Energy-saving tension preheating integrated device for cable conductor production

Abstract

The application relates to an energy-saving tension preheating integrated device for cable conductor production, which comprises a supporting assembly, a conveying assembly, a heating assembly and a control assembly. The supporting assembly comprises a machine box, a feeding pipe and a discharging pipe. The conveying assembly comprises a wire passing wheel and a conveying wheel installed on one side of the wire passing wheel. The conveying wheel cooperates with the wire passing wheel to convey the conductor. The heating assembly comprises a shell, a conduit and a heating element. The shell is arranged between the conveying wheel and the wire passing wheel. The conduit is installed in the shell for the conductor to pass through. The heating element is sleeved on the conduit. The control assembly comprises a speed detector, a temperature detector and a controller. The speed detector and the temperature detector are respectively installed at two ends of the shell. The speed detector detects the real-time linear velocity of the conductor. The temperature detector detects the real-time temperature of the conductor. The speed detector and the temperature detector are both signal-connected with the controller. The controller dynamically adjusts the output power of the heating element according to the real-time temperature of the cable conductor. The device improves the temperature control precision and realizes dynamic constant-temperature preheating of the cable conductor under variable-speed working conditions.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, and in particular to an energy-saving tension preheating integrated device for cable conductor production. Background Technology

[0002] In the cable manufacturing process, tension control and preheating of the conductors are required. Currently, tension control and preheating are two independent processes, and the industry commonly uses a combination of a split-type tension machine and a straight-through eddy current preheater. However, with the two machines controlled separately, it is difficult to synchronize the operating parameters, leading to problems such as tension fluctuations and uneven temperatures during cable conductor transport. Moreover, traditional straight-through eddy current preheaters rely on magnetic lines of force cutting the conductor to generate eddy current heating, requiring repeated searches for the resonant frequency point during operation. This results in poor operational stability and an inability to adapt to dynamic production conditions such as conductor acceleration and deceleration, making it difficult to guarantee product processing consistency. In addition, traditional straight-through eddy current preheaters have large temperature control deviations and are prone to temperature overshoot, lag, and oscillation during acceleration and deceleration, failing to achieve dynamic constant temperature control. Summary of the Invention

[0003] Therefore, it is necessary to provide an energy-saving tension preheating integrated device for cable and conductor production to address the above problems.

[0004] An energy-saving tension preheating integrated device for cable and conductor production includes a support assembly, a conveying assembly, a heating assembly, and a control assembly. The support assembly includes a chassis, an inlet pipe, and an outlet pipe, with the inlet pipe and outlet pipe respectively connected to both ends of the chassis. The conveying assembly includes a wire guide roller and a conveying wheel mounted on one side of the wire guide roller. Both the wire guide roller and the conveying wheel are rotatably connected to the chassis. The wire guide roller is positioned close to the inlet pipe, and the conveying wheel cooperates with the wire guide roller to convey the cable and conductor. The heating assembly includes a housing, a conduit, and a heating element. The housing is equipped with... On one side of the chassis, the outer shell is disposed between the conveyor wheel and the cable guide wheel; the conduit is installed inside the outer shell for cable conductors to pass through; the heating element is sleeved on the conduit; the control component includes a speed sensor, a temperature sensor, and a controller, the speed sensor and the temperature sensor are respectively installed at both ends of the outer shell, the speed sensor is used to detect the real-time linear velocity of the cable conductor; the temperature sensor is used to detect the real-time temperature of the cable conductor; both the speed sensor and the temperature sensor are signal-connected to the controller; the controller dynamically adjusts the output power of the heating element according to the real-time temperature of the cable conductor.

[0005] In one embodiment, the driving circuit of the heating component includes a first branch, a first electrode, and a second electrode. The first branch is provided with a temperature control element and the heating element, and the temperature control element is connected in series with the heating element. The first electrode and the second electrode are used to connect to a power source, and the first branch is electrically connected to the first electrode and the second electrode to form a parallel circuit.

[0006] In one embodiment, there are two heating components, which correspond to the top and bottom of the conveyor wheel, respectively. The driving circuit of the heating component also includes a second branch connected in parallel with the first branch, and the second branch is provided with another heating element. The first branch and the second branch are connected in parallel and their two ends are respectively connected to the first electrode and the second electrode.

[0007] In one embodiment, the support assembly further includes a frame, a horizontal guide rail, a slider, and a vertical guide rail. The chassis and the outer shell are both mounted on one side of the frame. The horizontal guide rail is mounted on the support surface, the slider slides on the horizontal guide rail, the vertical guide rail is mounted on the slider, and the frame slides on the vertical guide rail.

[0008] In one embodiment, the support assembly further includes a bracket, rollers, and pressure rollers. The bracket is installed at one end of the chassis where the feed pipe is installed. There are two rollers, which are slid laterally on the bracket and are used to abut against the cable conductor. There are two pressure rollers, which are slid vertically on the bracket and are used to abut against the cable conductor.

[0009] In one embodiment, the transmission assembly further includes a rotating shaft, a transmission shaft, and a transmission power element. Both the rotating shaft and the transmission shaft are rotatably connected to the frame. One end of the rotating shaft is mounted on the wire guide wheel, and the rotating shaft drives the wire guide wheel to rotate. One end of the transmission shaft is mounted on the transmission wheel, and the transmission shaft drives the transmission wheel to rotate. The transmission power element drives the transmission shaft to rotate. The controller adjusts the rotational speed of the transmission power element in real time based on the feedback linear velocity of the cable. The temperature sensor monitors the resistance change of the cable in real time. The controller accurately measures the current actual temperature based on the real-time feedback resistance of the cable and the positive temperature coefficient of the cable resistance, thus completing temperature signal acquisition. The controller adjusts the output power of the heating element in real time based on the real-time temperature of the cable to stabilize the temperature control accuracy within a predetermined range.

[0010] In one embodiment, the support assembly further includes an air intake pipe connected to the chassis; the heating assembly further includes an air intake connector, one end of which is connected to the outer casing and the other end of which is connected to the air intake pipe, the air intake pipe being used to deliver protective gas to the outer casing; the outer casing is mounted on one side of the frame; the outer casing is provided with through holes.

[0011] In one embodiment, the guide roller and the conveyor roller are offset vertically; the outer casing is tilted, with one end of the outer casing corresponding to the guide roller and the other end corresponding to the conveyor roller.

[0012] In one embodiment, the heating element is a resistive short-circuit heating element; the speed sensor is a rotary encoder; and the temperature sensor is installed at the output terminal of the housing.

[0013] In one embodiment, the guide wheel is provided with a plurality of guide grooves to accommodate the cable conductor.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0015] The present invention relates to an energy-saving tension preheating integrated device for cable and conductor production. The device uses a conveyor wheel and a guide wheel to transport the cable and conductor. The outer shell is located between the conveyor wheel and the guide wheel. The cable and conductor are threaded through a conduit. The device integrates cable and conductor tension adjustment and cable and conductor preheating functions. A speed sensor detects the linear velocity of the cable and conductor, and a temperature sensor detects the temperature of the cable and conductor. The controller dynamically adjusts the output power of the heating element according to the real-time temperature of the cable and conductor, thereby improving temperature control accuracy, response speed, and dynamic tracking capability, and realizing dynamic constant temperature preheating of the cable and conductor under variable speed conditions. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of an energy-saving tension preheating integrated device for cable and conductor production according to an embodiment of the present invention;

[0017] Figure 2 for Figure 1 Enlarged view of center circle A;

[0018] Figure 3 for Figure 1 The diagram shown is a structural schematic of an energy-saving tension preheating integrated device for cable and conductor production from another angle.

[0019] Figure 4 for Figure 1 Schematic diagram of the structure of the conveying component and the heating component;

[0020] Figure 5 for Figure 4 Cross-sectional view of the heating component;

[0021] Figure 6 for Figure 1 A schematic diagram of the circuit connection of the drive circuit for the heating component;

[0022] Figure 7 for Figure 1 The diagram shows the structure of the control component in an energy-saving tension preheating integrated device for cable and conductor production.

[0023] The meanings of the numbers in the attached diagram are as follows:

[0024] 100. Energy-saving tension preheating integrated device for cable and conductor production;

[0025] 10. Support assembly; 11. Chassis; 12. Feed pipe; 13. Discharge pipe; 14. Air inlet pipe; 15. Frame; 16. Support; 17. Roller; 18. Pressure roller; 19. Horizontal guide rail; 11a. Slider; 12a. Vertical guide rail; 20. Conveying assembly; 21. Wire guide roller; 210. Guide groove; 22. Conveying wheel; 23. Rotating shaft; 24. Conveying shaft; 25. Conveying power element;

[0026] 30. Heating component; 31. Housing; 311. Through hole; 32. Conduit; 33. Heating element; 34. Air inlet connector; 34. First branch; 35. First electrode; 36. Second electrode; 37. Temperature control element; 38. Second branch; 40. Control component; 41. Speed ​​sensor; 42. Temperature sensor; 43. Controller; 44. Full-condition fault self-test and protection module; 45. Alarm. Detailed Implementation

[0027] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0028] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention 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 this invention.

[0029] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0030] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0031] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0032] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0033] Please refer to Figures 1 to 7An energy-saving tension preheating integrated device 100 for cable and conductor production, according to one embodiment of the invention, includes a support assembly 10, a conveying assembly 20, a heating assembly 30, and a control assembly 40. The support assembly 10 includes a housing 11, an inlet pipe 12, and an outlet pipe 13, with the inlet pipe 12 and outlet pipe 13 respectively connected to both ends of the housing 11. The conveying assembly 20 includes a wire guide roller 21 and a conveying roller 22 mounted on one side of the wire guide roller 21. Both the wire guide roller 21 and the conveying roller 22 are rotatably connected to the housing 11. The wire guide roller 21 is positioned close to the inlet pipe 12, and the conveying roller 22 cooperates with the wire guide roller 21 to convey the cable and conductor. The heating assembly 30 includes a housing 31, a conduit 32, and a heating element 33. The housing 31 is mounted on the housing 11. On one side of the chassis 11, the outer shell 31 is disposed between the conveyor wheel 22 and the wire guide wheel 21; the conduit 32 is installed inside the outer shell 31 for cable conductors to pass through; the heating element 33 is sleeved on the conduit 32; the control component 40 includes a speed sensor 41, a temperature sensor 42, and a controller 43. The speed sensor 41 and the temperature sensor 42 are respectively installed at both ends of the outer shell 31. The speed sensor 41 is used to detect the real-time linear speed of the cable conductor; the temperature sensor 42 is used to detect the real-time temperature of the cable conductor; both the speed sensor 41 and the temperature sensor 42 are signal-connected to the controller 43; the controller 43 dynamically adjusts the output power of the heating element 33 according to the real-time temperature of the cable conductor to stabilize the temperature control accuracy within a predetermined range; in one embodiment, the cable conductor is a copper wire. The energy-saving tension preheating integrated device 100 for cable and conductor production in this embodiment uses a conveyor wheel 22 and a guide wheel 21 to transport the cable and conductor. The outer shell 31 is disposed between the conveyor wheel 22 and the guide wheel 21. The cable and conductor are passed through a conduit 32, integrating cable and conductor tension adjustment and cable and conductor preheating functions into one unit. The linear velocity of the cable and conductor is detected by a speed sensor 41, and the temperature of the cable and conductor is detected by a temperature sensor 42. The controller 43 dynamically adjusts the output power of the heating element 33 according to the real-time temperature of the cable and conductor, improving the temperature control accuracy, response speed and dynamic tracking capability, and realizing dynamic constant temperature preheating of the cable and conductor under variable speed conditions.

[0034] like Figures 1 to 3 As shown, in this embodiment, the support assembly 10 includes a chassis 11, an inlet pipe 12, and an outlet pipe 13. The inlet pipe 12 and the outlet pipe 13 are respectively connected to both ends of the chassis 11. In one embodiment, the support assembly 10 further includes an air inlet pipe 14, which is connected to the chassis 11 and is used to deliver protective gas to the chassis 11. Optionally, the protective gas is nitrogen; in other embodiments, the protective gas is other inert gases. The support assembly 10 also includes a frame 15, and both the chassis 11 and the heating assembly 30 are mounted on one side of the frame 15.

[0035] like Figure 2 As shown, the support assembly 10 also includes a bracket 16, rollers 17, and pressure rollers 18. The bracket 16 is installed at one end of the housing 11 where the feed pipe 12 is installed. There are two rollers 17, which are slid laterally on the bracket 16 and are used to abut against the cable conductor. There are two pressure rollers 18, which are slid vertically on the bracket 16 and are used to abut against the cable conductor. By adjusting the distance between the two pressure rollers 18 and the distance between the two rollers 17, the cable conductor is initially shaped to accommodate cables of different thicknesses.

[0036] like Figure 1 and Figure 3 As shown, the support assembly 10 also includes a horizontal guide rail 19, a slider 11a, and a vertical guide rail 12a. The horizontal guide rail 19 is mounted on the support surface, and the slider 11a is slidably mounted on the horizontal guide rail 19 to adjust the horizontal position. The vertical guide rail 12a is mounted on the slider 11a, and the frame 15 is slidably mounted on the vertical guide rail 12a to adjust the vertical position, thereby adjusting the position of the chassis 11.

[0037] Please refer to the following: Figure 1 and Figure 4 The conveying assembly 20 includes a wire guide roller 21 and a conveying roller 22 mounted on one side of the wire guide roller 21. Both the wire guide roller 21 and the conveying roller 22 are rotatably connected to the housing 11. The wire guide roller 21 is located close to the feed pipe 12, and the conveying roller 22 cooperates with the wire guide roller 21 to convey the cable conductor. Optionally, the wire guide roller 21 is provided with multiple guide grooves 210 to accommodate the cable conductor, and the guide grooves 210 play a guiding role. Further, the wire guide roller 21 and the conveying roller 22 are vertically offset. In one embodiment, the top of the wire guide roller 21 is lower than the top of the conveying roller 22.

[0038] In one embodiment, the conveying assembly 20 further includes a rotating shaft 23, a conveying shaft 24, and a conveying power element 25. Both the rotating shaft 23 and the conveying shaft 24 are rotatably connected to the frame 15. One end of the rotating shaft 23 is mounted on the wire guide wheel 21, and the rotating shaft 23 drives the wire guide wheel 21 to rotate. One end of the conveying shaft 24 is mounted on the conveying wheel 22, and the conveying shaft 24 drives the conveying wheel 22 to rotate. The conveying power element 25 drives the conveying shaft 24 to rotate. Optionally, the servo tension adjustment range is 0.5-10 kgf. Further, the conveying power element 25 is a magnetic powder brake, which is prior art.

[0039] like Figure 4 and Figure 5As shown, the heating assembly 30 is disposed between the conveyor wheel 22 and the wire guide wheel 21, and is used to heat the cable conductor. Optionally, the heating assembly 30 includes a housing 31, a conduit 32, and a heating element 33. The housing 31 is installed on one side of the chassis 11 and is disposed between the conveyor wheel 22 and the wire guide wheel 21; further, the housing 31 is installed on one side of the frame 15; the housing 31 has a through hole 311. The conduit 32 is installed inside the housing 31 for the cable conductor to pass through; the heating element 33 is sleeved on the conduit 32. Optionally, the heating assembly 30 includes an air inlet connector 34, one end of which is connected to the housing 31, and the other end is connected to the air inlet pipe 14, which is used to deliver protective gas to the housing 31. In one embodiment, the heating element 33 is a resistive short-circuit heating element, belonging to a purely resistive load. Its power factor is approximately 1, and its actual power is approximately the active power, maximizing efficiency and significantly improving heating efficiency. Optionally, the outer casing 31 is inclined, with one end corresponding to the wire guide wheel 21 and the other end corresponding to the conveyor wheel 22. In one embodiment, there are two heating components 30, corresponding to the top and bottom of the conveyor wheel 22, respectively.

[0040] like Figure 6 As shown, the driving circuit of the heating component 30 includes a first branch 34, a first electrode 35, and a second electrode 36. The first branch 34 is equipped with a temperature control element 37 and the heating element 33, with the temperature control element 37 connected in series with the heating element 33. The first electrode 35 and the second electrode 36 are used to connect to a power source. The first branch 34 electrically connects the first electrode 35 and the second electrode 36 to form a parallel circuit. Through the parallel circuit, the resistance of the wire is reduced, making the potential voltage approach zero, suppressing the change in sliding resistance, and protecting the surface quality of the wire. Optionally, the first electrode 35 is electrically connected to the live wire, and the second electrode 36 is electrically connected to the neutral wire, forming a parallel circuit. Further, the temperature control element 37 is an SSR solid-state relay. In one embodiment, the driving circuit of the heating component 30 further includes a second branch 38 connected in parallel with the first branch 34, and the second branch 38 is provided with another heating element 33; after the first branch 34 and the second branch 38 are connected in parallel, their two ends are respectively connected to the first electrode 35 and the second electrode 36; a dual parallel driving circuit is adopted.

[0041] like Figure 1 and Figure 7As shown, the control component 40 includes a speed sensor 41, a temperature sensor 42, and a controller 43. The speed sensor 41 and the temperature sensor 42 are respectively installed at both ends of the housing 31. The speed sensor 41 is used to detect the real-time linear velocity of the cable conductor; the temperature sensor 42 is used to detect the real-time temperature of the cable conductor; both the speed sensor 41 and the temperature sensor 42 are signal-connected to the controller 43. The controller 43 adjusts the tension in real time according to the linear velocity of the cable conductor, and dynamically adjusts the output power of the heating element 33 according to the real-time temperature of the cable conductor, so that the temperature control accuracy is stable within a predetermined range. Optionally, the controller 43 adjusts the rotational speed of the transmission power element 25 in real time according to the feedback linear velocity of the cable conductor, thereby adjusting the tension. Furthermore, the temperature sensor 42 is installed at the output end of the housing 31; the temperature sensor 42 monitors the resistance change of the cable in real time, and the controller 43 accurately measures the current actual temperature based on the real-time feedback of the cable resistance and the positive temperature coefficient characteristic of the wire resistance, thus completing the temperature signal acquisition; the controller 43 adjusts the output power of the heating element 33 in real time according to the real-time temperature of the cable to keep the temperature control accuracy stable within a predetermined range; optionally, the principle of accurately measuring the current actual temperature based on the positive temperature coefficient characteristic of the wire resistance refers to the principle of the thermal resistance sampling probe; further, the predetermined range of temperature control accuracy is ±5℃ of the predetermined value; the control response speed reaches 100ms, effectively eliminating temperature overshoot, lag, and oscillation problems; further, the speed sensor 41 is a rotary encoder; in one embodiment, the speed sensor 41 is a 2000-mesh rotary encoder, which samples the speed signal through a 2000-mesh rotary encoder, and has the characteristics of high speed resolution and fast response; the temperature sensor 42 is existing technology.

[0042] In one embodiment, the control component 40 further includes a housing (not shown) and a communication interface (not shown). The controller 43 is installed inside the housing, and the power transmission element 25 and the heating element 33 are respectively connected to the controller 43 via signals. The communication interface is connected to a host computer, which can view equipment operating data, modify operating parameters, and monitor status in real time through the communication interface, realizing remote control and seamless integration into automated production lines. The control system 40 also includes a full-condition fault self-check and protection module 44, which can monitor and handle abnormal states such as no-load, overload, short circuit, grounding, and parameter errors in real time. Once no-load, overload, short circuit, or parameter error is detected, the protection mechanism is immediately triggered. The control system 40 also includes an alarm 45, which sounds an alarm when the temperature of the conductor is lower than the minimum preset value or higher than the maximum preset value to remind the user. By controlling the tension and preheating processes through the controller 43, the synchronization of equipment operation is improved, and the stability and consistency of product processing are significantly improved. Operators only need to operate one piece of equipment to complete all processes, simplifying the work process and effectively reducing labor intensity.

[0043] In use, the cable conductor flows sequentially through roller 17, pressure roller 18, feed pipe 12, conveyor roller 22, lower guide tube 32, wire guide roller 21, upper guide tube 32, and discharge pipe 13. The transmission power element 25 drives the transmission shaft 24 to rotate, which in turn drives the conveyor roller 22 to rotate. The conveyor roller 22 then drives the cable conductor to rotate, which in turn drives the wire guide roller 21 to rotate, thereby realizing the transmission and tension control of the cable conductor. The heating element 33 heats the cable conductor flowing through the guide tube 32. At the same time, protective gas continuously enters the outer casing 31 through the air inlet pipe 14 and air inlet connector 34, and is then blown out through the through hole 311, which also discharges some heat into the chassis 11. A positive pressure environment and an inert gas isolation layer are formed in the preheating area to isolate air and prevent the cable conductor from oxidizing and discoloring due to high temperature, thus improving quality. The parallel circuit of the driving circuit of the heating component 30 eliminates the influence of potential voltage and protects the surface of the conductor. This energy-saving tension preheating integrated device 100 for cable and conductor production integrates cable and conductor tension adjustment and preheating functions, reducing footprint, improving operational synchronization, and reducing manual labor intensity. The transmission power element 25 outputs constant tension according to preset parameters, pulling the cable to be transported at a uniform speed, maintaining stable tension throughout the process. The linear velocity of the cable and conductor is detected in real time by the speed sensor 41, and the controller 43 adjusts the rotation speed of the transmission power element 25 in real time based on the feedback of the cable and conductor linear velocity, thereby adjusting the tension to ensure stable tension throughout the cable and conductor transport process, avoiding cable and conductor stretching and slack problems, and adapting to continuous production of cables of different specifications. During the uniform speed, acceleration, and deceleration of the cable and conductor, the controller 43 measures the real-time temperature based on the real-time resistance value of the cable and conductor, and then dynamically adjusts the output power of the heating element 33 to ensure that the temperature remains constant within a predetermined range under uniform speed, rapid acceleration, and rapid deceleration conditions. By using a resistive short-circuit heating element 33, the energy utilization rate and power factor are improved, resulting in enhanced heating efficiency and excellent energy-saving performance. Furthermore, the resistive short-circuit heating element 33 does not require real-time resonant frequency searching, thus improving control precision, response speed, and dynamic tracking capability. In contrast, traditional direct-flow eddy current preheating is limited by the weak magnetic properties of copper, resulting in an energy conversion efficiency of only about 30%, with approximately 70% of the electrical energy lost as heat through water cooling, leading to significant energy waste. Moreover, this heating method has a low power factor, large fluctuations in operating energy consumption, and persistently high electricity costs for production.

[0044] The energy-saving tension preheating integrated device 100 for cable and conductor production of the present invention uses a conveyor wheel 22 and a guide wheel 21 to convey cables and conductors. The outer shell 31 is disposed between the conveyor wheel 22 and the guide wheel 21. The cables and conductors are passed through a guide tube 32. The device integrates the functions of cable and conductor tension adjustment and cable and conductor preheating. The linear velocity of the cables and conductors is detected by a speed sensor 41, and the temperature of the cables and conductors is detected by a temperature sensor 42. The controller 43 dynamically adjusts the output power of the heating element 33 according to the real-time temperature of the cables and conductors, thereby improving the temperature control accuracy, response speed and dynamic tracking capability, and realizing dynamic constant temperature preheating of cables and conductors under variable speed conditions.

[0045] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0046] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. An energy-saving tension preheating integrated device for cable and conductor production, characterized in that, The system includes a support assembly, a conveying assembly, a heating assembly, and a control assembly. The support assembly includes a chassis, an inlet pipe, and an outlet pipe, with the inlet pipe and outlet pipe respectively connected to both ends of the chassis. The conveying assembly includes a wire guide roller and a conveying wheel mounted on one side of the wire guide roller. Both the wire guide roller and the conveying wheel are rotatably connected to the chassis. The wire guide roller is positioned close to the inlet pipe, and the conveying wheel cooperates with the wire guide roller to convey cable wires. The heating assembly includes a housing, a conduit, and a heating element. The housing is mounted on one side of the chassis. The outer casing is disposed between the conveyor wheel and the guide wheel; the conduit is installed inside the outer casing for the cable conductor to pass through; the heating element is sleeved on the conduit; the control component includes a speed sensor, a temperature sensor, and a controller, the speed sensor and the temperature sensor are respectively installed at both ends of the outer casing, the speed sensor is used to detect the real-time linear velocity of the cable conductor; the temperature sensor is used to detect the real-time temperature of the cable conductor; both the speed sensor and the temperature sensor are signal-connected to the controller; the controller dynamically adjusts the output power of the heating element according to the real-time temperature of the cable conductor.

2. The energy-saving tension preheating integrated device for cable and conductor production according to claim 1, characterized in that, The driving circuit of the heating component includes a first branch, a first electrode, and a second electrode. The first branch is provided with a temperature control element and the heating element, and the temperature control element is connected in series with the heating element. The first electrode and the second electrode are used to connect to a power source, and the first branch is electrically connected to the first electrode and the second electrode to form a parallel circuit.

3. The energy-saving tension preheating integrated device for cable and conductor production according to claim 2, characterized in that, There are two heating components, which correspond to the top and bottom of the conveyor wheel, respectively. The driving circuit of the heating component also includes a second branch connected in parallel with the first branch, and the second branch is provided with another heating element. The first branch and the second branch are connected in parallel and their two ends are respectively connected to the first electrode and the second electrode.

4. The energy-saving tension preheating integrated device for cable and conductor production according to claim 1, characterized in that, The support assembly also includes a frame, a horizontal guide rail, a slider, and a vertical guide rail. The chassis and the outer shell are both installed on one side of the frame. The horizontal guide rail is installed on the support surface, the slider slides on the horizontal guide rail, the vertical guide rail is installed on the slider, and the frame slides on the vertical guide rail.

5. The energy-saving tension preheating integrated device for cable and conductor production according to claim 4, characterized in that, The support assembly also includes a bracket, rollers, and pressure rollers. The bracket is installed at one end of the machine housing where the feed pipe is installed. There are two rollers, which are slid laterally on the bracket and are used to abut against the cable conductor. There are two pressure rollers, which are slid vertically on the bracket and are used to abut against the cable conductor.

6. The energy-saving tension preheating integrated device for cable and conductor production according to claim 4, characterized in that, The transmission assembly further includes a rotating shaft, a transmission shaft, and a transmission power element. Both the rotating shaft and the transmission shaft are rotatably connected to the frame. One end of the rotating shaft is mounted on the wire guide wheel, and the rotating shaft drives the wire guide wheel to rotate. One end of the transmission shaft is mounted on the transmission wheel, and the transmission shaft drives the transmission wheel to rotate. The transmission power element drives the transmission shaft to rotate. The controller adjusts the rotational speed of the transmission power element in real time based on the feedback linear velocity of the cable. The temperature sensor monitors the resistance change of the cable in real time. The controller accurately measures the current actual temperature based on the real-time feedback resistance of the cable and the positive temperature coefficient of the cable resistance, thus completing temperature signal acquisition. The controller adjusts the output power of the heating element in real time based on the real-time temperature of the cable to stabilize the temperature control accuracy within a predetermined range.

7. The energy-saving tension preheating integrated device for cable and conductor production according to claim 4, characterized in that, The support assembly further includes an air intake pipe that connects to the chassis; the heating assembly further includes an air intake connector, one end of which connects to the outer casing and the other end of which connects to the air intake pipe, the air intake pipe being used to deliver protective gas to the outer casing; the outer casing is mounted on one side of the frame; the outer casing is provided with through holes.

8. The energy-saving tension preheating integrated device for cable and conductor production according to claim 1, characterized in that, The guide roller and the conveyor roller are offset vertically; the outer casing is tilted, with one end of the outer casing corresponding to the guide roller and the other end corresponding to the conveyor roller.

9. The energy-saving tension preheating integrated device for cable and conductor production according to claim 1, characterized in that, The heating element is a resistive short-circuit heating element; the speed sensor is a rotary encoder; and the temperature sensor is installed at the output terminal of the housing.

10. The energy-saving tension preheating integrated device for cable and conductor production according to claim 1, characterized in that, The guide wheel is provided with multiple guide grooves to accommodate the cable conductors.

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