Ultrafine base material ring diameter repair device and process

Abstract

The present application relates to a superfine base material circle diameter repair device and process, the superfine base material is led out by a pay-off mechanism, is wound on a pay-off tension control mechanism, and then is wound on a traction tension control mechanism, enters a heating furnace; after being led out from the heating furnace, is wound on another traction tension control mechanism, and finally is wound on a take-up tension control mechanism and is wound by a take-up mechanism; a main control unit obtains real-time tension feedback values of the pay-off tension control mechanism and the take-up tension control mechanism respectively, adjusts the pay-off speed of the pay-off mechanism to control the pay-off tension according to the deviation of the real-time tension feedback value of the pay-off tension control mechanism and a target tension value, and adjusts the take-up speed of the take-up mechanism to control the take-up tension according to the deviation of the real-time tension feedback value of the take-up tension control mechanism and the target tension value; the traction speed of one traction tension control mechanism is consistent with the pay-off mechanism, and two traction tension control mechanisms are set to run at a constant speed according to a preset speed ratio.

Description

Technical Field

[0001] This invention relates to the field of drawn metal wire technology, and in particular to equipment and process for repairing the diameter of ultra-fine substrate coils. Background Technology

[0002] Metal wires with a diameter of no more than 100 micrometers are classified as ultrafine substrates, such as tungsten wires with a diameter of less than 45 micrometers and carbon steel wires with a diameter of less than 48 micrometers. One of the current production processes for ultrafine substrates is drawing, which involves drawing the substrate multiple times using wire drawing equipment to reduce its diameter, thereby obtaining the ultrafine substrate. Taking tungsten wire as an example, ultrafine tungsten wires are mainly used in high-tech fields such as photovoltaic silicon wafer cutting, semiconductor manufacturing, precision electronics, medical equipment, and high-end lighting.

[0003] After long-term operation of the drawing equipment, the die orifice of the drawing die wears down, which changes the compression ratio of the tungsten wire drawing passes. This results in uneven distribution of residual stress in the wire cross-section, a wavy wire shape, and unstable coil diameter, affecting the stability of the product's outer diameter and initial tensile force. Moreover, due to factors such as the design of the drawing die itself and residual emulsion, the free coil diameter of the drawn tungsten wire may be too small, potentially causing the drawn tungsten wire product to fail to meet standards.

[0004] Unstable coil diameter in tungsten wires refers to a section of tungsten wire that, when left freely, will coil or bend in a wavy shape, failing to meet quality requirements. To address this, patent publication number CN118635405A discloses a device and process for straightening the free coil diameter of ultrafine tungsten wires. The ultrafine tungsten wire with poor coil diameter on the wire feeding device is wound by guide wheels and then passed through a cylindrical heating furnace tube. After being wound by guide wheels again, it is wound by a wire take-up device. This allows for uniform temperature control, ensuring uniform stress relief in the ultrafine tungsten wire, improving the coil diameter of the wire, and significantly increasing the yield rate of ultrafine tungsten wires.

[0005] It can be seen that the existing patented technology for straightening the diameter of ultra-fine tungsten wire relies solely on uniform heating to eliminate wire stress, which is a "single thermal straightening" and does not control the mechanical state during the wire feeding process. In other words, the equipment does not have a segmented tension control structure throughout the entire process. During the wire feeding process, the tungsten wire is easily disturbed, which may cause problems such as uneven stress distribution and deformation rebound, which may lead to poor stability of the diameter after straightening. Summary of the Invention

[0006] To address the problem that existing repair equipment relies solely on heating for straightening, lacking segmented tension control of the substrate and resulting in poor stability in coil diameter correction, this invention provides an ultra-fine substrate coil diameter repair device and process for repairing ultra-fine substrates with abnormal coil diameters. This involves adding a tension control structure after unwinding and a tension control structure before winding. Simultaneously, a structure is added to control the tension of the substrate in the heating equipment, thereby achieving segmented tension control after unwinding, before winding, and during the heating process. This effectively reduces substrate fluctuations and deformation, improving the stability of coil diameter correction.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] An ultra-fine substrate diameter repair device includes a wire feeding device, a heating furnace, and a wire take-up device. The ultra-fine substrate is released by the wire feeding device, passes through the heating furnace, and is then taken up by the wire take-up device. The device is characterized in that the wire feeding device includes a wire feeding mechanism and a wire feeding tension control mechanism. The wire feeding tension control mechanism is configured to acquire the real-time tension value detected by itself, compare the real-time tension value with the target tension value, and adjust the wire feeding speed of the wire feeding mechanism according to the comparison result.

[0009] A traction tension control mechanism is provided between the wire feeding device and the heating furnace, and between the heating furnace and the wire taking-up device. The traction tension control mechanism is configured to operate at a preset speed ratio to control the tension of the ultrafine substrate in the heating furnace to be constant.

[0010] The take-up device and the release device have the same structure. The take-up device includes a take-up mechanism and a take-up tension control mechanism. The take-up tension control mechanism is configured to acquire the real-time tension value detected by itself, compare the real-time tension value with the target tension value, and adjust the take-up speed of the take-up mechanism according to the comparison result.

[0011] The ultrafine substrate is released by the unwinding mechanism, passes sequentially through the unwinding tension control mechanism, a traction tension control mechanism, a heating furnace, another traction tension control mechanism, and a take-up tension control mechanism, and is then wound up by the take-up mechanism.

[0012] Furthermore, the wire feeding mechanism consists of multiple sets arranged at intervals, and each set of wire feeding mechanism includes two sets of wire feeding units arranged in a stacked manner, with the two sets of wire feeding units arranged in opposite directions.

[0013] A mounting base is provided between two adjacent groups of wire feeding mechanisms. The wire feeding tension control mechanism is provided on both sides of the mounting base. The wire feeding tension control mechanism on both sides corresponds to the two sets of wire feeding units in each group of wire feeding mechanisms.

[0014] Furthermore, the number of take-up mechanisms is multiple, with one-to-one correspondence between the number of take-up mechanisms and the number of take-up mechanisms and the structure of the take-up mechanisms and the take-up mechanisms are identical. Each take-up mechanism includes two sets of take-up units arranged in an upper and lower stacked manner, with the two sets of take-up units arranged in opposite directions.

[0015] A mounting base two is provided between two adjacent sets of take-up mechanisms. The take-up tension control mechanism is provided on both sides of the mounting base two. The take-up tension control mechanism on both sides corresponds one-to-one with the two sets of take-up units in each set of take-up mechanisms.

[0016] Furthermore, the wire tension control mechanism includes a guide component, a first steering wheel, a tension component, a second steering wheel, and a guide wheel. The ultrafine substrate passes sequentially around the guide component, the first steering wheel, the tension component, the second steering wheel, and the guide wheel. The first steering wheel, the tension component, the second steering wheel, and the guide wheel are all mounted on the top seat.

[0017] Furthermore, the take-up tension control mechanism and the pay-off tension control mechanism have the same structure, and their arrangement directions are opposite.

[0018] Furthermore, the guide assembly includes a height plate and height wheels that are adjustable up and down on the height plate, the height wheels being arranged below the steering wheels;

[0019] The first steering wheel, the second steering wheel, and the guide wheel are arranged sequentially on the same horizontal plane. The distance between the first steering wheel and the second steering wheel is greater than the distance between the second steering wheel and the guide wheel. The first steering wheel and the second steering wheel are aligned in the same direction, while the second steering wheel and the guide wheel are perpendicular in the same direction. The second guide wheel is perpendicular to the ground.

[0020] The tension assembly includes a tension motor, a tension rod, and a tension wheel. The tension motor is mounted on the top seat. The two ends of the tension rod are connected to the output end of the tension motor and the tension wheel, respectively. The tension wheel swings in an arc-shaped trajectory with the output end of the tension motor as the center. The tension wheel is arranged below the first steering wheel and the second steering wheel, and is also arranged between the height wheel and the first steering wheel.

[0021] Furthermore, after the ultrafine substrate is led out by the wire feeding mechanism, it passes sequentially around the height wheel, the first steering wheel, the tension wheel, the second steering wheel, and the guide wheel before entering a traction tension control mechanism.

[0022] Furthermore, the traction tension control mechanism includes a frame, a drive motor, a drive roller, and a driven roller. The drive motor is mounted on the frame, and its output end is connected and fixed to the drive roller. The driven roller is also rotatably mounted on the frame, and the drive roller and the driven roller are arranged vertically at intervals.

[0023] A wire splitting assembly is also provided on one side of the frame. The wire splitting assembly on the two traction tension control mechanisms is configured to uniformly separate multiple ultra-fine substrates wound inside the heating furnace.

[0024] The ultra-fine substrate diameter repair process uses the aforementioned repair equipment. An H-beam with an abnormally large ultra-fine substrate is mounted on a pay-off mechanism. After being drawn out by the pay-off mechanism, the ultra-fine substrate is wound around a pay-off tension control mechanism, then around a traction tension control mechanism, and enters a heating furnace. After being drawn out of the heating furnace, the ultra-fine substrate is wound around another traction tension control mechanism, and finally around a take-up tension control mechanism before being wound up by the take-up mechanism.

[0025] The main control unit acquires the real-time tension feedback values ​​from the pay-off tension control mechanism and the take-up tension control mechanism, respectively. Based on the deviation between the real-time tension feedback value of the pay-off tension control mechanism and the target tension value, the pay-off speed of the pay-off mechanism is adjusted to control the pay-off tension. Simultaneously, based on the deviation between the real-time tension feedback value of the take-up tension control mechanism and the target tension value, the take-up speed of the take-up mechanism is adjusted to control the take-up tension. The traction speed of one traction tension control mechanism is kept consistent with that of the pay-off mechanism, and the two traction tension control mechanisms are set to operate at a constant speed ratio according to a preset schedule.

[0026] The beneficial effects of the present invention through the above technical solution are:

[0027] This invention features a rational structural design. Addressing the shortcomings of existing ultrafine tungsten wire free coil diameter straightening equipment that relies solely on heating for straightening and lacks mechanical control, this invention employs a segmented tension control structure to achieve segmented tension control of the ultrafine substrate. Specifically, a feeding tension control mechanism is added after feeding to adjust the feeding tension in real time; traction tension control mechanisms are added before and after the heating furnace to ensure constant tension of the substrate within the furnace; and a take-up tension control mechanism is added before take-up to adjust the take-up tension in real time. This solves the problem of repair equipment relying solely on heating for straightening and lacking segmented tension control of the substrate. It reduces wire fluctuation and secondary deformation throughout the entire process of ultrafine substrate entering the furnace, straightening in the furnace, and shaping after exiting the furnace, thereby improving the accuracy and stability of ultrafine tungsten wire coil diameter straightening. Attached Figure Description

[0028] Figure 1 This is an isometric view of the ultrafine substrate diameter repair device of the present invention.

[0029] Figure 2 This is a front view of the ultrafine substrate diameter repair device of the present invention.

[0030] Figure 3 This is a front axonometric view of the wire laying mechanism of the ultrafine substrate diameter repair device of the present invention.

[0031] Figure 4This is a rear-view isometric view of the wire-laying mechanism of the ultra-fine substrate diameter repair device of the present invention.

[0032] Figure 5 This is a schematic diagram of the arrangement of two wire feeding units in the ultra-fine substrate diameter repair device of the present invention.

[0033] Figure 6 This is a schematic diagram of the ultrafine substrate winding through two sets of wire feeding units in the ultrafine substrate diameter repair device of the present invention. In order to clearly show the path of the ultrafine substrate winding through each set of wire feeding units, the two sets of wire feeding units are placed in a staggered manner from left to right. In the actual equipment, they are placed vertically corresponding to each other.

[0034] Figure 7 This is an isometric view of the wire laying unit of the ultrafine substrate diameter repair device of the present invention.

[0035] Figure 8 This is a cross-sectional view of the wire laying unit of the ultra-fine substrate diameter repair device of the present invention.

[0036] Figure 9 This is a schematic diagram of the tension control mechanism for the ultrafine substrate diameter repair device of the present invention.

[0037] Figure 10 This is a schematic diagram of the guide component of the ultra-fine substrate diameter repair device of the present invention.

[0038] Figure 11 This is a schematic diagram of the take-up mechanism of the ultra-fine substrate diameter repair device of the present invention.

[0039] Figure 12 This is a schematic diagram of the heating furnace of the ultrafine substrate diameter repair device of the present invention.

[0040] Figure 13 This is an isometric view of the traction tension control mechanism of the ultrafine substrate diameter repair device of the present invention.

[0041] Figure 14 This is a cross-sectional view of the traction tension control mechanism of the ultra-fine substrate diameter repair device of the present invention.

[0042] Figure 15 This is a schematic diagram showing the disassembled components of the ultrafine substrate diameter repair device of the present invention.

[0043] Figure 16 This is a schematic diagram of the winding path of the ultrafine substrate on the traction tension control mechanism of the ultrafine substrate diameter repair device of the present invention.

[0044] Figure 17 This is a front view of the wire feeding path of the ultrafine substrate between the wire feeding mechanism and the wire taking-up mechanism in the ultrafine substrate diameter repair process of the present invention.

[0045] Figure 18This is a top view of the wire feeding path of the ultrafine substrate between the wire feeding mechanism and the heating furnace in the ultrafine substrate diameter repair process of the present invention.

[0046] The attached diagram is labeled as follows: 1 wire feeding device, 2 heating furnace, 3 wire take-up device;

[0047] 4. Wire feeding mechanism; 5. Wire feeding table; 6. Wire feeding unit; 61. Linear module; 62. Wire feeding module; 621. Wire feeding frame; 622. Wire feeding motor; 623. Wire feeding shaft; 624. I-beam wheel; 625. Inner stop plate; 6251. Positioning notch; 6252. Stop groove; 626. Stop rod; 627. Outer stop plate; 628. Locking nut; 629. Positioning protrusion; 632. Support sleeve.

[0048] 7. Wire tension control mechanism; 8. Mounting base one; 81. Top seat; 9. Guide assembly; 91. Height plate; 911. Fixed plate segment; 912. Movable plate segment; 92. Height wheel; 93. Height bolt; 10. Steering wheel one; 11. Tension assembly; 111. Tension motor; 112. Tension rod; 113. Tension wheel; 14. Steering wheel two; 15. Guide wheel.

[0049] 161 Take-up mechanism, 162 Take-up tension control mechanism, 163 Mounting base two;

[0050] 17 Traction tension control mechanism, 18 Traction table, 19 Frame, 20 Drive motor, 21 Drive roller, 211 Main roller body, 212 Main roller sleeve, 22 Driven roller, 221 Driven roller body, 222 Driven roller sleeve, 23 Limiting ring, 24 Winding area;

[0051] 25. Divider assembly, 251. Divider rod, 252. Divider plate, 26. Cable splitter assembly, 261. Cable splitter frame, 262. Cable splitter wheel. Detailed Implementation

[0052] The specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings:

[0053] like Figures 1-16 As shown, the ultrafine substrate coil diameter repair equipment includes a wire feeding device 1, a heating furnace 2, and a wire take-up device 3 arranged in sequence. The ultrafine substrate is released by the wire feeding device 1, passes through the heating furnace 2, and is then wound up by the wire take-up device 3. The coil diameter repair equipment also includes a main control unit, which adopts a PLC control cabinet. The main control unit is used to receive monitoring signals and data from relevant electrical components and control the operation of corresponding drive components.

[0054] The wire feeding device 1 includes a wire feeding mechanism 4 and a wire feeding tension control mechanism 7. The wire feeding mechanism 4 is used for feeding ultra-fine substrates. The wire feeding tension control mechanism 7 is configured to control the wire feeding tension of the wire feeding mechanism 4. Specifically, the wire feeding tension control mechanism 7 acquires the real-time wire feeding tension value detected by itself, compares the real-time tension value with the target tension value, and adjusts the wire feeding speed of the wire feeding mechanism 4 according to the comparison result to control the wire feeding tension.

[0055] The take-up device 3 and the unwinding device 1 have the same structure. The take-up device 3 includes a take-up mechanism 161 and a take-up tension control mechanism 162. The take-up mechanism 161 is used for winding up the ultrafine substrate. The take-up tension control mechanism 162 is configured to control the take-up tension of the take-up mechanism 161. Specifically, the take-up tension control mechanism 162 acquires the real-time take-up tension value detected by itself, compares the real-time tension value with the target tension value, and adjusts the take-up speed of the take-up mechanism 3 according to the comparison result to control the take-up tension.

[0056] The target tension value is set according to the diameter specification of the ultra-fine substrate. For each predetermined size increase in the diameter of the ultra-fine substrate, the target tension value is multiplied by a first coefficient A, which is 1.000~1.100. For each predetermined size decrease in the diameter of the ultra-fine substrate, the target tension value is multiplied by a second coefficient B, which is 0.900~1.000.

[0057] Specifically, obtain the current diameter value D of the ultrafine substrate, and set the target tension value based on D, where:

[0058] When D equals the reference diameter of 30 micrometers, the target tension value is 1.2 N;

[0059] For every 1 micrometer increase in D relative to D0, the target tension value is 1.2 × A;

[0060] When D decreases by 1 micrometer relative to D0, the target tension value is 1.2 × B.

[0061] The wire feeding speed of the wire feeding mechanism 4 and the wire take-up speed of the wire take-up mechanism 161 are set according to the target tension value of the ultrafine substrate. The wire feeding speed of the wire feeding mechanism 4 is calculated according to the following formula:

[0062] Target tension value = T / 0.15, where the target tension value is calculated based on the diameter of the substrate and is known, in N; T is the actual power of the pay-off motor, in N / M; and 0.15 is the lever arm of the tension rod 112 in the pay-off tension control mechanism 7, in M.

[0063] The actual power of the wire-laying motor, T, is calculated as T = K × 0.4 / R, where K is a constant (9550), 0.4 is the power of the wire-laying motor (in KW), and R is the speed of the wire-laying motor. Based on these two formulas, R can be calculated, which gives the wire-laying speed of the wire-laying mechanism 4. The wire-retrieving speed of the wire-retrieving mechanism 161 is also calculated as described above, and will not be repeated here.

[0064] For example: Given that the target tension value is 8.45 N, 8.45 = T / 0.15, we can get T as 1.27 N / M; 1.27 = 9550 × 0.4 / R, we can calculate R as 3000 r / min.

[0065] Meanwhile, traction tension control mechanisms 17 are respectively installed between the wire feeding device 1 and the heating furnace 2, and between the heating furnace 2 and the wire taking-up device 3. That is, a traction tension control mechanism 17 is arranged before and after the heating furnace 2. The traction tension control mechanism 17 is configured to operate according to a preset speed ratio to control the tension of the ultrafine substrate in the heating furnace 2 to be constant. Figures 1-2 As shown.

[0066] The traction speed of the traction tension control mechanism 17 before the heating furnace 2 is consistent with the wire feeding speed of the wire feeding mechanism 4. The preset speed ratio of the two traction tension control mechanisms 17 is 1:1.05 to 1:1.1, and the traction speed of the traction tension control mechanism 17 after the heating furnace 2 is greater than that of the traction tension control mechanism 17 after the heating furnace 2.

[0067] The above can achieve segmented tension control of ultrafine substrates, overcome the disadvantage of conventional hot straightening equipment that only controls temperature, eliminate the problem of wire fluctuation and secondary deformation of ultrafine substrates after unwinding, in heating furnace 2, and before winding, and improve the stability of ultrafine substrate diameter correction.

[0068] The ultrafine substrate is released by the unwinding mechanism 4, and then passes sequentially through the unwinding tension control mechanism 7, a traction tension control mechanism 17, the heating furnace 2, another traction tension control mechanism 17 and the take-up tension control mechanism 162 before being wound up by the take-up mechanism 161.

[0069] As can be seen, the pay-off tension control mechanism 7, the two traction tension control mechanisms 17, and the take-up tension control mechanism 162 are arranged sequentially along the direction of the ultra-fine substrate. Based on the position of the ultra-fine substrate on the conveying path, the ultra-fine substrate between the pay-off mechanism 4 and one traction tension control mechanism 17 is called the pay-off substrate section; the ultra-fine substrate between the two traction tension control mechanisms 17 is called the heating substrate section; and the ultra-fine substrate between the other traction tension control mechanism 17 and the take-up mechanism 161 is called the take-up substrate section.

[0070] In application, the two traction tension control mechanisms 17 are controlled to operate at preset speeds. The tension of the wire feeding base section between the wire feeding mechanism 4 and one traction tension control mechanism 17, and the tension of the wire take-up base section between the other traction tension control mechanism 17 and the wire take-up mechanism 161 are respectively acquired. Based on the deviation between the tension of the wire feeding base section, the tension of the wire take-up base section and the target tension value, the operating speeds of the wire feeding mechanism 4 and the wire take-up mechanism 161 are adjusted to match the tension of each base section with the target tension value.

[0071] In this embodiment, a repair device can be used to perform batch repair operations, that is, to perform batch repair processing on ultrafine substrates with abnormal ring diameters.

[0072] like Figures 3-6 As shown, specifically, the wire feeding mechanism 4 consists of three sets arranged at intervals, all three sets of wire feeding mechanisms 4 are uniformly installed on the wire feeding table 5. Each set of wire feeding mechanism 4 includes two sets of wire feeding units 6 arranged in a stacked manner, with the two sets of wire feeding units 6 located at the bottom and top of the wire feeding table 5, respectively. The two sets of wire feeding units 6 are arranged in opposite directions, that is, one set of wire feeding units 6 is arranged facing one side of the width direction of the wire feeding table 5, and the other set of wire feeding units 6 is arranged facing the other side of the width direction of the wire feeding table 5.

[0073] Each pay-off unit 6 can be matched with an I-beam reel 624 containing an ultra-fine substrate with an abnormally large diameter. The pay-off unit 6 includes a linear module 61 and a pay-off module 62 controlled by the linear module 61. The linear module 61 is a lead screw module driven by a servo motor. The linear module 61 is arranged along the width of the pay-off table 5. The linear module 61 can control the linear reciprocating movement of the pay-off module 62, such as... Figure 7 and Figure 8 As shown.

[0074] The pay-off module 62 has a built-in I-beam reel 624. Ultra-fine substrates with abnormal diameters are wound and wound onto the I-beam reel 624. When the I-beam reel 624 is installed with the pay-off module 62, the pay-off module 62 controls the rotation of the I-beam reel 624 to release the ultra-fine substrate, and controls the rotation speed through pay-off tension. The pay-off module 62 includes a pay-off frame 621, a pay-off motor 622, a pay-off shaft 623, and the I-beam reel 624. The bottom of the pay-off frame 621 is connected and fixed to the linear module 61. The pay-off motor 622, which is a servo motor, is installed at one end of the pay-off frame 621. The pay-off shaft 623 is rotatably connected to the pay-off frame 621 via bearings. One end of the pay-off shaft 623 is connected and fixed to the output end of the pay-off motor 622 via a coupling, and the pay-off motor 622 drives the pay-off shaft 623 to rotate.

[0075] The other end of the pay-off spool 623 extends out of the pay-off frame 621. An inner stop plate 625 is fitted onto the pay-off spool 623, and the inner stop plate 625 is keyed to the pay-off spool 623, so that the pay-off spool 623 drives the inner stop plate 625 to rotate together. The inner stop plate 625 has two symmetrically arranged positioning notches 6251, which are U-shaped recesses. The edge of the inner stop plate 625 also has a stop groove 6252, and a stop rod 626 is slidably connected to the pay-off frame 621. One end of the stop rod 626 slides into the stop groove 6252 to restrict the rotation of the inner stop plate 625, thereby preventing the inner stop plate 625 and the pay-off spool 623 from rotating during the installation of the I-beam wheel 624.

[0076] Meanwhile, an outer stop plate 627 is also fitted onto the pay-off shaft 623. The diameter of the outer stop plate 627 is smaller than that of the inner stop plate 625. A locking nut 628 is threaded onto the other end of the pay-off shaft 623, thereby limiting the outer stop plate 627. After tightening the locking nut 628, the outer stop plate 627 and the inner stop plate 625 cooperate to clamp the I-beam wheel 624. The I-beam wheel 624 is also fitted onto the pay-off shaft 623. The axial direction of the I-beam wheel 624 is consistent with the axial direction of the pay-off shaft 623, and both ends of the I-beam wheel 624 abut against the outer stop plate 627 and the inner stop plate 625 respectively, thereby preventing the I-beam wheel 624 from moving axially. Two positioning protrusions 629 are symmetrically arranged at each end of the I-beam wheel 624. The positioning protrusions 629 are inserted into the positioning notches 6251, and the I-beam wheel 624 can be rotated by the inner stop plate 625. To ensure the stability of the operation of the I-beam 624, a support sleeve 632 is fitted on the wire feeding shaft 623 to support the I-beam 624 from the inside.

[0077] In this embodiment, during installation, a mounting base 8 is provided between two adjacent sets of wire feeding mechanisms 4, and a wire feeding tension control mechanism 7 is provided on each side of the mounting base 8, thus two wire feeding tension control mechanisms 7 are arranged on the mounting base 8. The wire feeding tension control mechanisms 7 on both sides correspond one-to-one with the two sets of wire feeding units 6 in each set of wire feeding mechanisms 4, that is, one set of wire feeding units 6 is matched with one wire feeding tension control mechanism 7.

[0078] like Figure 9 and Figure 10 As shown, the wire tension control mechanism 7 includes a guide assembly 9, a first steering wheel 10, a tension assembly 11, a second steering wheel 14, and a guide wheel 15. The first steering wheel 10, tension assembly 11, second steering wheel 14, and guide wheel 15 are all mounted on a top seat 81, which is located on top of the mounting base 8. When the ultrafine substrate is wound on the wire tension control mechanism 7, it passes sequentially through the guide assembly 9, the first steering wheel 10, the tension assembly 11, the second steering wheel 14, and the guide wheel 15.

[0079] The installation position of the guide component 9 is adapted to the wire feeding unit 6. Since the two sets of wire feeding units 6 in a set of wire feeding mechanisms 4 are respectively arranged on the top and bottom of the wire feeding table 5, the guide components 9 in the corresponding two wire feeding tension control mechanisms 7 are also respectively installed on the top and bottom of the wire feeding table 5.

[0080] The guide assembly 9 includes a height plate 91 and height wheels 92 that are adjustable on the height plate 91. The height plate 91 includes a fixed plate segment 911 and a movable plate segment 912. The bottom of the fixed plate segment 911 is connected and fixed to the wire feeding table 5. The movable plate segment 912 is adjustablely installed on the top of the fixed plate segment 911, and the two overlap. The height wheels 92 are installed on the top of the movable plate segment 912 and are arranged below the steering wheel 10. Specifically, a strip-shaped hole is opened on the movable plate segment 912, and a height bolt 93 passes through the strip-shaped hole. The height bolt 93 passes through the strip-shaped hole and is threadedly connected and fixed to the fixed plate segment 911. After tightening the height bolt 93, the height plate 91 is fixed and cannot be adjusted. After loosening the height bolt 93, the height plate 91 is in an adjustable state, so the height of the height wheel 92 can be adjusted to ensure that the height wheel 92 is adapted to the height of the I-beam wheel 624.

[0081] Steering wheel 10, steering wheel 2 14 and guide wheel 15 are arranged at intervals on the same horizontal plane. The distance between steering wheel 10 and steering wheel 2 14 is greater than the distance between steering wheel 2 14 and guide wheel 15. Steering wheel 10 and steering wheel 2 14 are aligned in the same direction. Steering wheel 2 14 and guide wheel 15 are perpendicular in the same direction. The second axis of guide wheel 15 is perpendicular to the ground.

[0082] The tension assembly 11 includes a tension motor 111, a tension rod 112, and a tension wheel 113. The tension motor 111 is a servo motor and is mounted on the top seat 81. The two ends of the tension rod 112 are connected to the output end of the tension motor 111 and the tension wheel 113, respectively. The tension wheel 113 oscillates in an arc-shaped trajectory around the output end of the tension motor 111, and the oscillation motion can be represented by the rotation of the servo motor. The tension wheel 113 is positioned below and between the first steering wheel 10 and the second steering wheel 14, and is also positioned between the height wheel 92 and the first steering wheel 10.

[0083] After being led out by the pay-off mechanism 4, the ultrafine substrate sequentially passes through the height roller 92, the first steering roller 10, the tension roller 113, the second steering roller 14, and the guide roller 15 before entering a traction tension control mechanism 17. During the wire feeding process, the positions of the height roller 92, the first steering roller 10, the second steering roller 14, and the guide roller 15 are fixed. Because the ultrafine substrate passes through the tension roller 113, any fluctuation in the ultrafine substrate will directly cause the tension roller 113 to swing around the tension motor 111, and the tension motor 111 to rotate. This generates a feedback signal, and the main control unit obtains the real-time tension value. Based on the current tension value, the operating speed of the pay-off unit 6 is controlled to ensure that the actual tension value matches the target tension value.

[0084] like Figure 11 As shown, the pay-off mechanism 4 and the take-up mechanism 161 are corresponding. Since the pay-off mechanism 4 can pay off six coils of ultra-fine substrate with abnormal coil diameter at once, the take-up mechanism 161 also needs to take up the six coils of ultra-fine substrate with the corrected coil diameter one by one. Therefore, there are three sets of take-up mechanisms 161, and the number of take-up mechanisms 161 corresponds one-to-one with the pay-off mechanism 4. The take-up mechanism 161 and the pay-off mechanism 4 have the same structure. Each set of take-up mechanisms 161 includes two sets of take-up units arranged in layers, with the two sets of take-up units arranged in opposite directions. The take-up unit and the pay-off unit 6 have the same structure.

[0085] Meanwhile, a mounting base 163 is provided between two adjacent sets of take-up mechanisms 161. Take-up tension control mechanisms 162 are respectively installed on both sides of the mounting base 163, and each take-up tension control mechanism 162 corresponds one-to-one with the two take-up units in each set of take-up mechanisms 161. The take-up tension control mechanism 162 and the pay-off tension control mechanism 7 have the same structure, and their arrangement directions are opposite.

[0086] In this embodiment, two traction tension control mechanisms 17 cooperate to suspend the ultrafine substrate in mid-air through the heating furnace 2. The heating furnace 2 does not directly contact the ultrafine substrate, but is affected by the temperature inside the heating furnace 2. There is at least one heating furnace 2. If there are multiple heating furnaces 2, they are arranged in a straight line, with adjacent heating furnaces 2 close together. Here, there are two heating furnaces 2, placed on a platform, which lifts the heating furnace 2. Figure 12 As shown. Heating furnace 2 adopts the diamond wire substrate heating furnace 2 disclosed in patent publication number CN121916657A, and the temperature of heating furnace 2 is controlled at 320-480°.

[0087] The temperature control of heating furnace 2 is set according to the diameter of the ultrafine substrate, specifically:

[0088] Obtain the current diameter value D of the ultrafine substrate, and set the temperature of heating furnace 2 according to D, where:

[0089] When D equals the reference diameter of 30 micrometers, the temperature of heating furnace 2 is set to 340℃;

[0090] When D increases by 1 micrometer relative to D0, the temperature of heating furnace 2 is set to 340×X, where X is 1.000~1.100;

[0091] When D decreases by 1 micrometer relative to D0, the temperature of furnace 2 is set to 340×Y, where Y is 0.900~1.000.

[0092] like Figures 13-16 As shown, the traction tension control mechanism 17 is mounted on the traction table 18 and supported by the traction table 18. The traction tension control mechanism 17 includes a frame 19, a drive motor 20, a driving roller 21, and a driven roller 22. The frame 19 is fixedly connected to the traction table 18, and the drive motor 20 is mounted on the frame 19. The drive motor 20 is a servo motor, and its output end is fixedly connected to the driving roller 21.

[0093] Specifically, the drive roller 21 includes a main roller body 211 and a main roller sleeve 212. The main roller body 211 is rotatably connected to the frame 19 via bearings, and the drive motor 20 can directly drive the drive roller 21 to operate. The main roller sleeve 212 is fixedly fitted onto the main roller body 211, and the main roller sleeve 212 and the main roller body 211 rotate together. The outer wall of the main roller sleeve 212 is cylindrical, and multiple limiting rings 23 are evenly spaced on the outer wall of the main roller sleeve 212 to evenly divide the outer wall of the main roller sleeve 212 into six winding areas 24, corresponding to six sets of wire feeding units 6.

[0094] A driven roller 22 is rotatably mounted on the frame 19. The driving roller 21 and the driven roller 22 are arranged vertically at intervals, with the driven roller 22 located below the driving roller 21. The diameter of the driving roller 21 is larger than that of the driven roller 22, and the driving roller 21 and the driven roller 22 are axially aligned. The driving roller 21 includes a driven roller body 221 and a driven roller sleeve 222. One end of the driven roller body 221 is fixedly connected to the frame 19. Six driven roller sleeves 222 are rotatably connected to the driven roller body 221 via bearings. The driven roller sleeves 222 have a grooved wheel structure, and each driven roller sleeve 222 corresponds to one of the six winding areas 24, with a gap between adjacent driven roller sleeves 222.

[0095] As can be seen, the traction tension control mechanism 17 can simultaneously supply six ultra-fine substrates for winding, providing separate areas for each of the six ultra-fine substrates. One ultra-fine substrate is wound between a winding area 24 and the corresponding slave roller sleeve 222. One ultra-fine substrate is wound three times, with each winding shape resembling a drive belt. During the winding process, one ultra-fine substrate contacts the slave roller sleeve 222 twice and the main roller sleeve 212 three times. The main roller sleeve 212 rotates actively, while the slave roller sleeve 222 rotates passively.

[0096] To prevent interference between adjacent ultrafine substrates, a separating assembly 25 is provided on the frame 19. The separating assembly 25 includes separating rods 251 and separating plates 252. One end of the separating rod 251 is connected and fixed to the frame 19. The separating rods 251 are arranged parallel between the driving roller 21 and the driven roller 22. Five separating plates 252 are fixedly fitted onto the separating rods 251. Each separating plate 252 is vertically arranged and has round holes at both its upper and lower ends. The upper end of the separating plate 252 is fitted over the main roller sleeve 212 and corresponds to the limiting ring 23. The lower end of the separating plate 252 is fitted over the driven roller body 221 and corresponds to the interval area between two adjacent driven roller sleeves 222. The separating plates 252 uniformly divide the six ultrafine substrates, preventing mutual interference.

[0097] Since the ultrafine substrates can be released in batches, in order to guide the six ultrafine substrates to enter or exit the traction tension control mechanism 17 evenly, a splitting assembly 26 is also provided on one side of the frame 19. The splitting assembly 26 is configured to evenly separate the multiple ultrafine substrates wound in the heating furnace 2.

[0098] The wire separating assembly 26 includes a wire separating frame 261 and wire separating wheels 262. Six wire separating wheels 262 are arranged above the wire separating frame 261, and are evenly divided into two groups of three. The two groups of wire separating wheels 262 are arranged symmetrically in a figure-eight shape. The axis of the wire separating wheels 262 is perpendicular to the ground, and each wire separating wheel 262 corresponds to one of the six winding areas 24 on the drive roller 21. Thus, the wire separating assembly 26 on one traction tension control mechanism 17 can evenly guide the ultrafine substrate from the wire feeding mechanism 4 to the traction tension control mechanism 17, and the wire separating assembly 26 on the other traction tension control mechanism 17 can evenly guide the ultrafine substrate to the wire take-up mechanism 161.

[0099] The repair equipment of this invention, based on heating and straightening, adds three independent tension control structures: between the wire feeding mechanism 4 and the heating furnace 2, between the front and rear of the heating furnace 2, and between the heating furnace 2 and the wire take-up mechanism 161. These are the wire feeding tension control mechanism 7, the traction tension control mechanism 17, and the wire take-up tension control mechanism 162. Thus:

[0100] 1. By adding a wire feeding tension control mechanism 7 between the wire feeding mechanism 4 and the heating furnace 2, the problems of wire feeding vibration, uneven tension, and offset shaking can be solved, allowing the ultrafine substrate to enter the heating furnace 2 in a constant, straight, and stress-free state. This avoids the problem of wires with initial bending and residual stress entering the furnace for straightening in the existing technology, ensuring the uniformity of stress elimination in the furnace from the source, and significantly improving the uniformity of coil diameter correction.

[0101] 2. By adding traction tension control mechanisms 17 before and after the heating furnace 2, precise and constant tension control can be achieved, allowing the ultrafine substrate softened at high temperature to complete stress release and straightening under the dual conditions of uniform temperature and uniform tension. This effectively solves the problems of uneven cross-sectional stress distribution, wavy deformation, and local straightening failure caused by the existing technology that only controls temperature but not force, ensuring that the diameter of the entire wire strand is consistent.

[0102] 3. A winding tension control mechanism 162 is added between the heating furnace 2 and the winding mechanism 161. This mechanism provides constant force constraint on the ultrafine substrate that has just undergone high-temperature straightening and has not yet fully cooled and set, preventing secondary deformation and coil diameter rebound caused by fluctuations in winding speed, pulling, and slack. This achieves integrated high-temperature straightening and room-temperature setting, firmly locking in the straightening effect and preventing re-bending and defective product rebound after straightening.

[0103] like Figure 17 and Figure 18 As shown, in the ultra-fine substrate diameter repair process, an H-beam 624 with an ultra-fine substrate of abnormal diameter is installed on the pay-off mechanism 4. After the ultra-fine substrate is led out by the pay-off mechanism 4, it is wound around the pay-off tension control mechanism 7, then around a traction tension control mechanism 17, and enters the heating furnace 2. After the ultra-fine substrate is led out by the heating furnace 2, it is wound into another traction tension control mechanism 17, and finally around the take-up tension control mechanism 162 and is wound up by the take-up mechanism 161.

[0104] The target tension value is set on the main control unit according to the diameter specifications of the ultrafine substrate. The temperature of heating furnace 2 is set according to the diameter specifications of the ultrafine substrate, and the temperature range inside heating furnace 2 is 320-480°.

[0105] During the ultra-fine substrate wire feeding process, the main control unit acquires the real-time tension feedback values ​​from the pay-off tension control mechanism 7 and the take-up tension control mechanism 162, respectively. Based on the deviation between the real-time tension feedback value of the pay-off tension control mechanism 7 and the target tension value, the pay-off speed of the pay-off mechanism 4 is adjusted to control the pay-off tension. Simultaneously, based on the deviation between the real-time tension feedback value of the take-up tension control mechanism 162 and the target tension value, the take-up speed of the take-up mechanism 161 is adjusted to control the take-up tension. The traction speed of one traction tension control mechanism 17 is consistent with that of the pay-off mechanism 4, and the two traction tension control mechanisms 17 are set to operate at a constant speed ratio according to a preset schedule.

[0106] The repair process of this invention allows for the determination of a target tension value based on the diameter of the ultrafine substrate. The tension of the ultrafine substrate during the pay-off, heating, and take-up stages can be independently adjusted according to this target tension value, achieving optimal straightening tension in real time. This significantly reduces the straightening defect rate and improves the stability of coil diameter straightening. Through segmented tension optimization control, stress fluctuations and deformation risks can be eliminated throughout the entire process, from wire entering the furnace and in-furnace straightening to final shaping. This significantly improves the coil diameter qualification rate, continuous strip stability, and mass production capacity of the ultrafine substrate.

[0107] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present invention should be included within the scope of the present invention.

Claims

1. A device for repairing the diameter of ultrafine substrate, comprising a wire feeding device (1), a heating furnace (2), and a wire take-up device (3), wherein the ultrafine substrate is released by the wire feeding device (1), passes through the heating furnace (2), and is then wound up by the wire take-up device (3), characterized in that, The wire feeding device (1) includes a wire feeding mechanism (4) and a wire feeding tension control mechanism (7). The wire feeding tension control mechanism (7) is configured to acquire the real-time tension value of the wire feeding and compare it with the target tension value in order to adjust the wire feeding speed of the wire feeding mechanism (4) and control the wire feeding tension. A tension control mechanism (17) is provided between the wire feeding device (1) and the heating furnace (2), and between the heating furnace (2) and the wire taking device (3). The tension control mechanism (17) is configured to operate at a preset speed ratio to control the tension of the ultrafine substrate in the heating furnace (2) to be constant. The take-up device (3) and the release device (1) have the same structure. The take-up device (3) includes a take-up mechanism (161) and a take-up tension control mechanism (162). The take-up tension control mechanism (162) is configured to acquire the real-time tension value of the take-up and compare it with the target tension value in order to adjust the take-up speed of the take-up mechanism (161) and control the take-up tension.

2. The ultrafine substrate diameter repair equipment according to claim 1, characterized in that, The wire feeding mechanism (4) consists of multiple sets arranged at intervals. Each set of wire feeding mechanism (4) includes two sets of wire feeding units (6) arranged in a stacked manner, with the two sets of wire feeding units (6) arranged in opposite directions. An installation base (8) is provided between two adjacent groups of wire feeding mechanisms (4). The wire feeding tension control mechanism (7) is provided on both sides of the installation base (8). The wire feeding tension control mechanism (7) on both sides corresponds one-to-one with the two sets of wire feeding units (6) in each group of wire feeding mechanisms (4).

3. The ultrafine substrate diameter repair equipment according to claim 2, characterized in that, The number of take-up mechanisms (161) is multiple, and the number of take-up mechanisms (161) and the number of release mechanisms (4) are one-to-one. The take-up mechanisms (161) and the release mechanisms (4) have the same structure. Each take-up mechanism (161) includes two sets of take-up units arranged in a stacked manner, and the arrangement directions of the two sets of take-up units are opposite. A mounting base (163) is provided between two adjacent sets of take-up mechanisms (161). The take-up tension control mechanism (162) is provided on both sides of the mounting base (163). The take-up tension control mechanism (162) on both sides corresponds to the two sets of take-up units in each set of take-up mechanisms (161).

4. The ultrafine substrate diameter repair equipment according to claim 1, characterized in that, The wire tension control mechanism (7) includes a guide assembly (9), a first steering wheel (10), a tension assembly (11), a second steering wheel (14), and a guide wheel (15). The ultrafine substrate passes sequentially around the guide assembly (9), the first steering wheel (10), the tension assembly (11), the second steering wheel (14), and the guide wheel (15). The first steering wheel (10), the tension assembly (11), the second steering wheel (14), and the guide wheel (15) are all mounted on the top seat (81). The take-up tension control mechanism (162) and the pay-off tension control mechanism (7) have the same structure, and their arrangement directions are opposite.

5. The ultrafine substrate diameter repair equipment according to claim 4, characterized in that, The guide assembly (9) includes a height plate (91) and height wheels (92) that are adjustable up and down on the height plate (91). The height wheels (92) are arranged below the steering wheel (10). The first steering wheel (10), the second steering wheel (14), and the guide wheel (15) are arranged sequentially on the same horizontal plane. The distance between the first steering wheel (10) and the second steering wheel (14) is greater than the distance between the second steering wheel (14) and the guide wheel (15). The first steering wheel (10) and the second steering wheel (14) are aligned in the same direction. The second steering wheel (14) and the guide wheel (15) are perpendicular in the same direction. The second guide wheel (15) is perpendicular to the ground in the same direction. The tension assembly (11) includes a tension motor (111), a tension rod (112), and a tension wheel (113). The tension motor (111) is mounted on the top seat (81). The two ends of the tension rod (112) are connected to the output end of the tension motor (111) and the tension wheel (113) respectively. The tension wheel (113) swings in an arc-shaped trajectory with the output end of the tension motor (111) as the center. The tension wheel (113) is arranged below the first steering wheel (10) and the second steering wheel (14), and the tension wheel (113) is arranged between the height wheel (92) and the first steering wheel (10).

6. The ultrafine substrate diameter repair equipment according to claim 5, characterized in that, The ultrafine substrate is released by the pay-off mechanism (4), and passes in sequence through the pay-off tension control mechanism (7), a traction tension control mechanism (17), the heating furnace (2), another traction tension control mechanism (17) and the take-up tension control mechanism (162), and is then wound up by the take-up mechanism (161). After the ultrafine substrate is drawn out by the wire feeding mechanism (4), it is wound into the wire feeding tension control mechanism (7) and then sequentially wound around the height wheel (92), the first steering wheel (10), the tension wheel (113), the second steering wheel (14) and the guide wheel (15) before being wound into a traction tension control mechanism (17).

7. The ultrafine substrate diameter repair equipment according to claim 1, characterized in that, The traction tension control mechanism (17) includes a frame (19), a drive motor (20), an active roller (21), and a driven roller (22). The drive motor (20) is mounted on the frame (19), and the output end of the drive motor (20) is connected and fixed to the active roller (21). The driven roller (22) is also rotatably mounted on the frame (19). The active roller (21) and the driven roller (22) are arranged vertically at intervals. A wire splitting assembly (26) is also provided on one side of the frame (19). The wire splitting assembly (26) on the traction tension control mechanism (17) is configured to uniformly separate multiple ultra-fine substrates wound in the heating furnace (2).

8. The ultrafine substrate diameter repair equipment according to claim 1, characterized in that, The preset speed ratio of the two traction tension control mechanisms (17) is 1:1.05 to 1:1.1; The target tension value is set according to the diameter specification of the ultra-fine substrate. For each predetermined size increase in the diameter of the ultra-fine substrate, the target tension value is multiplied by a first coefficient A, which is 1.000~1.

100. For each predetermined size decrease in the diameter of the ultra-fine substrate, the target tension value is multiplied by a second coefficient B, which is 0.900~1.

000.

9. The ultrafine substrate diameter repair equipment according to claim 8, characterized in that, The wire feeding speed of the wire feeding mechanism (4) and the wire take-up speed of the wire take-up mechanism (161) are set according to the target tension value of the ultrafine substrate. The traction speed of the traction tension control mechanism (17) between the wire feeding mechanism (4) and the heating furnace (2) is consistent with the wire feeding speed of the wire feeding mechanism (4). The wire feeding speed of the wire feeding mechanism (4) is calculated according to the following formula: Target tension value = T / 0.15, where T is the actual power of the wire feeding motor and 0.15 is the lever arm of the tension rod in the wire feeding tension control mechanism (7), in meters; The actual power of the wire feeding motor is T = K × 0.4 / R, where K is a constant 9550, 0.4 is the power of the wire feeding motor in KW, and R is the speed of the wire feeding motor.

10. A process for repairing the diameter of ultra-fine substrate rings, characterized in that, Using the repair equipment described in any one of claims 1-9, an I-beam reel (624) with an abnormally fine substrate is installed on the wire feeding mechanism (4). After the ultrafine substrate is drawn out by the wire feeding mechanism (4), it is wound around the wire feeding tension control mechanism (7), and then around a traction tension control mechanism (17) and enters the heating furnace (2). After the ultrafine substrate is drawn out by the heating furnace (2), it is wound into another traction tension control mechanism (17), and finally around the take-up tension control mechanism (162) and is wound up by the take-up mechanism (161). The main control unit obtains the real-time tension feedback value of the pay-off tension control mechanism (7) and the real-time tension feedback value of the take-up tension control mechanism (162) respectively. Based on the deviation between the real-time tension feedback value of the pay-off tension control mechanism (7) and the target tension value, the pay-off speed of the pay-off mechanism (4) is adjusted to control the pay-off tension. At the same time, based on the deviation between the real-time tension feedback value of the take-up tension control mechanism (162) and the target tension value, the take-up speed of the take-up mechanism (161) is adjusted to control the take-up tension. The traction speed of one traction tension control mechanism (17) is consistent with that of the pay-off mechanism (4), and the two traction tension control mechanisms (17) are set to operate at a constant speed ratio according to a preset speed.

Images