Diamond bus wire drawing device and control method

Abstract

A kind of diamond bus wire drawing device and control method, including wire drawing machine, drawing module, traction unit, guide pulley group and cold liquid unit, water tank is connected with circulating conduit corresponding to each cold liquid unit, and each circulating conduit is provided with concentration sensor, fresh water connector and concentrated liquid connector in turn along the direction of cooling liquid delivery.Based on the present application, by integrating concentration sensor, temperature sensor and corresponding adjusting connector and heat preservation sleeve on circulating conduit, and combining real-time adjustment of cooling liquid physical parameters with feedback of traction motor, according to sensor signal, actively control cooling liquid concentration and temperature, stabilize friction coefficient between wire and die from source, use electrical parameters of traction motor as quantitative feedback of system resistance, when resistance exceeds reference range, cooperatively adjust motor speed or torque to dynamically compensate traction force mutation, solve the defect that cooling liquid parameters and traction control are mutually disjointed, reduce the risk of broken wire rate and wire diameter out-of-tolerance.

Description

Technical Field

[0001] This invention belongs to the field of metal wire drawing technology, specifically referring to a diamond busbar wire drawing device and control method. Background Technology

[0002] Diamond wire is a core consumable in fields such as photovoltaic silicon wafer slicing. Its wire drawing process directly determines the wire's toughness and dimensional accuracy. A water-tank type wire drawing machine is a diameter reduction device that relies on a cooling lubricant (emulsion) to achieve wet, multi-pass continuous drawing. The wire passes through multiple drawing dies one by one for cross-sectional compression, and stable traction is provided by progressively faster traction wheels at the rear. During this process, the circulating coolant comprehensively coats the wire and dies, providing strong lubrication, reducing friction, washing away metal powder, and promptly removing drawing heat. In the drawing process, the cooling lubricant, as the core medium, plays a crucial role in reducing die friction and removing processing heat.

[0003] Currently, most wire drawing equipment relies on periodic sampling and testing of coolant, lacking precise online real-time control methods. After prolonged continuous operation, the coolant is prone to abnormal conditions such as decreased concentration and increased temperature. This directly leads to a thinning of the lubricating film between the wire and the drawing die, causing drastic fluctuations in the coefficient of friction and resulting in frequent and abrupt changes in system resistance during drawing. Such irregular changes in physical parameters severely interfere with the stable operation of the constant tension control system of the traction unit motor, easily causing wire breakage or exceeding tolerances in wire diameter. Summary of the Invention

[0004] In view of the above situation and to overcome the defects of the prior art, the purpose of the present invention is to provide a diamond busbar wire drawing device and control method to at least partially solve the problems mentioned in the background art.

[0005] The technical solution adopted in this invention is as follows: A diamond busbar wire drawing device is proposed, comprising: The wire drawing machine is equipped with a horizontally arranged water receiving tray; Multiple wire drawing modules are installed sequentially on the wire drawing machine according to the wire feeding direction; Multiple traction units are mounted on the wire drawing machine and configured on the rear side of each wire drawing module for drawing wire; Multiple sets of guide wheels are configured and installed on the front and rear sides of each wire drawing module; Multiple sets of cooling liquid units are configured and installed above each of the wire drawing modules, and spray cooling liquid onto the wire drawing modules; The bottom of the water receiving tray is fixedly equipped with a water tank. Each water tank is connected to a circulation conduit for each coolant unit. Each circulation conduit is provided with a concentration sensor, a clean water inlet, and a concentrate inlet in sequence along the coolant delivery direction. The concentration sensor is configured to detect the coolant concentration in the circulation conduit. Based on the concentration detected by the concentration sensor, fluid is introduced into the circulation conduit through the clean water inlet and the concentrate inlet to adjust the coolant concentration at the outlet of the coolant unit, so as to maintain the system resistance when the filament contacts the drawing module and the traction unit.

[0006] Furthermore, a raw liquid connector is also installed on the circulation conduit behind the concentrate connector. A temperature sensor and an insulation sleeve are correspondingly installed on the rear side of the raw liquid connector. The temperature sensor is configured to detect the temperature of the coolant in the circulation conduit. The raw liquid connector is used to input low-temperature coolant into the circulation conduit. The insulation sleeve is used to heat the coolant in the circulation conduit to maintain the coolant temperature at the outlet of the cold liquid unit.

[0007] Furthermore, the wire drawing module includes a wire drawing die, a die mounting base, and a flow guide pool. The wire drawing die is fixed to the wire drawing machine via the die mounting base, and the wire passes through the wire drawing die in a horizontal position. The flow guide pool is installed on the outside of the die mounting base, and a wire passage is opened on the flow guide pool corresponding to the path of the wire. The coolant unit is located above the wire drawing die and sprays coolant toward the wire drawing die and the die mounting base.

[0008] Furthermore, the interior of the flow guide pool has a flow guide cavity for containing coolant, and a flow guide cylinder is fixedly installed at the bottom center of the flow guide pool. The flow guide cylinder is connected to the flow guide cavity and can guide the coolant in the flow guide cavity to the water receiving tray. The orientation of the wire passage corresponds to the position of the traction unit and the guide wheel assembly.

[0009] Furthermore, the traction unit includes a traction wheel and a motor. The motor is fixed to the wire drawing machine, and the traction wheel is fixed to the output end of the motor. The motor drives the traction wheel to pull the wire through the wire drawing die at a set speed.

[0010] Furthermore, the motor includes a variable frequency motor or a servo motor, and multiple motors are connected to a motor control system. Along the wire drawing direction, the speed of the motor increases step by step to maintain constant tension during the wire drawing process.

[0011] Furthermore, the guide wheel assembly includes a pair of guide wheels disposed on the front and rear sides of the wire drawing die assembly. The guide wheels are used to transport the wire and make the wire at the same height as the die hole in the wire drawing die.

[0012] Furthermore, the cooling liquid unit includes a universal hose and a supply pipe. The supply pipe is fixed to the drawing machine and is connected to the circulation conduit. The universal hose is fixed to the supply pipe, and the outlet of the universal hose faces the drawing module and the traction wheel.

[0013] A second aspect of the present invention provides a method for controlling the drawing of diamond busbar wire, which utilizes the aforementioned diamond busbar wire drawing device and includes the following steps: Step 1: Start the wire drawing machine, multiple traction units and circulation pipes to make the coolant circulate between the coolant unit and the water tank, and drive multiple traction units to pull the wire through the wire drawing module at a set speed with progressively increasing speed. Step 2: The concentration and temperature of the coolant are detected in real time by the concentration sensor and temperature sensor on the circulation duct, respectively, and the detection signals are fed back to the motor control system. Step 3: The motor control system controls the water inlet and / or concentrate inlet to introduce the corresponding fluid into the circulation pipe according to the deviation between the real-time concentration and the preset target concentration; at the same time, according to the deviation between the real-time temperature and the preset target temperature, it controls the raw liquid inlet to introduce low-temperature coolant and / or controls the insulation sleeve to heat, so that the coolant at the outlet of the cold liquid unit is maintained within the preset target concentration and target temperature range, so as to ensure that the friction coefficient between the wire and the drawing module is within the set range; Step 4: While adjusting the coolant parameters in step 3, the motor control system reads the torque or current signal of the motor in the traction unit in real time, and calculates the real-time system resistance value of the wire during the drawing process based on the torque or current signal. Step 5: Compare the real-time system resistance value with the preset system resistance fluctuation reference range. When the real-time system resistance value exceeds the reference range, the motor control system adjusts the motor speed setpoint or torque output value in coordination to offset the sudden change in traction force caused by the change in the physical state of the coolant, thereby dynamically maintaining the constant tension of the entire wire drawing process.

[0014] Furthermore, in step 5: when the coolant temperature is detected to be higher than the target temperature upper limit, or the coolant concentration is lower than the target concentration lower limit, causing the friction coefficient between the wire and the drawing module to rise sharply, and the torque or current signal of the motor to exceed the preset upper limit threshold, the motor control system, while quickly adjusting the coolant to restore lubrication performance in step 3, sends a dynamic buffer command to the motor to temporarily reduce the speed difference between adjacent traction motors or reduce its torque response slope to compensate for the instantaneous increase in traction force and prevent the wire from breaking due to sudden tension changes; When the concentration sensor and temperature sensor report that the coolant index has returned to normal, and the motor torque or current signal falls back to the preset system resistance fluctuation range, the motor control system then smoothly restores each traction motor to the preset steady-state constant tension control curve. When the coolant parameters improve and the system resistance is low, the motor control system adjusts the motor speed difference accordingly to reduce tension. Through real-time cross-compensation of the coolant physical lubrication parameters and the electric power traction parameters, the system resistance is stabilized under complex working conditions.

[0015] Beneficial effects: This invention integrates a concentration sensor, a temperature sensor, and corresponding regulating pipes and insulation sleeves into the circulation conduit. It combines real-time adjustment of coolant physical parameters with feedback from the traction motor. Based on sensor signals, it actively regulates coolant concentration and temperature, stabilizing the friction coefficient between the wire and the die from the source. The electrical parameters of the traction motor serve as quantitative feedback for system resistance. When the resistance exceeds a reference range, the motor speed or torque is adjusted to dynamically compensate for sudden changes in traction force. This solves the problem of disconnect between coolant parameters and traction control, reducing wire breakage rate and the risk of wire diameter deviation. Attached Figure Description

[0016] Figure 1 This is a three-dimensional structural schematic diagram of a diamond busbar wire drawing device proposed in an embodiment of the present invention; Figure 2 This is a front view schematic diagram of a diamond busbar wire drawing device according to an embodiment of the present invention; Figure 3 This is a partial structural diagram of the wire drawing module and traction unit proposed in an embodiment of the present invention; Figure 4 This invention provides a schematic diagram of the internal structure of a wire drawing module according to an embodiment of the invention. Figure 5 This is a side view of a diamond busbar wire drawing device according to an embodiment of the present invention.

[0017] Among them, 10, wire drawing machine; 11, water receiving tray; 12, machine frame; 20, wire drawing module; 200, flow guide cavity; 21, wire drawing die; 22, die mounting base; 23, flow guide pool; 230, wire passage channel; 231, flow guide cylinder; 30, traction unit; 31, traction wheel; 32, motor; 40, guide wheel assembly; 41, guide wheel; 50, cold liquid unit; 51, universal hose; 52, liquid supply pipe; 60, water tank; 61, circulation conduit; 62, concentration sensor; 63, clean water connection pipe; 64, concentrated liquid connection pipe; 65, raw liquid connection pipe; 66, temperature sensor; 67, insulation sleeve.

[0018] The accompanying drawings are provided to further understand the embodiments and form part of the specification. They are used together with the embodiments for explanation and do not constitute a limitation on the embodiments. Detailed Implementation

[0019] The technical solutions in 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, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection.

[0020] In the description of the embodiments, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing the embodiments and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments.

[0021] like Figure 1 and Figure 2 As shown, an embodiment of the present invention provides a wire drawing device for diamond busbars, including a wire drawing machine 10, a wire drawing module 20, a traction unit 30, a guide wheel group 40, a coolant unit 50, and a water tank 60.

[0022] The wire drawing machine 10 has a frame 12 at its bottom and a horizontally arranged water receiving tray 11 on the top of the frame 12. Multiple wire drawing modules 20 are installed on the wire drawing machine 10 in sequence according to the wire conveying direction. Multiple traction units 30 are installed on the wire drawing machine 10 and are arranged on the rear side of each wire drawing module 20 for traction of wire. Multiple sets of guide wheel groups 40 are arranged and installed on the front and rear sides of each wire drawing module 20. Multiple sets of coolant units 50 are arranged and installed above each wire drawing module 20 and spray coolant onto the wire drawing module 20.

[0023] In some embodiments, the frame 12 provides rigid support for the entire device, and the water receiving tray 11 is located below all the drawing dies 20 and the traction unit 30 to receive and collect the sprayed coolant. Multiple drawing dies 20 are arranged sequentially according to the wire's travel path, forming a multi-pass diameter reduction process. Each drawing die 20 is backed by a corresponding traction unit 30 to provide the required traction force for that pass. Each set of guide rollers 40 is respectively located on the inlet and outlet sides of each drawing die 20 to guide the wire smoothly in and out. After being sprayed by the cooling liquid unit 50, the coolant covers the drawing die 21 and the surface of the wire, and then flows into the water receiving tray 11 under gravity.

[0024] Furthermore, such as Figure 5 As shown, a water tank 60 is fixedly installed at the bottom of the water receiving tray 11. Each water tank 60 is connected to a circulation conduit 61 corresponding to each coolant unit 50. Each circulation conduit 61 is provided with a concentration sensor 62, a clean water connector 63, and a concentrate connector 64 in sequence along the coolant delivery direction. The concentration sensor 62 is configured to detect the coolant concentration in the circulation conduit 61. Based on the concentration detected by the concentration sensor 62, fluid is introduced into the circulation conduit 61 through the clean water connector 63 and the concentrate connector 64 to adjust the coolant concentration at the outlet of the coolant unit 50, so as to maintain the system resistance when the filament contacts the drawing module 20 and the traction unit 30.

[0025] The water tank 60 serves as the main coolant storage container, and coolant is pumped to each coolant unit 50 via circulation pipes 61. On each circulation pipe 61, a concentration sensor 62 is installed near the outlet side of the water tank 60 to measure the coolant concentration in real time. A clean water inlet 63 and a concentrate inlet 64 are located downstream of the concentration sensor 62, respectively connected to an external clean water source and a concentrate source, and each is equipped with a flow control valve. When the concentration sensor 62 detects that the coolant concentration is lower than a preset target value, the control system controls the valve of the concentrate inlet 64 to open, adding a high-concentration concentrate to the pipeline; when the concentration is higher than the target value, it controls the valve of the clean water inlet 63 to open, injecting clean water for dilution, thereby achieving online active adjustment of the coolant concentration.

[0026] Furthermore, a raw liquid inlet pipe 65 is also installed on the circulation conduit 61 behind the concentrate inlet pipe 64. A temperature sensor 66 and an insulation sleeve 67 are installed on the rear side of the raw liquid inlet pipe 65. The temperature sensor 66 is configured to detect the temperature of the coolant in the circulation conduit 61. The raw liquid inlet pipe 65 is used to input low-temperature coolant into the circulation conduit 61. The insulation sleeve 67 is used to heat the coolant in the circulation conduit 61 to maintain the coolant temperature at the outlet of the coolant unit 50.

[0027] In some embodiments, the raw fluid inlet 65 introduces a low-temperature reserve coolant that has not participated in the circulation. Its function differs from the concentrate inlet 64, primarily serving for temperature regulation. A temperature sensor 66 is installed after the raw fluid inlet 65 to acquire the temperature of the mixed coolant in real time. An insulation sleeve 67 is fitted over the outer wall of the circulation conduit 61, and hot water or an electric heating medium can be introduced into it to heat the coolant within the conduit. When the temperature sensor 66 detects that the coolant temperature is too high, the control system opens the valve of the raw fluid inlet 65 to introduce fresh, low-temperature coolant for mixing and cooling; when the temperature is too low, the insulation sleeve 67 is activated for heating, thereby stabilizing the coolant temperature within the process window. Through the coordinated operation of the raw fluid inlet 65 and the insulation sleeve 67, temperature fluctuations can be responded to quickly, ensuring a constant coolant temperature at the outlet of the coolant unit 50.

[0028] like Figure 3 and Figure 4 As shown, the wire drawing module 20 includes a wire drawing die 21, a die mounting base 22, and a flow guide pool 23. The wire drawing die 21 is fixed to the wire drawing machine 10 through the die mounting base 22, and the wire passes through the wire drawing die 21 in a horizontal position. The flow guide pool 23 is installed on the outside of the die mounting base 22, and a wire passage 230 is opened on the flow guide pool 23 corresponding to the path of the wire. The coolant unit 50 is located above the wire drawing die 21 and sprays coolant toward the wire drawing die 21 and the die mounting base 22.

[0029] In some embodiments, the drawing die 21 has a die hole inside, through which the wire passes under traction to achieve diameter reduction. The die mounting base 22 is used to precisely fix the drawing die 21 at a designated position on the drawing machine 10 and ensure that the axis of its die hole is aligned with the direction of wire travel. The guide pool 23 is disposed on the outlet side of the drawing die 21 and arranged around the wire path. The wire passage 230 on it allows the wire to pass through, and the sidewalls and bottom of the guide pool 23 can temporarily collect the coolant sprayed into this area to prevent it from splashing everywhere. The outlet of the coolant unit 50 is aligned with the inlet end of the drawing die 21 and its contact area with the wire to ensure that the coolant can be directly sprayed onto the main friction-heating interface.

[0030] Furthermore, the interior of the flow guide pool 23 has a flow guide cavity 200 for containing coolant. A flow guide cylinder 231 is fixedly installed at the middle position of the bottom of the flow guide pool 23. The flow guide cylinder 231 communicates with the flow guide cavity 200 and can guide the coolant in the flow guide cavity 200 to the water receiving tray 11. The orientation of the wire passage 230 corresponds to the position of the traction unit 30 and the guide wheel assembly 40. The flow guide cavity 200 is a hollow structure located inside the flow guide pool 23, used to collect the coolant sprayed down from above.

[0031] The guide tube 231 is vertically positioned at the center of the bottom of the guide pool 23, with its upper opening communicating with the bottom of the guide cavity 200 and its lower outlet extending above the water receiving tray 11. Coolant entering the guide cavity 200 converges to the guide tube 231 under gravity, and then falls stably into the water receiving tray 11, thus preventing coolant accumulation or disorderly flow around the mold. The wire passage 230 is located on the front and rear side walls of the guide pool 23, with its center height consistent with the height of the die hole of the drawing die 21, the guide wheel groove of the guide wheel assembly 40, and the traction surface of the traction wheel 31, ensuring smooth horizontal passage of the wire.

[0032] Furthermore, the traction unit 30 includes a traction wheel 31 and a motor 32. The motor 32 is fixed on the wire drawing machine 10, and the traction wheel 31 is fixed to the output end of the motor 32. The motor 32 drives the traction wheel 31 to pull the wire through the wire drawing die 21 at a set speed.

[0033] Furthermore, the traction wheel 31 is a rotating body with grooves on its circumference. The wire winds around the grooves of the traction wheel 31, and traction is achieved through the friction between the wheel surface and the wire. The motor 32 provides rotational power to the traction wheel 31, and its output shaft is directly or through a transmission mechanism connected to the traction wheel 31. When the motor 32 is running, the traction wheel 31 rotates accordingly, using the static friction between its grooves and the wire to drive the wire to move along the direction of travel, thereby overcoming the deformation resistance generated by the drawing die 21 and achieving continuous drawing. Each traction unit 30 is driven independently, and its speed can be adjusted separately.

[0034] In some embodiments, the motor 32 includes a variable frequency motor or a servo motor. Multiple motors 32 are connected to a motor control system, and their speeds increase progressively along the wire drawing direction to maintain constant tension during the wire drawing process. Using variable frequency motors or servo motors facilitates precise speed and torque control. All motors 32 are connected to a unified motor control system, which has speed setting, torque monitoring, and closed-loop regulation functions. Since the wire diameter continuously decreases during each drawing pass, to maintain stable wire tension between passes and compensate for changes in volumetric flow rate, the linear speed of the subsequent traction wheel 31 along the drawing direction needs to be slightly higher than that of the previous traction wheel 31. Therefore, the speed setting of the motor 32 increases progressively in the order of passes. The motor control system coordinates the speed differences between the motors 32 to maintain appropriate tension in the wire between each drawing module 20, preventing loosening or overstretching.

[0035] Furthermore, the guide wheel assembly 40 includes a pair of guide wheels 41 disposed on the front and rear sides of the drawing die 20. The guide wheels 41 are used to transport the wire and ensure that the wire is at the same height as the die hole in the drawing die 21. Each drawing die 20 has one guide wheel 41 on the inlet side and one on the outlet side. The guide wheel 41 on the inlet side guides the wire from the previous traction unit 30 or the wire feeding mechanism to the center line of the die hole of the drawing die 21, ensuring that the wire enters the die hole at the correct angle and height, avoiding uneven wear. The guide wheel 41 on the outlet side leads the drawn wire out of the die hole and guides it to the next traction unit 30 or the wire take-up mechanism. The installation positions of the two guide wheels 41 are calibrated so that the axis of the wire passing between them coincides with the axis of the die hole of the drawing die 21, thereby ensuring that the wire travels horizontally and reducing additional stress and die wear caused by angular deviation.

[0036] Furthermore, the coolant unit 50 includes a universal hose 51 and a supply pipe 52. The supply pipe 52 is fixed to the wire drawing machine 10 and is connected to the circulation conduit 61. The universal hose 51 is fixed to the supply pipe 52, and the outlet of the universal hose 51 faces the wire drawing module 20 and the traction wheel 31.

[0037] The supply pipe 52 serves as a rigid channel for coolant delivery, with one end connected to the circulation conduit 61 and the other end connected to the universal hose 51, its position fixed. The universal hose 51 is a flexible, shape-adjustable metal or plastic hose, allowing for adjustment of its outlet orientation and height within a certain spatial range. Operators can manually bend the universal hose 51 according to actual working conditions, ensuring its outlet is precisely aligned with the inlet cone surface of the wire drawing die 21 and the wire groove area of ​​the traction wheel 31. This ensures that the coolant can simultaneously lubricate and cool the contact areas between the die and the wire, as well as the contact areas between the traction wheel 31 and the wire, improving lubrication and cooling effects.

[0038] A second aspect of the present invention provides a method for controlling the drawing of diamond busbar wire, which utilizes the aforementioned diamond busbar wire drawing device and includes the following steps: Step 1: Start the wire drawing machine 10, multiple traction units 30, and circulation conduit 61 to circulate the coolant between the coolant unit 50 and the water tank 60, and drive the multiple traction units 30 to pull the wire through the wire drawing module 20 at a set speed with progressively increasing speeds. This step is the initialization and steady-state operation start-up stage of the device. First, start the coolant circulation pump to deliver the coolant in the water tank 60 to the supply pipe 52 of each coolant unit 50 through the circulation conduit 61, and spray it onto the corresponding wire drawing die 21 and traction wheel 31 through the universal hose 51. The sprayed coolant flows back to the water tank 60 through the guide pool 23 and the water receiving tray 11, forming a continuous circulation. At the same time, the motor control system sends an initial speed command to each motor 32 according to the preset wire drawing process parameters, so that the linear speed of the traction wheel 31 of the subsequent pass is proportionally higher than that of the previous pass, thereby establishing and maintaining the initial tension of the wire at the moment of start-up, driving the wire to pass through all the wire drawing modules 20 in sequence, and starting continuous drawing.

[0039] Step 2: The concentration sensor 62 and temperature sensor 66 on the circulation conduit 61 detect the real-time concentration and temperature of the coolant, respectively, and feed the detection signals back to the motor control system. During the wire drawing process, the concentration sensor 62 continuously measures the concentration of the coolant flowing through the circulation conduit 61, and the temperature sensor 66 continuously measures the temperature of the coolant. Both sensors transmit the detected electrical or digital signals to the data processing module in the motor control system in real time. The control system compares these real-time data with the internally stored setpoints as the input for subsequent adjustments. This step ensures that the control system can grasp the current true physical state of the coolant.

[0040] Step 3: The motor control system controls the clean water inlet 63 and / or the concentrate inlet 64 to introduce the corresponding fluid into the circulation conduit 61 according to the deviation between the real-time concentration and the preset target concentration; at the same time, according to the deviation between the real-time temperature and the preset target temperature, it controls the raw liquid inlet 65 to introduce low-temperature coolant and / or controls the heat insulation sleeve 67 to heat it, so that the coolant at the outlet of the cold liquid unit 50 is maintained within the preset target concentration and target temperature range, so as to ensure that the friction coefficient between the wire and the drawing module 20 is within the set range.

[0041] Thus, this step constitutes an automatic adjustment process for the physical properties of the coolant. When the real-time concentration is higher than the target concentration, the control system outputs a signal to open the valve of the clean water inlet 63, injecting clean water for dilution; when the real-time concentration is lower than the target concentration, the valve of the concentrate inlet 64 is opened to replenish the concentrate. Regarding temperature regulation, if the real-time temperature is higher than the target temperature, the valve of the original liquid inlet 65 is opened to introduce new, low-temperature liquid for mixing and cooling; if the real-time temperature is lower than the target temperature, the heating function of the insulation sleeve 67 is activated. Through the above closed-loop regulation, the concentration and temperature of the coolant ultimately sprayed from the coolant unit 50 are controlled within a pre-set reasonable range, thereby stabilizing the lubrication film characteristics between the wire and the mold, and keeping the coefficient of friction essentially constant.

[0042] Step 4: While adjusting the coolant parameters in Step 3, the motor control system reads the torque or current signal of the motor 32 in the traction unit 30 in real time, and calculates the real-time system resistance value of the wire during the drawing process based on the torque or current signal. Simultaneously with the coolant adjustment, the motor control system uses the feedback function of the frequency converter or servo driver to collect the current output torque value or drive current value of each motor 32 in real time. Since the traction force is proportional to the motor torque, the control system calculates the actual traction force borne by the wire in each pass using a preset mathematical model based on known parameters such as the torque constant of the motor 32 and the diameter of the traction wheel 31. This traction force reflects the comprehensive system resistance experienced by the wire when passing through the drawing die 21. This calculated value serves as a quantitative indicator for determining whether the system is in a stable working state.

[0043] Step 5: Compare the real-time system resistance value with the preset system resistance fluctuation reference range. When the real-time system resistance value exceeds the reference range, the motor control system coordinates the adjustment of the speed setpoint or torque output value of motor 32 to offset the sudden change in traction force caused by the change in the physical state of the coolant, thereby dynamically maintaining constant tension throughout the wire drawing process. This step is the dynamic compensation process for electrical traction parameters. The control system internally stores the allowable fluctuation range of system resistance obtained from process experiments.

[0044] When the real-time system resistance value calculated in step 4 exceeds this range, it indicates that the coolant lubrication condition has not been completely eliminated, or that there is an abnormality in the wire itself. In this case, the control system does not rely on the hysteresis feedback of coolant regulation, but directly issues commands to fine-tune the speed setpoint of the corresponding motor 32. For example, it may temporarily change the speed difference between adjacent passes or directly adjust its torque output upper limit to quickly compensate for the traction force. This proactive intervention can quickly counteract the tension disturbance caused by sudden changes in the friction coefficient, ensuring that the force state of the wire within the die cavity remains stable and preventing wire breakage.

[0045] When the coolant temperature is detected to be higher than the target upper limit or the coolant concentration is lower than the target lower limit, causing a sharp increase in the coefficient of friction between the wire and the drawing module 20, or when the torque or current signal of the motor 32 exceeds the preset upper limit threshold, the motor control system, while quickly adjusting the coolant to restore lubrication performance through step 3, sends a dynamic buffer command to the motor 32 to temporarily reduce the speed difference between adjacent traction motors 32 or reduce their torque response slope to compensate for the instantaneous increase in traction force and prevent the wire from breaking due to sudden tension changes.

[0046] In this situation, a single coolant adjustment response speed may not be sufficient to prevent wire breakage. Therefore, after the control system identifies the danger signal through the motor electrical parameters, it actively reduces the speed difference between adjacent traction wheels 31, that is, reduces the tensile strain rate acting on the wire, or reduces the response slope of the motor torque controller to make the traction force increase gradually, thereby buying time for the coolant system to restore lubrication performance, effectively buffering the impact load, and preventing wire breakage.

[0047] When the concentration sensor 62 and temperature sensor 66 report that the coolant index has returned to normal, and the motor torque or current signal falls back to the preset system resistance fluctuation range, the motor control system then smoothly restores each traction motor 32 to the preset steady-state constant tension control curve.

[0048] Thus, when the coolant physical parameters return to the target range and the motor load signal shows that the system resistance has returned to normal, the control system confirms that the system has escaped the dangerous state. At this point, it will gradually withdraw the previously applied dynamic buffering measures, restoring the speed difference and torque response slope of motor 32 to the steady-state value set by the normal wire drawing process with a smooth slope, avoiding secondary impacts during the recovery process, and achieving a smooth transition to the stable state of the system.

[0049] Conversely, when the coolant parameters tend to be favorable, resulting in lower system resistance, the motor control system accordingly fine-tunes the speed difference of motor 32 to reduce tension. Through real-time cross-compensation of the coolant physical lubrication parameters and the electric power traction parameters, the system resistance under complex working conditions is stabilized.

[0050] When abnormal coolant lubrication performance leads to a decrease in system resistance, the wire may become loose or slip due to insufficient tension. In this situation, the control system detects that the motor torque / current is below the reference range and automatically and appropriately increases the speed difference between adjacent traction wheels 31, increasing the tension acting on the wire to compensate for the reduced frictional resistance and ensure the wire remains taut. Through bidirectional cross-control of active coolant regulation and real-time electrical parameter compensation, this invention effectively addresses wide fluctuations in coolant properties, suppressing system resistance fluctuations within an extremely narrow range.

[0051] 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.

[0052] The embodiments have been described above, and such description is not restrictive. The figures shown are only one embodiment, and the actual structure is not limited to this. In short, if a person skilled in the art is inspired by this description and designs a similar structure and embodiment without departing from the inventive spirit, such design should fall within the scope of protection.

Claims

1. A wire drawing device for diamond busbars, characterized in that, include: The wire drawing machine (10) is equipped with a horizontally arranged water receiving tray (11). Multiple wire drawing modules (20) are installed sequentially on the wire drawing machine (10) according to the wire conveying direction; Multiple traction units (30) are mounted on the wire drawing machine (10) and arranged on the rear side of each wire drawing module (20) for drawing wire; Multiple sets of guide rollers (40) are configured to be installed on the front and rear sides of each of the wire drawing modules (20); Multiple sets of coolant units (50) are configured to be installed above each of the wire drawing modules (20) and spray coolant onto the wire drawing modules (20); The bottom of the water receiving tray (11) is fixedly equipped with a water tank (60). The water tank (60) is connected to a circulation pipe (61) for each of the coolant units (50). Each circulation pipe (61) is provided with a concentration sensor (62), a clean water pipe (63), and a concentrate pipe (64) in sequence along the coolant delivery direction. The concentration sensor (62) is configured to detect the coolant concentration in the circulation pipe (61). Based on the concentration detected by the concentration sensor (62), fluid is introduced into the circulation pipe (61) through the clean water pipe (63) and the concentrate pipe (64) to adjust the coolant concentration at the outlet of the coolant unit (50) so as to maintain the system resistance when the wire comes into contact with the drawing module (20) and the traction unit (30).

2. The diamond busbar wire drawing device according to claim 1, characterized in that: A raw liquid inlet (65) is also installed on the circulation conduit (61) behind the concentrate inlet (64). A temperature sensor (66) and an insulation sleeve (67) are installed on the rear side of the raw liquid inlet (65). The temperature sensor (66) is configured to detect the temperature of the coolant in the circulation conduit (61). The raw liquid inlet (65) is used to input low-temperature coolant into the circulation conduit (61). The insulation sleeve (67) is used to heat the coolant in the circulation conduit (61) to maintain the coolant temperature at the outlet of the cold liquid unit (50).

3. The diamond busbar wire drawing device according to claim 1, characterized in that: The wire drawing module (20) includes a wire drawing die (21), a die mounting base (22), and a flow guide pool (23). The wire drawing die (21) is fixed to the wire drawing machine (10) through the die mounting base (22) and the wire passes through the wire drawing die (21) in a horizontal posture. The flow guide pool (23) is installed on the outside of the die mounting base (22), and a wire passage (230) is opened on the flow guide pool (23) corresponding to the path of the wire. The coolant unit (50) is located above the wire drawing die (21) and sprays coolant toward the wire drawing die (21) and the die mounting base (22).

4. The diamond busbar wire drawing device according to claim 3, characterized in that: The interior of the flow guide pool (23) has a flow guide cavity (200) for containing coolant. A flow guide cylinder (231) is fixedly provided at the middle position of the bottom of the flow guide pool (23). The flow guide cylinder (231) is connected to the flow guide cavity (200) and can guide the coolant in the flow guide cavity (200) to the water receiving tray (11). The orientation of the wire passage (230) corresponds to the position of the traction unit (30) and the guide wheel group (40).

5. The diamond busbar wire drawing device according to claim 3, characterized in that: The traction unit (30) includes a traction wheel (31) and a motor (32). The motor (32) is fixed on the wire drawing machine (10), and the traction wheel (31) is fixed to the output end of the motor (32). The motor (32) drives the traction wheel (31) to pull the wire through the wire drawing die (21) at a set speed.

6. The diamond busbar wire drawing device according to claim 5, characterized in that: The motor (32) includes a variable frequency motor or a servo motor. Multiple motors (32) are connected to a motor control system. Along the wire drawing direction, the speed of the motor (32) increases step by step to maintain constant tension during the wire drawing process.

7. The diamond busbar wire drawing device according to claim 3, characterized in that: The guide wheel assembly (40) includes a pair of guide wheels (41) disposed on the front and rear sides of the wire drawing die (20). The guide wheels (41) are used to transport the wire and make the wire at the same height as the die hole in the wire drawing die (21).

8. The diamond busbar wire drawing device according to claim 5, characterized in that: The cooling unit (50) includes a universal hose (51) and a supply pipe (52). The supply pipe (52) is fixed to the wire drawing machine (10) and is connected to the circulation conduit (61). The universal hose (51) is fixed to the supply pipe (52), and the outlet of the universal hose (51) faces the wire drawing module (20) and the traction wheel (31).

9. A method for controlling the wire drawing of diamond busbars, characterized in that: The diamond busbar wire drawing device according to any one of claims 1-8 includes the following steps: Step 1: Start the wire drawing machine (10), multiple traction units (30) and circulation pipe (61) to make the coolant circulate between the coolant unit (50) and the water tank (60), and drive the multiple traction units (30) to pull the wire through the wire drawing module (20) at a set speed with progressively increasing speed. Step 2: The real-time concentration and temperature of the coolant are detected by the concentration sensor (62) and temperature sensor (66) on the circulation conduit (61), and the detection signals are fed back to the motor control system. Step 3: The motor control system controls the clean water inlet (63) and / or the concentrate inlet (64) to introduce the corresponding fluid into the circulation pipe (61) according to the deviation between the real-time concentration and the preset target concentration; at the same time, according to the deviation between the real-time temperature and the preset target temperature, it controls the raw liquid inlet (65) to introduce low-temperature coolant and / or controls the heat insulation sleeve (67) to heat, so that the coolant at the outlet of the cold liquid unit (50) is maintained within the preset target concentration and target temperature range, so as to ensure that the friction coefficient between the wire and the drawing module (20) is within the set range; Step 4: While adjusting the coolant parameters in step 3, the motor control system reads the torque or current signal of the motor (32) in the traction unit (30) in real time, and calculates the real-time system resistance value of the wire during the drawing process based on the torque or current signal. Step 5: Compare the real-time system resistance value with the preset system resistance fluctuation reference range. When the real-time system resistance value exceeds the reference range, the motor control system coordinates to adjust the speed setpoint or torque output value of the motor (32) to offset the sudden change in traction force caused by the change in the physical state of the coolant, thereby dynamically maintaining the constant tension of the entire wire drawing process.

10. The method for controlling the wire drawing of diamond busbars according to claim 9, characterized in that: In step 5: when the coolant temperature is detected to be higher than the target temperature upper limit, or the coolant concentration is lower than the target concentration lower limit, causing the friction coefficient between the wire and the drawing module (20) to rise sharply, and the torque or current signal of the motor (32) to exceed the preset upper limit threshold, the motor control system sends a dynamic buffer command to the motor (32) while quickly adjusting the coolant to restore lubrication performance in step 3, temporarily reducing the speed difference between adjacent traction motors (32) or reducing their torque response slope to compensate for the instantaneous increase in traction force and prevent the wire from breaking due to sudden tension changes; When the concentration sensor (62) and temperature sensor (66) report that the coolant index has returned to normal, and the motor torque or current signal falls back to the preset system resistance fluctuation range, the motor control system then smoothly restores each traction motor (32) to the preset steady-state constant tension control curve. When the coolant parameters tend to be better, resulting in a lower system resistance, the motor control system will adjust the speed difference of the motor (32) accordingly to reduce the tension. Through real-time cross-compensation of the physical lubrication parameters of the coolant and the traction parameters of the electric power, the system resistance under complex working conditions can be stabilized.

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