 N / cm, an increase of 62%; the surface bubble rate of the film layer decreases from 3.5% in conventional solutions to below 0.2%, and the film thickness uniformity deviation is controlled within ±0.008 mm.

[0040] like Figure 1 As shown, the control system 9 includes a main control device 910, an alarm light group, a control button group, and an indicator light group. The main control device 910 is a PLC programmable logic controller or an industrial computer, which is electrically connected via signal cables to the following components: the wire feeding motor, the control valve of the tension adjusting cylinder 126, the membrane wrapping motor 223, the traction motor 234, the control valve of the wheel limiting cylinder 236, the servo motor in the moving module of the adjustable wire storage wheel 322, the wire diameter testing device 4, the high voltage testing device 5, the take-up motor, the refrigeration device 6, the temperature control device and moving motor of the baking heating oven 7, and the temperature control device of the heat energy recycling system 8, etc., for unified control of the start-up, stop, running speed, and parameter settings of each mechanism. The alarm light group includes a wire feeding alarm light 901, a film wrapping alarm light 902, and a take-up alarm light 903. The wire feeding alarm light 901 is fixedly installed on the top of the wire feeding machine 1, the film wrapping alarm light 902 is fixedly installed on the top of the film wrapping machine 2, and the take-up alarm light 903 is fixedly installed on the top of the take-up machine 3. Each alarm light is a three-color LED warning light (red / yellow / green). When the corresponding equipment malfunctions, the main control device 910 controls the red light to flash as an alarm. The control button group includes a wire feeding button 904, a film wrapping button 905, and a take-up button 906. The wire feeding button 904 is fixedly installed on the front side of the wire feeding machine 1, the film wrapping button 905 is fixedly installed on the front side of the film wrapping machine 2, and the take-up button 906 is fixedly installed on the front side of the take-up machine 3. Each button is an illuminated self-reset button, used to control the start and stop of each device on-site, facilitating individual operation during debugging and maintenance. The indicator light group includes a wire feeding indicator light 907, a film wrapping indicator light 908, and a wire take-up indicator light 909. All three are located in the indicator light box on the front side of the take-up machine 3, or can be set synchronously on the control panel of the main control device 910. Each indicator light displays the operating status of the corresponding device (green for running, yellow for standby, and red for fault). Example

[0041] A method for preparing a membrane-covered wire A1, using the membrane-covered wire production equipment described in any of the above embodiments, includes the following steps: S1. Threading and Winding: First, the operator loads the original wire A0 onto the feed roller 111 of the upper threading mechanism 11, pulls out the end of the original wire A0, passes it upwards over the top of the feed guide roller 102, and then guides it downwards into the tension adjustment mechanism 12. After winding it 3-5 times between the fixed tension roller 121 and the adjustable tension roller 122, it is pulled out from the fixed tension roller 121, horizontally to the right, around the feed guide roller 103, and enters the film wrapping box 201 of the film wrapping machine 2. The original wire A0 passes over the bottom surface of the film wrapping guide roller 211 and is pulled vertically upwards from the side of the film wrapping guide roller 211, passing through the center hole of the wrapping frame 222 of the wrapping mechanism 22. Driven by the film wrapping motor 223, the wrapping mechanism 22 wraps insulating tape around the surface of the original wire A0 to form the film-wrapped wire A1. After passing through the wrapping mechanism 22, the film-wrapped wire A1 extends upwards, successively winding around the traction wheel 231 and the guide wheel 232. After winding 2-4 turns between them, it is pulled out from the guide wheel 232, passes through the top take-up guide wheel 311 and the second take-up guide wheel 312, and winds downwards to the wire storage tensioning mechanism 32. After circulating 4-6 turns between the fixed wire storage wheel 321 and the adjustable wire storage wheel 322, it is pulled out from the fixed wire storage wheel 321 and winds around the bottom surface of the take-up guide wheel 313. Then, it passes through the measuring optical path of the wire diameter testing device 4 and winds around the take-up guide wheel 313. The upper side of the wire guide roller 314 passes through the detection electrode of the high voltage testing device 5, winds around to the top of the take-up guide roller 315, then passes through the gap between the first limit roller group 318 and the second limit roller group 319 in sequence, and then winds around to the sixth take-up guide roller 316 and the seventh take-up guide roller 317 in sequence. Finally, the take-up roller 331 of the wire gathering mechanism 33 completes the take-up. In this step, the specific arrangement of each guide roller makes the original wire A0 and the film-coated wire A1 form a continuous "S" or "U" shaped wire path on the entire production line, ensuring that the wire maintains stable contact and guidance between each process.

[0042] S2. Start-up: After winding is completed, the entire line of equipment is started through the control system 9. The wire feeding motor starts and drives the wire feeding wheel 111 to rotate, continuously feeding out the original wire A0. When the original wire A0 passes through the tension adjustment mechanism 12, it is stretched to the set tension value by the friction between the fixed tension wheel 121 and the adjustable tension wheel 122 and the tension applied by the weight 124, and then transmitted to the film wrapping machine 2. The film wrapping mechanism 22 of the film wrapping machine 2 rotates under the drive of the film wrapping motor 223, and performs film wrapping operation on the surface of the original wire A0 to form film-wrapped wire A1. The traction motor 234 starts and drives the traction wheel 231 to rotate, continuously pulling the film-wrapped wire A1 out of the film wrapping machine 2 and pulling it to the wire storage and tensioning mechanism 32 for wire storage and tension buffering. The adjustable wire storage wheel 322 is driven by the moving module to move horizontally up and down to control the tension. If the film-coated wire A1 needs to be heated, during the process of the film-coated wire A1 being drawn by the traction mechanism 23 to the wire storage and tensioning mechanism 32, the control system 9 controls the electric heating tube of the baking heating box 7 to be energized and heated. When the film-coated wire A1 passes through the heating wire groove, the surface film layer is heated and softened and tightly adhered, achieving the baking and shaping effect. After being heated and shaped, the film-coated wire A1 is then drawn to the wire storage and tensioning mechanism 32 for stretching and storage. After being buffered by the wire storage and tensioning mechanism 32, the film-coated wire A1 is drawn by the take-up motor of the wire gathering mechanism 33 and passes through the wire diameter testing device 4 and the high voltage testing device 5 in sequence for online testing of wire diameter and insulation performance. The film-coated wire A1 that passes the test is finally collected into a bundle by the wire gathering mechanism 33. The overall running speed of the line is synchronized and coordinated by the control system 9 according to the speed feedback of each motor to ensure that the wire feeding speed, coating speed, traction speed and take-up speed are consistent. During this process, since the tension adjustment mechanism 12 adopts a combination of mechanical main adjustment and pneumatic auxiliary compensation, it does not rely on sensor signals. Therefore, even if the diameter of the original thread A0 on the thread feed roller 111 gradually decreases due to unwinding, causing load changes, the tension adjustment mechanism 12 can still provide a stable tension output through the constant gravity of the weight 124. At the same time, the tension adjustment cylinder 126 applies a downward auxiliary adjustment force to the adjustment rod 123 according to the preset air pressure value of the control system 9, quickly compensating for the instantaneous tension changes caused by speed fluctuations. This hybrid tension control method ensures that the original thread A0 maintains a constant tension state before entering the film wrapping machine 2, effectively avoiding problems such as film wrinkling and uneven film thickness caused by tension fluctuations.

[0043] S3. Heat Recovery and Temperature Control: During the wrapping process, the electric heating tube of the baking heating box 7 is energized to generate heat to heat and bake the wrapping line A1. The heat lost during operation (high-temperature hot air) is actively collected by the heat recovery device 801 through the heat energy inlet pipe 802. The heat exchange core inside the heat recovery device 801 absorbs the collected heat and transfers it to the circulating air flowing through the heat recovery device 801. The clean hot air after heat exchange is directly sent into the interior of the wrapping machine 2 through the heat energy outlet pipe 803. The cooling device 6 monitors the internal temperature of the wrapping machine 2 in real time through a temperature sensor installed inside the wrapping machine 2. When the clean hot air supplied by the heat recovery device 801 is sufficient to keep the internal temperature of the film wrapping machine 2 within the set range of 20℃ to 30℃, the cooling device 6 does not actively adjust it. When the internal temperature of the film wrapping machine 2 exceeds 30℃, the cooling device 6 initiates adjustment based on the feedback signal from the temperature sensor. Specifically, when the temperature exceeds the upper limit of the set range, the cooling device 6 activates the cold air introduction function to cool the inside of the film wrapping machine. Through the above control logic, the internal temperature of the film wrapping machine 2 is always maintained between 20℃ and 30℃. The heat recovery device 801 can effectively filter dust and volatiles in the hot air, ensuring that the air supplied into the film wrapping machine 2 is clean and avoiding any impact on the wrapping quality. In this step, the heating function of the baking heating chamber 7 and the heat recovery function of the heat energy reuse system 8 work synergistically: the heat loss generated by the baking heating chamber 7 while heating the film-wrapping wire A1 should have been discharged into the atmosphere and wasted, but this solution recovers this "waste heat" through the heat energy inlet pipe 802 and sends it to the film wrapping machine 2. This not only reduces the external heating energy consumption required by the film wrapping machine 2 itself, but also ensures that the constant temperature environment inside the film wrapping machine 2 is conducive to the insulation tape being in the optimal stretching temperature window during the wrapping process, resulting in a tighter film adhesion. At the same time, the "passive reception, active compensation" control mode of the refrigeration device 6 avoids frequent start-stop of its cooling fan, significantly reducing the number of cold cycles and overload losses of the internal components of the refrigeration device 6.

[0044] S4. Manual Tension Adjustment: During equipment operation, if the operator observes that the original wire A0 is loose, vibrating, or the sheath is wrinkled, it indicates that the tension of the original wire A0 is insufficient. In this case, the operator can adjust the tension as follows: Loosen the adjusting screw 125 on the weight 124, allowing the weight 124 to return to a free-sliding state on the adjusting rod 123. Then, move the weight 124 to the left an appropriate distance along the scale, and then retighten the adjusting screw 125 to lock the weight 124 in the new position. After the weight 124 moves to the left, its gravitational torque on the right end of the adjusting rod 123 increases. The adjusting rod 123 rotates clockwise around the adjusting seat 127, and the adjustable tension wheel 122 installed on the left end of the adjusting rod 123 moves downward, increasing the vertical distance between the adjustable tension wheel 122 and the fixed tension wheel 121. This further tightens the original wire A0 wound between them, achieving the purpose of increasing tension. The presence of the scale allows operators to accurately record the position of each adjustment. When it is necessary to restore the original tension value, the position markings on the scale can be directly referenced for quick reset. If it is necessary to reduce the tension, the weight 124 can be moved to the right. The tension adjusting cylinder 126 acts as an auxiliary compensation device in this process. Its output force is automatically adjusted by the control system 9 according to the current operating speed without manual intervention, and it always maintains a downward auxiliary support for the adjusting rod 123.

[0045] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0046] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A production equipment for film-coated wires, characterized in that: The system includes a wire feeder (1), a film wrapping machine (2), a wire take-up machine (3), and a control system (9). The wire feeder (1) and the wire take-up machine (3) are located on both sides of the film wrapping machine (2). The wire feeder (1) is equipped with a wire feeding mechanism (11) and a tension adjustment mechanism (12). The lower part of the film wrapping machine (2) is equipped with a film wrapping conductor mechanism (21). The inside of the film wrapping machine (2) is equipped with a film winding mechanism (22). The top of the film wrapping machine (2) is equipped with a traction mechanism (23). The upper end of the wire take-up machine (3) is equipped with a wire take-up conductor mechanism (31). The front side of the wire take-up machine (3) is equipped with a wire storage tensioning mechanism (32). The front center of the wire take-up machine (3) is equipped with a wire diameter testing device (4), a high voltage testing device (5), and a wire gathering mechanism (33). The control system (9) is used to control the coordinated operation of each mechanism and device. The original wire (A0) is wound on the upper winding mechanism (11). The original wire (A0) is wound from the upper winding mechanism (11) to the tension adjustment mechanism (12), then to the film wrapping conductor mechanism (21) of the film wrapping machine (2), and then to the film wrapping mechanism (22). The film wrapping mechanism (22) performs a film wrapping operation on the surface of the original wire (A0) to form a film-wrapped wire (A1). The film-wrapped wire (A1) is wound from the film wrapping mechanism (22) to the traction mechanism (23), then through the take-up conductor mechanism (31), and then to the wire storage tensioning mechanism (32). Then it passes through the wire diameter testing device (4) and the high voltage testing device (5) in sequence, and is then wound by the wire gathering mechanism (33).

2. The film-coated wire production equipment according to claim 1, characterized in that: The wire feeding mechanism (11) includes a wire feeding wheel (111) and a wire feeding motor. The wire feeding motor is located inside the wire feeding box (101). The wire feeding wheel (111) is located on the lower part of the outer front of the wire feeding box (101) and is connected to the output end of the wire feeding motor. It is driven to rotate by the wire feeding motor. The tension adjustment mechanism (12) includes a fixed tension wheel (121) and an adjustable tension wheel (122). The fixed tension wheel (121) is fixed on the wire feeding box (101). The adjustable tension wheel (122) is located directly below the fixed tension wheel (121) and is installed at one end of the adjusting rod (123). The middle part of the adjusting rod (123) is rotatably installed on the adjusting seat (127). The adjusting seat (127) is fixed on the wire feeding box (101). A scale is provided on the other side of the adjusting rod (123) away from the adjustable tension wheel (122). A weight (124) is movably mounted on the adjusting rod (123). The weight (124) is mounted on one side of the scale. An adjusting screw (125) is provided on the weight (124). The tension adjustment mechanism (12) also includes a tension adjustment cylinder (126), which is fixed on the wire feeding box (101), and its output end is fixed on the adjustment rod (123) and between the adjustment seat (127) and the adjustable tension wheel (122). The upper end of the wire feeding box (101) is provided with a wire feeding guide wheel one (102), and the side of the wire feeding box (101) near the film wrapping machine (2) is provided with a wire feeding guide wheel two (103). The wire feeding guide wheel two (103) is located between the fixed tension wheel (121) and the adjustable tension wheel (122).

3. The film-coated wire production equipment according to claim 1, characterized in that: The membrane-wrapped conductor mechanism (21) includes at least one membrane-wrapped conductor wheel (211), which is fixed to the lower part of the membrane-wrapped housing (201); The film wrapping mechanism (22) includes a film storage rack (221) and a film wrapping rack (222). The film storage rack (221) is fixed inside the film wrapping box (201), and the film wrapping rack (222) is located outside the film storage rack (221) and is driven by the film wrapping motor (223) through a transmission mechanism. The traction mechanism (23) includes a traction wheel (231) and a traction guide wheel (232). The traction wheel (231) and the traction guide wheel (232) are arranged and installed on the traction seat (233). The traction seat (233) is fixed on the top of the membrane box (201). The traction wheel (231) is driven by a traction motor (234). The traction motor (234) is located on the back of the traction seat (233). A wheel limiting plate (235) is also provided on the top of the traction wheel (231). The wheel limiting plate (235) is rotatably installed on the traction seat (233) and driven by a wheel limiting cylinder (236). The wheel limiting cylinder (236) is fixed on the back of the traction seat (233).

4. The film-coated wire production equipment according to claim 1, characterized in that: The take-up wire mechanism (31) includes a take-up wire wheel one (311) and a take-up wire wheel two (312). The take-up wire wheel one (311) and the take-up wire wheel two (312) are both mounted on a wire wheel seat. The wire wheel seat is fixed to the top of the take-up box (301). The take-up wire wheel one (311) and the take-up wire wheel two (312) are arranged on the top of the take-up box (301). The wire storage tensioning mechanism (32) includes a fixed wire storage wheel (321) and an adjustable wire storage wheel (322) arranged vertically. The fixed wire storage wheel (321) is fixedly installed on the front side of the take-up box (301), and the adjustable wire storage wheel (322) is slidably installed on the front side of the take-up box (301) and is driven to move up and down by the moving module. The cable gathering mechanism (33) includes a take-up reel (331) and a take-up motor. The take-up motor is fixed inside the take-up box (301), and its output end is connected to the take-up reel (331) and can drive the take-up reel (331). The take-up reel (331) is rotatably mounted on the front of the take-up box (301).

5. The film-coated wire production equipment according to claim 4, characterized in that: The front of the take-up box (301) is also provided with take-up guide roller three (313), take-up guide roller four (314), take-up guide roller five (315), take-up guide roller six (316), take-up guide roller seven (317), limit wheel group one (318), and limit wheel group two (319). The take-up guide roller three (313) is located between the wire diameter testing device (4) and the wire storage tensioning mechanism (32). The take-up guide roller four (314) is located between the wire diameter testing device (4) and the high voltage testing device (5). The take-up guide roller five (315) is located between the wire diameter testing device (4) and the high voltage testing device (5). The first limit wheel group (318) and the second limit wheel group (319) are arranged on the other side of the take-up guide wheel (315) away from the high voltage test device (5). The sixth take-up guide wheel (316) is located outside the second limit wheel group (319). The seventh take-up guide wheel (317) is installed at one end of the guide wheel adjusting rod (310), and the other end of the guide wheel adjusting rod (310) is installed on the sixth take-up guide wheel (316), so that the seventh take-up guide wheel (317) can be adjusted in distance.

6. The film-coated wire production equipment according to claim 1, characterized in that: The production equipment for the membrane wrapping line also includes a refrigeration device (6) with a temperature setting range of -40℃ to 20℃. The refrigeration device (6) is located on the side of the membrane wrapping machine (2) and is connected to the inside of the membrane wrapping machine (2) through a gas duct to regulate the internal temperature of the membrane wrapping machine (2).

7. The film-coated wire production equipment according to claim 1, characterized in that: The top of the take-up machine (3) is also provided with a baking heating box (7), with a temperature setting range of 20℃~400℃. The baking heating box (7) is installed on the front and rear moving mechanism, and a heating wire groove is provided in the middle of the baking heating box (7).

8. The production equipment for film-coated wire according to claim 1, characterized in that: The production equipment for the membrane wrapping line also includes a heat energy recycling system (8), with a temperature setting range of 15℃~50℃. The heat energy recycling system (8) includes a heat recovery device (801), a heat energy inlet pipe (802), and a heat energy outlet pipe (803). The heat recovery device (801) is installed on the back of the membrane wrapping machine (2). One end of the heat energy inlet pipe (802) is connected to the baking heating box (7), and the other end is connected to the heat recovery device (801). One end of the heat energy outlet pipe (803) is connected to the heat recovery device (801), and the other end is connected to the inside of the membrane wrapping machine (2).

9. The film-coated wire production equipment according to claim 1, characterized in that: The control system (9) includes a main control device (910), an alarm light group, a control button group, and an indicator light group; The alarm light group includes a wire feeding alarm light (901), a membrane wrapping alarm light (902), and a wire take-up alarm light (903). The control button group includes a wire feeding button (904), a membrane wrapping button (905), and a wire take-up button (906). The indicator light group includes a wire feeding indicator light (907), a film wrapping indicator light (908), and a wire take-up indicator light (909).

10. A method for preparing a membrane-coated wire, characterized in that: The production equipment for film-coated wires according to any one of claims 1-4 and 6-8 further includes the following steps: S1. First, the operator loads the original wire (A0) onto the wire feeding wheel (111) of the upper wire mechanism (11), pulls out the wire end, passes through the first wire feeding wheel (102), and then winds it around the tension adjustment mechanism (12). After winding it multiple times between the fixed tension wheel (121) and the adjustable tension wheel (122) of the tension adjustment mechanism (12), it is pulled out from the fixed tension wheel (121), passes through the second wire feeding wheel (103), and winds it to the bottom surface of the membrane wrapping wheel (211) of the membrane wrapping mechanism (21). Then, it is pulled vertically upward from the side of the membrane wrapping wheel (211) and passes through the wrapping mechanism (22). The wrapping mechanism (22) wraps the surface of the original wire (A0) with insulating tape to form a membrane-wrapped wire (A1). Then, after passing through the membrane wrapping machine (2), the membrane-wrapped wire (A1) winds around the traction wheel (231) and the traction guide wheel (232) in sequence. After winding multiple times between the guide wheel (231) and the traction guide wheel (232), the wire is pulled out from the traction guide wheel (232) and wound onto the take-up guide wheel one (311) and the take-up guide wheel two (312), and then wound onto the wire storage tensioning mechanism (32). After circulating multiple times between the fixed wire storage wheel (321) and the adjustable wire storage wheel (322) of the wire storage tensioning mechanism (32), the wire is pulled out from the fixed wire storage wheel (321) and wound onto the take-up guide wheel two (312). The bottom surface of the wire guide wheel three (313) passes through the wire diameter testing device (4), then goes around to the upper side of the take-up guide wheel four (314), passes through the high voltage testing device (5), goes around to the top of the take-up guide wheel five (315), then passes through the first limit wheel group one (318) and the second limit wheel group two (319) in sequence, then goes around to the sixth take-up guide wheel six (316) and the seventh take-up guide wheel seven (317) in sequence, and finally the take-up is completed by the wire gathering mechanism (33); S2. After the winding is completed, start the entire line equipment. The upper winding mechanism (11) sends out the original wire (A0), which is stretched and transmitted to the film wrapping machine (2) by the tension adjustment mechanism (12). The film wrapping machine (2) then performs the film wrapping operation. After the original wire (A0) completes the film wrapping operation by the film wrapping machine (2), it forms a film-wrapped wire (A1). Then, the traction mechanism (23) pulls it to the wire storage tensioning mechanism (32) for stretching and storage. If it is necessary to heat the film-wrapped wire (A1), then the traction mechanism (23) pulls it to the tensioning mechanism (32) for stretching and storage. During the pulling process, the film-wrapped wire (A1) is heated by the baking heating box (7) with a baking heating temperature range of 20℃~400℃. After heating, it is pulled to the wire storage tensioning mechanism (32) for stretching and storage. After being stretched and stored by the wire storage tensioning mechanism (32), the film-wrapped wire (A1) is pulled by the wire take-up mechanism (31) and passes through the wire diameter testing device (4) and the high voltage testing device (5) in sequence for relevant performance and parameter testing. Finally, the wire collection mechanism (33) collects the wire into bundles. S3. During the wrapping process, when the wrapping mechanism (22) starts working, the high temperature of 60℃~80℃ is generated by friction with the air when the wrapping mechanism rotates at high speed. The cooling device (6) outputs -40℃~20℃ and automatically adjusts the temperature to deliver cold air to the inside of the wrapping machine (2) for cooling, so that the internal temperature of the wrapping machine (2) is maintained between 20℃~30℃. During the operation of the baking heating box (7), when the internal temperature of the wrapping machine is lower than 10℃, the heat generated by the baking heating box (7) during the operation is collected by the heat recovery device (801) through the heat energy inlet pipe (802) and the temperature is adjusted to output hot air of 15℃~50℃. Then, it is delivered to the inside of the wrapping machine (2) through the heat energy outlet pipe (803) to maintain the internal temperature of the wrapping machine (2) between 20℃~30℃. S4. If the original line (A0) becomes loose during equipment operation, the operator can loosen the adjusting screw (125) so that the weight (124) can move left and right on the adjusting rod (123). The weight (124) can then be moved to the left, causing the end of the adjusting rod (123) with the adjustable tension wheel (122) to sink downwards. This allows the adjustable tension wheel (122) to move downwards, thereby increasing the distance between the adjustable tension wheel (122) and the fixed tension wheel (121), and thus tightening the original line (A0).

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