A multi-level gradient shaping and curing device for electromagnetic wire insulation coating

Abstract

This invention relates to the field of cable manufacturing technology, and in particular to a multi-level gradient shaping and curing device for electromagnetic wire insulation coating. The device includes a curing chamber, a low-temperature solidification zone, a medium-temperature shaping zone, a high-temperature curing zone, a heating unit, a rolling unit, and a shaping unit. This invention solves the following problems existing in the prior art: the inability to perform full-coverage, multi-directional rolling of the cable's outer insulation layer without dead angles leads to uneven circumferential thickness of the insulation layer, easily affecting its subsequent insulation performance; the inability to continuously heat the insulation material results in the cooled insulation layer being difficult to roll and shape, affecting the rolling effect; this invention can perform multi-gradient heating of the insulation coating, during which multi-level circumferential rolling is performed on the insulation coating, continuously achieving solidification, shaping, and curing of the insulation coating. During this process, an annular air curtain seals the wire-passing hole, preventing crosstalk between external air or air between adjacent temperature zones, thereby providing a stable temperature environment for the shaping and curing of the insulation coating.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, and in particular to a multi-level gradient shaping and curing device for electromagnetic wire insulation coating. Background Technology

[0002] As the core protective barrier of cables, the insulation coating's curing quality directly determines the cable's electrical insulation performance and service life. The insulation coating is typically applied to the cable's outer wall using an extruder, with molten insulating material applied. The insulation coating thickness for low-voltage cables is 0.7mm–2mm, for medium-voltage cables it's 3.4mm–9mm, while for high-voltage and ultra-high-voltage cables it's 18.5mm and 24mm–27mm, respectively. Defects such as bubbles, pinholes, stress concentration, and uneven circumferential thickness in the insulation coating can directly lead to localized electric field distortion and a significant drop in breakdown voltage. During long-term operation, this can result in coating cracking, peeling, and accelerated aging, potentially causing major safety accidents such as short circuits, power outages, and fires, resulting in incalculable economic losses and safety hazards. Therefore, after coating the cable's outer wall with insulation, appropriate curing and shaping are necessary to improve the yield rate.

[0003] In the prior art, those skilled in the art have also provided technical solutions for the shaping and curing of cable insulation coatings. For example, Chinese Patent No. CN120148969A discloses a roll forming production line for cable production, including multiple roll forming tables and two pressure rollers on one side of the roll forming tables for rolling cables. An electric heating wire for heating the insulation layer is fixedly installed inside the pressure rollers. A pressure roller cylinder is fixedly installed in the middle of the inside of the pressure rollers, and a drive shaft is fixedly installed in the middle of the inside of the pressure roller cylinder. A vibrator for generating vibration is fixedly installed at one end of the drive shaft. When this prior art is used, the cable is rolled by the upper and lower sets of pressure rollers. During this process, the vibration generated by the vibrator is transmitted to the pressure roller cylinder along the drive shaft, which makes the insulation material adhere more closely to the battery core under the vibrating pressure rollers. At the same time, the electric heating wire provides heat to the pressure rollers to prevent the cable insulation sleeve from cooling down and making it difficult to roll forming.

[0004] However, the existing technology described above has some shortcomings in the process of shaping and curing the electromagnetic wire insulation coating: 1. The cable is only rolled by two sets of pressure rollers, so it can only roll cables of the same diameter. It cannot roll cables of different diameters. If it is necessary to roll cables of different diameters, the pressure rollers may not be able to make full contact with the outer wall of the cable. This makes it difficult to achieve full coverage and multi-directional rolling of the insulation layer of the cable, affecting the rolling effect. In addition, the circumferential thickness of the insulation layer is uneven, which can easily affect its subsequent insulation performance.

[0005] 2. Using only a single set of pressure rollers with built-in heating wires for single-temperature zone rolling of the cable insulation layer results in the insulation material being cooled to room temperature between adjacent sets of pressure rollers in the horizontal direction. It then needs to be reheated before contacting the next set of pressure rollers. This makes the cooled insulation layer difficult to roll and shape, and prevents the effective removal of air bubbles and pinholes within the insulation layer. Furthermore, the frequent heating and cooling causes internal stress in the insulation layer due to contraction and expansion, preventing the insulation layer from effectively adhering to the cable. Therefore, this affects the rolling effect and the quality of the insulation layer. Therefore, based on the above-stated viewpoints, there is still room for improvement in existing methods for shaping and curing electromagnetic wire insulation coatings. Summary of the Invention

[0006] To address the aforementioned problems, this invention provides a multi-level gradient shaping and curing device for electromagnetic wire insulation coating, comprising a curing chamber. Two partitions are installed inside the curing chamber to sequentially divide the interior of the curing chamber along the cable's movement direction into a low-temperature solidification zone, a medium-temperature shaping zone, and a high-temperature curing zone. These zones are respectively used for solidification and venting, heating and shaping, and high-temperature curing of the insulation coating applied to the cable's outer wall. Each of the low-temperature solidification zone, medium-temperature shaping zone, and high-temperature curing zone has an operating port on its side wall, with an opening and closing door for cable threading.

[0007] It also includes a heating unit installed at the top of the curing chamber. The heating unit comprises multiple electric heating rods installed inside the low-temperature solidification zone, the medium-temperature shaping zone, and the high-temperature curing zone, respectively. Multiple temperature controllers electrically connected to the electric heating rods are installed on the outer wall of the curing chamber. The temperature controllers utilize existing technology and are mainly used to heat the electric heating rods. A wire-passing hole is provided, coaxially on both the curing chamber and the partition. A sealing unit is installed on the side wall of the wire-passing hole to prevent crosstalk between airflows of different temperatures. A roller pressing unit is located in the low-temperature solidification zone and the high-temperature curing zone, used for low-temperature roller pressing to vent air and high-temperature roller pressing to release internal stress on the insulation coating of the cable's outer wall. A shaping unit is installed in the medium-temperature shaping zone, used for medium-temperature roller pressing to shape the insulation coating of the cable's outer wall. A control box is located outside the curing chamber, and the heating unit, sealing unit, roller pressing unit, and shaping unit are all electrically connected to the control box. When the cable with the insulation coating passes through the threading hole, the rolling unit, and the shaping unit, the heating unit heats the low-temperature solidification zone, the medium-temperature shaping zone, and the high-temperature curing zone to different temperatures. During this process, the insulation coating on the outer wall of the cable is rolled in multiple directions around the circumference through the rolling unit and the shaping unit. This process sequentially transforms the insulation coating from a liquid state to a deformable solid state, eliminates air bubbles in the insulation coating, rolls and shapes it, eliminates the internal stress caused by the shrinkage of the insulation coating, and ensures that the circumferential thickness of the insulation coating is consistent.

[0008] Preferably, the heating unit further includes multiple through holes opened at the upper end of the curing chamber, the multiple through holes corresponding to the positions of the electric heating rods, and multiple sealing covers corresponding to the positions of the electric heating rods are also installed at the upper end of the curing chamber. The sealing covers are placed over the multiple through holes above the electric heating rods. An air pump is installed at the upper end of the sealing cover. The air pump is electrically connected to the control box. A delivery pipe is installed at the output end of the air pump. The output end of the delivery pipe extends into the interior of the sealing cover.

[0009] Preferably, the enclosed unit includes an annular cylinder installed outside two wire holes on the inner wall of the low-temperature solidification zone, the medium-temperature shaping zone, and the high-temperature curing zone. A positioning air pump is provided at the upper end of the annular cylinder. The input end of the positioning air pump extends into the curing chamber, and the output end of the positioning air pump extends into the annular cylinder. Multiple exhaust pipes connected to the annular cylinder are evenly arranged on the inner side wall of the annular cylinder.

[0010] Preferably, a diffuser plate is installed at one end of the exhaust pipe near the axis of the wire hole, and the diffuser plate has multiple equally spaced air outlets on the side facing the wire hole.

[0011] Preferably, the partition has an air collection chamber inside that communicates with the wire hole, and the outer wall of the air collection chamber has multiple exhaust holes that communicate with the outside evenly.

[0012] Preferably, the rolling unit includes multiple first U-shaped frames installed in the low-temperature solidification zone and the high-temperature curing zone. The first U-shaped frames are fixedly installed on the bottom wall of the curing chamber by a support frame. Two extrusion rollers are rotatably arranged at the opening of the first U-shaped frame for rolling the insulation coating on the outer wall of the cable. Multiple first U-shaped frames are arranged clockwise and staggered around the axis of the cable threading hole. When the cable passes through the extrusion roller, the extrusion roller on the multiple first U-shaped frames can perform circumferential multi-angle roller pressing on the insulation coating on the outer wall of the cable, so as to fully cover the insulation coating without dead angles.

[0013] Preferably, a rubber cylinder is fixedly sleeved on the outer wall of the extrusion roller. The diameter of the outer wall of the rubber cylinder gradually decreases from both ends to the middle, which is used to increase the contact area with the insulating coating. The rubber cylinder is also prone to elastic deformation, ensuring a tight fit with the insulating coating.

[0014] Preferably, two sliding grooves are symmetrically opened on opposite sides of the two parallel sections of the first U-shaped frame, and adjusting blocks are rotatably provided at both ends of the extrusion roller via bearings. The adjusting blocks are slidably installed in the sliding grooves, and double-headed screws are rotatably provided on both parallel sections of the first U-shaped frame. The double-headed screws pass through the adjusting blocks by means of threaded connection. The two double-ended screws on the first U-shaped frame are connected by a belt drive. A positioning shaft is provided at the end of the double-ended screw away from the first U-shaped frame. The positioning shaft is installed on the inner side wall of the curing chamber through a shaft bracket. Drive motors are provided on the inner walls of the low-temperature solidification zone and the high-temperature curing zone through motor mounts. The drive motors are electrically connected to the control box and connected to the end of any one of the positioning shafts in the low-temperature solidification zone and the high-temperature curing zone. The double-ended screws between two adjacent first U-shaped frames are connected by a belt drive. A universal coupling is installed between the double-ended screw on the clockwise offset first U-shaped frame and the positioning shaft, so that the positioning shaft can drive the double-ended screw to rotate through the universal coupling.

[0015] Preferably, the shaping unit includes a support base installed on the bottom wall of the medium-temperature shaping zone. Two guide rails are symmetrically arranged on the upper end of the support base along the width direction of the curing box. A reciprocating plate is slidably arranged on the upper end of the two guide rails. Multiple second U-shaped frames are installed on the upper end of the reciprocating plate through a fixed seat. The multiple second U-shaped frames are arranged clockwise and staggered with the axis of the threading hole as the center. Limiting grooves are opened on opposite sides of the two parallel sections of the second U-shaped frames. Linkage blocks are slidably installed inside the limiting grooves. A shaping roller is rotatably arranged between two corresponding linkage blocks through a bearing. The diameter of the shaping roller gradually decreases from both ends to the middle. The shaping roller can be rotated under the action of external force. A support spring rod is installed between the linkage block and the inner wall of the limiting groove.

[0016] Preferably, the shaping unit further includes a reciprocating lead screw rotatably mounted on a support base. A positioning motor connected to the reciprocating lead screw is mounted on the upper end of the support base through a motor cover. Both ends of the reciprocating plate are equipped with reciprocating slides sleeved outside the reciprocating lead screw, which are used to cooperate with the reciprocating lead screw to drive the reciprocating plate to reciprocate.

[0017] In summary, this application includes the following beneficial technical effects: I. This invention utilizes a three-stage gradient heating structure consisting of a low-temperature solidification zone, a medium-temperature shaping zone, and a high-temperature curing zone. Combined with a rolling unit and a shaping unit, it performs multi-stage circumferential rolling on the insulating coating, achieving continuous processing of the entire process from liquid solidification and degassing to plastic shaping and curing. This not only improves the curing efficiency of the insulating coating but also ensures the shaping effect of the insulating coating.

[0018] Second, this invention forms an annular air curtain by venting hot air at the wire hole, which can seal the wire hole and prevent crosstalk between external air or air between adjacent temperature zones, thereby providing a stable temperature environment for the shaping and curing of the insulating coating, and thus improving the shaping and curing effect of the insulating coating.

[0019] Third, the present invention uses multiple clockwise staggered extrusion rollers to perform circumferential multi-angle rolling pressing on the insulation coating of the cable outer wall, which is used to perform full-coverage rolling pressing of the insulation coating without dead angles. Moreover, the distance between the two extrusion rollers on the first U-shaped frame can be adjusted according to the diameter of the cable, which can adapt to the rolling pressing of electromagnetic wire insulation coatings of different diameters, thereby improving the applicability of the present invention.

[0020] Fourth, this invention uses multiple reciprocating shaping rollers to roll and contact the cable, allowing the shaping rollers to rotate adaptively. These multiple shaping rollers can perform multi-angle comprehensive roll forming on the insulation coating of the cable's outer wall, precisely controlling the circumferential thickness of the insulation coating, eliminating thickness deviations caused by the coating process, and also squeezing out and eliminating tiny depressions and flow marks inside the coating, significantly improving the density and roundness of the coating, thereby enhancing the shaping effect of the insulation coating. Attached Figure Description

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] Figure 1 This is a schematic diagram of the structure of the present invention.

[0023] Figure 2 This is a schematic diagram of the internal structure of the curing chamber of the present invention.

[0024] Figure 3 This is a schematic diagram of the heating unit of the present invention.

[0025] Figure 4 This is a structural diagram of the curing box, partition, and sealing unit of the present invention.

[0026] Figure 5 This is a schematic diagram of the structure of the closed unit of the present invention.

[0027] Figure 6 This is the present invention. Figure 5 A magnified view of part A.

[0028] Figure 7 This is a schematic diagram of the structure of the roller pressing unit of the present invention.

[0029] Figure 8 This is a schematic diagram of the structure between the first U-shaped frame, the rubber cylinder, the double-ended screw, and the positioning shaft of the present invention.

[0030] Figure 9 This is a schematic diagram of the shaping unit of the present invention.

[0031] Figure 10 This is the present invention. Figure 9 A magnified view of section B.

[0032] In the diagram, 1 is the curing chamber; 2 is the partition; 21 is the low-temperature solidification zone; 22 is the medium-temperature shaping zone; and 23 is the high-temperature curing zone. 3. Heating unit; 31. Electric heating rod; 32. Thermostat; 33. Through hole; 34. Sealing cover; 35. Air pump; 36. Delivery pipe; 4. Threading hole; 5. Enclosed unit; 51. Annular cylinder; 52. Positioning air pump; 53. Exhaust pipe; 54. Air diffuser; 55. Air outlet; 56. Air collection chamber; 57. Exhaust hole; 6. Roller pressing unit; 61. First U-shaped frame; 62. Extrusion roller; 63. Rubber cylinder; 64. Adjusting block; 65. Double-ended screw; 66. Positioning shaft; 67. Shaft bracket; 68. Drive motor; 7. Shaping unit; 71. Support base; 711. Reciprocating lead screw; 712. Positioning motor; 72. Guide rail; 73. Reciprocating plate; 731. Reciprocating slide; 74. Second U-shaped frame; 75. Limiting slide groove; 76. Linkage block; 77. Shaping roller; 78. Support spring rod; 8. Control box. Detailed Implementation

[0033] The following is in conjunction with the appendix Figures 1-10 The embodiments of the present invention will be described in detail below.

[0034] This application discloses a multi-level gradient shaping and curing device for electromagnetic wire insulation coating. It should be noted that this device is mainly used in the process of shaping and curing the insulation coating applied to the outer wall of a cable. Technically, it can perform multi-level heating of the insulation coating on the cable's outer wall, during which multi-level circumferential rolling is applied to continuously achieve the solidification, shaping, and curing of the insulation coating. In particular, during the multi-level heating of the insulation coating, the through-hole 4 is sealed to prevent crosstalk between external air or air in adjacent temperature zones, thereby providing a stable temperature environment for the shaping and curing of the insulation coating. Furthermore, this multi-level gradient shaping and curing device can also roll the insulation coating through a circumferential, full-coverage, and dead-angle-free rolling method, and can adapt to cables of different diameters, thus improving the applicability of this application.

[0035] Reference Figure 1 and Figure 2 As shown, a multi-level gradient shaping and curing device for electromagnetic wire insulation coating includes a curing chamber 1. Two partitions 2 are installed inside the curing chamber 1 to divide the interior of the curing chamber 1 into a low-temperature solidification zone 21, a medium-temperature shaping zone 22, and a high-temperature curing zone 23 along the direction of cable movement. These zones are used to solidify and degas the insulation coating coated on the outer wall of the cable, perform heating and shaping, and high-temperature curing treatments, respectively. The side walls of the low-temperature solidification zone 21, the medium-temperature shaping zone 22, and the high-temperature curing zone 23 are all provided with operation ports, and the operation ports are equipped with opening and closing doors for cable threading.

[0036] It also includes a heating unit 3, installed on the upper end of the curing chamber 1. The heating unit 3 includes multiple electric heating rods 31 installed inside the low-temperature solidification zone 21, the medium-temperature shaping zone 22, and the high-temperature curing zone 23, respectively. The outer wall of the curing chamber 1 is provided with multiple temperature controllers 32 electrically connected to the electric heating rods 31. The temperature controllers 32 adopt existing technology and are mainly used to heat the electric heating rods 31. A wire hole 4 is provided on both the curing chamber 1 and the partition 2. A wire hole 4 with a coaxial axis is provided on the side wall of the wire hole 4 to prevent crosstalk between airflows of different temperatures. A roller pressing unit 6 is set in the low-temperature solidification zone 21 and the high-temperature curing zone 23 and is used to perform low-temperature roller pressing to degas the insulation coating on the outer wall of the cable and high-temperature roller pressing to release internal stress. A shaping unit 7 is installed in the medium-temperature shaping zone 22 and is used to perform medium-temperature roller pressing shaping treatment on the insulation coating on the outer wall of the cable. A control box 8 is set on the outside of the curing chamber 1. The heating unit 3, the sealing unit 5, the roller pressing unit 6, and the shaping unit 7 are all electrically connected to the control box 8.

[0037] In the specific implementation process, the heating unit 3, controlled by the control box 8, heats the low-temperature solidification zone 21, the medium-temperature shaping zone 22, and the high-temperature curing zone 23. Then, the cable coated with the insulating layer is sequentially passed through the through-hole 4 on the curing box 1 and the partition 2. The temperature in the low-temperature solidification zone 21 is set to 60℃~90℃. When the cable passes through the low-temperature solidification zone 21, the insulating coating on its outer wall changes from a liquid state to a deformable solidified state due to heating. The rolling unit 6 in the low-temperature solidification zone 21 performs circumferential rolling on the insulating coating to eliminate air bubbles and improve the adhesion between the insulating coating and the cable. The temperature in the medium-temperature shaping zone 22 is set to 100℃~140℃. When the cable passes through the medium-temperature shaping zone 22, the insulating coating is further heated, changing from a solidified state to a solidified state with plastic deformation. The shaping unit 7 then further heats the insulating coating... Circumferential rolling molding ensures the flatness of the insulation coating and avoids protrusions and depressions on the surface of the insulation coating that would affect its insulation performance. The temperature in the high-temperature curing zone 23 is set at 150℃~180℃. The temperatures in the low-temperature solidification zone 21, the medium-temperature molding zone 22, and the high-temperature curing zone 23 can be adjusted according to the thickness of the insulation coating to accommodate the molding and curing of insulation coatings of different thicknesses. When the cable passes through the high-temperature curing zone 23, the insulation coating is further cured by heat. During this period, the insulation coating can be rolled again by the rolling unit 6 in the high-temperature curing zone 23 to eliminate the internal stress generated when the insulation coating shrinks, ensuring that the circumferential thickness of the insulation coating is consistent and that the adhesion between the insulation coating and the cable is more stable. Subsequently, the cable is collected on the outer wall of the online roller under the action of the external winding equipment. During this period, the insulation coating on the outside of the cable is cooled and shaped at room temperature.

[0038] During this period, the sealing unit 5 is used to isolate the wire holes 4 on both sides of the low-temperature solidification zone 21, the medium-temperature shaping zone 22 and the high-temperature curing zone 23, so as to avoid crosstalk between air at different temperatures affecting the curing and shaping effect of the insulation coating. In this way, the insulation coating on the outer wall of the cable can be heated in multiple gradients through the synergistic effect of the heating unit 3, the sealing unit 5, the rolling unit 6 and the shaping unit 7. During this period, the insulation coating is subjected to multi-stage circumferential rolling, which continuously realizes the solidification, shaping and curing of the insulation coating. This not only improves the curing efficiency of the insulation coating, but also ensures the shaping effect of the insulation coating.

[0039] Reference Figure 3 As shown, in order to facilitate the heating of the low-temperature solidification zone 21, the medium-temperature shaping zone 22 and the high-temperature curing zone 23, the heating unit 3 in this embodiment is specifically as follows: The heating unit 3 also includes multiple through holes 33 opened at the upper end of the curing chamber 1. The multiple through holes 33 correspond to the positions of the electric heating rods 31. Multiple sealing covers 34 corresponding to the positions of the electric heating rods 31 are also installed at the upper end of the curing chamber 1. The sealing covers 34 cover the multiple through holes 33 above the electric heating rods 31. An air pump 35 is installed at the upper end of the sealing cover 34. The air pump 35 is electrically connected to the control box 8. A delivery pipe 36 is installed at the output end of the air pump 35. The output end of the delivery pipe 36 extends into the interior of the sealing cover 34.

[0040] In the specific implementation process, before the cable passes through the wiring hole 4, the control box 8 transmits a command to the air pump 35, energizing and starting the air pump 35. The air pump 35 delivers air to the sealing cover 34 through the delivery pipe 36. The air inside the sealing cover 34 is then sent into the curing chamber 1 through the through hole 33. At the same time, the control box 8 transmits commands to the temperature controller 32 and the electric heating rod 31, energizing and starting the electric heating rod 31. Multiple electric heating rods 31 heat the air sent into the curing chamber 1, and the temperature of the multiple electric heating rods 31 is adjusted according to the molding and curing requirements of the insulating coating, so that hot air at different temperatures enters the low-temperature solidification chamber. The insulation coating on the outer wall of the cable is heated in zone 21, the medium-temperature shaping zone 22, and the high-temperature curing zone 23. During this period, multiple temperature controllers 32 can monitor the temperature in the low-temperature solidification zone 21, the medium-temperature shaping zone 22, and the high-temperature curing zone 23 respectively. If the temperature is too low, the temperature controller 32 transmits a signal to the control box 8. The control box 8 receives the signal and transmits a command to the temperature controller 32, causing the temperature controller 32 to control the electric heating rod 31 to increase the heating power. Conversely, if the temperature is too high, the control box 8 controls the electric heating rod 31 to decrease the heating power through the temperature controller 32, so that the temperature environment is within the set range, ensuring the shaping and curing effect of the electromagnetic wire insulation coating.

[0041] Reference Figure 4 , Figure 5 and Figure 6As shown, since the low-temperature solidification zone 21, the medium-temperature shaping zone 22 and the high-temperature curing zone 23 need to provide different temperatures for the insulating coating, in this embodiment, the wire hole 4 can be sealed by airflow to avoid crosstalk of hot airflows at different temperatures. Specifically, the sealing unit 5 includes an annular cylinder 51 installed on the outer side of the two wire holes 4 on the inner wall of the low-temperature solidification zone 21, the medium-temperature shaping zone 22 and the high-temperature curing zone 23. A positioning air pump 52 is provided at the upper end of the annular cylinder 51. The input end of the positioning air pump 52 extends into the curing chamber 1 and the output end of the positioning air pump 52 extends into the annular cylinder 51. Two positioning air pumps 52 are provided in each of the low-temperature solidification zone 21, the medium-temperature shaping zone 22 and the high-temperature curing zone 23. Multiple exhaust pipes 53 connected to the annular cylinder 51 are evenly arranged on the inner side wall of the annular cylinder 51.

[0042] Furthermore, in this embodiment, a diffuser plate 54 is installed at one end of the exhaust pipe 53 near the axis of the wire hole 4, and the diffuser plate 54 has multiple equally spaced air outlets 55 on the side pointing towards the wire hole 4.

[0043] Furthermore, in this embodiment, the partition 2 has an air collection chamber 56 that communicates with the wire hole 4, and the outer wall of the air collection chamber 56 has a plurality of exhaust holes 57 that communicate with the outside evenly.

[0044] In the specific implementation process, the control box 8 powers on and starts multiple positioning air pumps 52. The multiple positioning air pumps 52 respectively transport the hot air in the low temperature solidification zone 21, the medium temperature shaping zone 22 and the high temperature curing zone 23 to the annular cylinder 51. The hot air passes through the annular cylinder 51, the exhaust pipe 53, the air diffuser plate 54 and the air outlet 55 and is discharged to the wire hole 4. The air diffuser plate 54 and the air outlet 55 are used to increase the dispersion range of the hot air discharged from the exhaust pipe 53, so that the hot air discharged from the multiple air diffuser plates 54 can form an air curtain that can completely seal the wire hole 4. During this period, the hot air in the wire hole 4 on the side of the low temperature solidification zone 21 and the high temperature curing zone 23 away from the partition plate 2 is discharged to the outside of the curing box 1. The hot air in the wire hole 4 on both sides of the partition plate 2 generates convection, and the convective hot air accumulates in the air collection chamber 5. In step 6, the convective hot air can effectively prevent hot air of different temperatures from passing through the wire hole 4 and causing crosstalk. When the convective hot air continues to be discharged into the air collection chamber 56, the hot air will be discharged to the outside of the curing chamber 1 through the exhaust hole 57. In this way, the hot air discharged through multiple air diffusers 54 forms an annular air curtain, which can seal the wire hole 4 and avoid crosstalk between the external air or the air between adjacent temperature zones, thereby providing a stable temperature environment for the shaping and curing of the insulation coating, and thus improving the shaping and curing effect of the insulation coating. In addition, the top of the curing chamber 1 is continuously supplied with constant temperature hot air by the air pump 35. Therefore, when the positioning air pump 52 extracts the hot air in its working space, it will not create negative pressure in the working space, thereby effectively preventing the entry of external air of different temperatures into the working space under negative pressure and disturbing the temperature environment.

[0045] Reference Figure 7 and Figure 8 As shown, in order to facilitate the rolling of the electromagnetic wire insulation coating in the low-temperature solidification zone 21 and the high-temperature curing zone 23, in this embodiment, the rolling unit 6 includes a plurality of first U-shaped frames 61 installed in the low-temperature solidification zone 21 and the high-temperature curing zone 23. The first U-shaped frames 61 are fixedly installed on the bottom wall of the curing box 1 by a support frame. Two extrusion rollers 62 are rotatably arranged at the opening of the first U-shaped frames 61 for rolling the insulation coating on the outer wall of the cable. The plurality of first U-shaped frames 61 are arranged clockwise and staggered with the axis of the wire hole 4 as the center. When the cable passes through the extrusion rollers 62, the extrusion rollers 62 on the plurality of first U-shaped frames 61 can perform circumferential multi-angle rolling of the insulation coating on the outer wall of the cable for full coverage and no dead angle rolling of the insulation coating.

[0046] Furthermore, in this embodiment, a rubber cylinder 63 is fixedly sleeved on the outer wall of the extrusion roller 62. The diameter of the outer wall of the rubber cylinder 63 gradually decreases from both ends to the middle, which is used to increase the contact area with the insulating coating. The rubber cylinder 63 is easy to undergo elastic deformation, ensuring a tight fit with the insulating coating and avoiding the existence of roller pressing dead angles. The rubber cylinder 63 is made of silicone rubber, which can work stably in a high-temperature environment of 180°C for a long time without permanent deformation.

[0047] Furthermore, in this embodiment, two sliding grooves are symmetrically provided on opposite sides of the two parallel sections of the first U-shaped frame 61. Adjusting blocks 64 are rotatably mounted on both ends of the extrusion roller 62 via bearings. The adjusting blocks 64 are slidably installed within the sliding grooves. Double-ended screws 65 are rotatably mounted on both parallel sections of the first U-shaped frame 61. The double-ended screws 65 pass through the adjusting blocks 64 via threaded connections. The adjusting blocks 64 are limited by the sliding grooves, allowing them to slide only along the length of the sliding grooves. Thus, the rotation of the double-ended screws 65 can drive the adjusting blocks 64 to move. The two double-ended screws 65 on the first U-shaped frame 61 are connected by a belt drive. A positioning shaft 66 is provided at the end of the double-ended screw 65 away from the first U-shaped frame 61. The positioning shaft 66 is connected by a shaft... The frame 67 is installed on the inner wall of the curing chamber 1. The inner walls of the low-temperature curing zone 21 and the high-temperature curing zone 23 are equipped with drive motors 68 through motor mounts. The drive motors 68 are electrically connected to the control box 8. The drive motors 68 are connected to the end of any one of the positioning shafts 66 in the low-temperature curing zone 21 and the high-temperature curing zone 23. The double-headed screws 65 between two adjacent first U-shaped frames 61 are connected by belt drive. A universal coupling is installed between the double-headed screws 65 on the clockwise offset first U-shaped frame 61 and the positioning shaft 66, so that the positioning shaft 66 can drive the double-headed screws 65 to rotate through the universal coupling. In this embodiment, the belt drive between the double-headed screws 65 and the positioning shaft 66 are both made of high-temperature resistant rubber belts, which can work stably in a temperature environment of 180°C for a long time.

[0048] In the specific implementation process, before the cable passes through the low-temperature solidification zone 21 and the high-temperature curing zone 23, the control box 8 transmits a command to the drive motor 68 to start the drive motor 68. The drive motor 68 drives the double-headed screw 65 to rotate through the positioning shaft 66. During this process, the positioning shaft 66 drives the double-headed screw 65 to rotate synchronously through the universal coupling. While the double-headed screw 65 rotates, it drives the two adjusting blocks 64 on its outer wall to move synchronously towards each other or synchronously away from each other. The adjusting blocks 64 drive the extrusion roller 62 to move synchronously. In this way, the spacing of the extrusion roller 62 can be adjusted according to the diameter of the cable, which can adapt to the rolling of electromagnetic wire insulation coatings of different diameters, thereby improving the applicability of the invention. After adjustment, the rubber cylinder 63 on the outer wall of the extrusion roller 62 abuts against the cable to apply pressure to the insulation coating on the outer wall of the cable, thereby improving the rolling effect. The pressing effect: When the cable passes through the two extrusion rollers 62, the friction between the cable and the rubber cylinder 63 causes the rubber cylinder 63 to rotate adaptively. Thus, through the coordinated cooperation of multiple extrusion rollers 62 in the low-temperature solidification zone 21 and the high-temperature curing zone 23, the low-temperature roll pressing and high-temperature roll pressing of the insulating coating can be completed. Among them, the extrusion rollers 62 in the low-temperature solidification zone 21 can squeeze out the air and bubbles trapped inside the insulating coating, avoiding the formation of pinholes, air gaps and other fatal defects during the subsequent heating process. At the same time, it can make the insulating coating circumferentially level, laying the foundation for subsequent shaping. The extrusion rollers 62 in the high-temperature curing zone 23 perform circumferential uniform roll pressing on the shaped insulating coating, which can gradually release the internal stress generated by curing shrinkage, avoid the internal stress concentration that leads to cracking of the coating in the later stage, and ensure the crosslinking density and structural stability of the insulating coating.

[0049] Reference Figure 9 and Figure 10As shown, in order to facilitate the roll forming of the insulation coating on the outer wall of the cable, in this embodiment, the forming unit 7 includes a support base 71 installed on the bottom wall of the medium-temperature forming zone 22. Two guide rails 72 are symmetrically arranged on the upper end of the support base 71 along the width direction of the curing chamber 1. A reciprocating plate 73 is slidably mounted on the upper end of the two guide rails 72. The reciprocating plate 73 is restricted by the guide rails 72, so that it can only slide along the length direction of the guide rails 72. Multiple second U-shaped frames 74 are mounted on the upper end of the reciprocating plate 73 via a fixed seat. The multiple second U-shaped frames 74 are arranged clockwise and staggered around the axis of the wire hole 4. The two... Limiting grooves 75 are provided on opposite sides of the parallel section. Linkage blocks 76 are slidably installed inside the limiting grooves 75. A shaping roller 77 is rotatably arranged between two corresponding linkage blocks 76 via bearings. The diameter of the shaping roller 77 gradually decreases from both ends to the middle. The concave structure of the shaping roller 77 can increase the contact area with the electromagnetic wire insulation coating. A support spring rod 78 is installed between the linkage block 76 and the inner wall of the limiting groove 75. The support spring rod 78 is used to apply a supporting force to the linkage block 76. Under the action of the support spring rod 78, the two linkage blocks 76 on the same second U-shaped frame 74 drive the shaping roller 77 to move closer to each other in the initial state.

[0050] Furthermore, in this embodiment, the shaping unit 7 also includes a reciprocating lead screw 711 rotatably mounted on the support base 71. A positioning motor 712 connected to the reciprocating lead screw 711 is mounted on the upper end of the support base 71 through a motor cover. Both ends of the reciprocating plate 73 are equipped with reciprocating slide blocks 731 sleeved outside the reciprocating lead screw 711, which are used to cooperate with the reciprocating lead screw 711 to drive the reciprocating plate 73 to reciprocate.

[0051] In the specific implementation process, the control box 8 transmits a command to the positioning motor 712, which powers on and starts the positioning motor 712. The positioning motor 712 drives the reciprocating screw 711 to rotate. The reciprocating screw 711, in conjunction with the reciprocating slide 731, drives the reciprocating plate 73, the second U-shaped frame 74, and the shaping roller 77 to move back and forth as a whole. During this period, the shaping roller 77 rolls against the outer wall of the cable. Through the friction between the shaping roller 77 and the cable, the shaping roller 77 rotates adaptively. Moreover, multiple shaping rollers 77 can perform multi-angle comprehensive roll forming on the insulation coating of the cable outer wall, accurately control the circumferential thickness of the insulation coating, eliminate the thickness deviation caused by the coating process, and also squeeze out and eliminate the small depressions and flow marks inside the coating, greatly improving the density and roundness of the coating, thereby enhancing the shaping effect of the insulation coating.

[0052] During operation: Step 1: The control box 8 transmits a command to the air pump 35 to start the air pump 35. The air pump 35 sends air into the curing chamber 1 through the through hole 33. At the same time, the control box 8 transmits commands to the temperature controller 32 and the electric heating rod 31 to heat the air sent into the curing chamber 1. The multiple temperature controllers 32 can control the temperature of the electric heating rods 31 to heat the air to different temperatures according to the molding and curing requirements of the insulation coating. The hot air at different temperatures enters the low temperature solidification zone 21, the medium temperature molding zone 22 and the high temperature curing zone 23 respectively to heat the insulation coating on the outer wall of the cable.

[0053] Step 2: The control box 8 transmits a command to the drive motor 68, which is located in the low-temperature solidification zone 21 and the high-temperature curing zone 23, so that the drive motor 68 is powered on and started. The drive motor 68 drives the double-headed screw 65 to rotate through the positioning shaft 66. The double-headed screw 65 drives the two adjusting blocks 64 on its outer wall to move synchronously towards each other or synchronously away from each other. The adjusting blocks 64 drive the extrusion roller 62 to move synchronously. In this way, the spacing of the extrusion roller 62 can be adjusted according to the diameter of the cable, which can adapt to the rolling of electromagnetic wire insulation coatings of different diameters.

[0054] Step 3: Open the opening and closing door, and pass the cable coated with the insulating coating through the wire hole 4 on the curing box 1 and the partition 2 in sequence. Then close the opening and closing door to ensure that the outside air will not enter the low temperature solidification zone 21, the medium temperature shaping zone 22 and the high temperature curing zone 23 and affect the temperature environment. Power on the multiple positioning air pumps 52 through the control box 8. The multiple positioning air pumps 52 respectively transport the hot air in the low temperature solidification zone 21, the medium temperature shaping zone 22 and the high temperature curing zone 23 to the annular cylinder 51. The hot air passes through the annular cylinder 51, the exhaust pipe 53, the air diffuser plate 54 and the air outlet 55 in sequence and is discharged to the wire hole 4, forming an air curtain that can completely seal the wire hole 4, avoiding crosstalk between the outside air or the air between adjacent temperature zones, thereby providing a stable temperature environment for the shaping and curing of the insulating coating.

[0055] Step 4: When the cable passes through the two extrusion rollers 62 in the low-temperature solidification zone 21 and the high-temperature curing zone 23, the friction between the cable and the rubber cylinder 63 can cause the rubber cylinder 63 to rotate adaptively. Thus, the low-temperature roll pressing and high-temperature roll pressing of the insulation coating can be completed through the coordinated cooperation of multiple extrusion rollers 62 in the low-temperature solidification zone 21 and the high-temperature curing zone 23. When the cable passes through the low-temperature solidification zone 21, the insulation coating on the outer wall changes from a liquid state to a deformable solidified state when heated. The extrusion rollers 62 in the low-temperature solidification zone 21 can squeeze out the air and bubbles trapped inside the insulation coating, avoiding fatal defects such as pinholes and air gaps caused by the expansion of bubbles during the subsequent heating process. At the same time, it can make the insulation coating flow smoothly in the circumference, laying the foundation for subsequent shaping.

[0056] Step 5: The control box 8 transmits a command to the positioning motor 712, which powers on and starts the positioning motor 712. The positioning motor 712 drives the reciprocating screw 711 to rotate. The reciprocating screw 711, in conjunction with the reciprocating slide 731, drives the reciprocating plate 73, the second U-shaped frame 74, and the shaping roller 77 to move back and forth as a whole. During this period, the shaping roller 77 rolls against the outer wall of the cable and rotates adaptively. Multiple shaping rollers 77 can perform multi-angle comprehensive roll forming on the insulation coating of the cable outer wall, accurately control the circumferential thickness of the insulation coating, eliminate thickness deviations caused by the coating process, and also squeeze out and eliminate tiny depressions and flow marks inside the coating, greatly improving the density and roundness of the coating, thereby enhancing the shaping effect of the insulation coating.

[0057] Step 6: When the cable passes through the high-temperature curing zone 23, the insulation coating is further cured by heat. The extrusion roller 62 in the high-temperature curing zone 23 performs circumferential uniform rolling on the shaped insulation coating, which can gradually release the internal stress generated by curing shrinkage, avoid internal stress concentration leading to later coating cracking, and at the same time ensure the cross-linking density and structural stability of the insulation coating.

[0058] Step 7: After shaping and curing, the cable is collected on the outer wall of the online roller by an external winding device. During this process, the insulation coating on the outside of the cable cools and sets at room temperature.

[0059] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0060] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A multi-level gradient shaping and curing device for an electromagnetic wire insulation coating, characterized in that, include: Curing box (1), with two partitions (2) installed inside the curing box (1) to divide the interior of the curing box (1) into a low-temperature solidification zone (21), a medium-temperature shaping zone (22) and a high-temperature curing zone (23) along the direction of cable movement. These are used to solidify and vent, heat and shape, and cure the insulation coating coated on the outer wall of the cable, respectively. The side walls of the low-temperature solidification zone (21), the medium-temperature shaping zone (22) and the high-temperature curing zone (23) are all provided with operation ports. The operation ports are equipped with opening and closing doors for cable threading. Heating unit (3) is installed on the upper end of curing chamber (1). Heating unit (3) includes multiple electric heating rods (31) installed in the low temperature solidification zone (21), medium temperature shaping zone (22) and high temperature curing zone (23) respectively. Multiple temperature controllers (32) electrically connected to the electric heating rods (31) are provided on the outer wall of curing chamber (1). The temperature controllers (32) adopt existing technology and are mainly used to heat the electric heating rods (31). The wire hole (4) is provided on both the curing box (1) and the partition (2). The wire hole (4) is provided on the side wall of the wire hole (4) to prevent airflows of different temperatures from interfering with each other. The rolling unit (6) is set in the low-temperature solidification zone (21) and the high-temperature curing zone (23) to perform low-temperature rolling to degas the insulation coating on the outer wall of the cable and high-temperature rolling to release internal stress. The forming unit (7) is installed in the medium-temperature forming zone (22) and is used to perform medium-temperature roll forming on the insulation coating of the cable outer wall; The control box (8) is located outside the curing box (1). The heating unit (3), the sealing unit (5), the rolling unit (6) and the shaping unit (7) are all electrically connected to the control box (8). When the cable with the insulation coating passes through the wire hole (4), the rolling unit (6) and the shaping unit (7), the heating unit (3) heats the low temperature solidification zone (21), the medium temperature shaping zone (22) and the high temperature curing zone (23) to different temperatures. During this period, the insulation coating on the outer wall of the cable is rolled in multiple directions around the circumference through the rolling unit (6) and the shaping unit (7), so that the insulation coating changes from a liquid state to a deformable solid state when heated, eliminates air bubbles in the insulation coating, rolls and shapes, eliminates the internal stress caused by the shrinkage of the insulation coating, and ensures that the circumferential thickness of the insulation coating is consistent.

2. The multi-level gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 1, characterized in that: The heating unit (3) also includes multiple through holes (33) opened at the upper end of the curing box (1). The multiple through holes (33) correspond to the positions of the electric heating rod (31). The upper end of the curing box (1) is also equipped with multiple sealing covers (34) corresponding to the positions of the electric heating rod (31). The sealing covers (34) are covered outside the multiple through holes (33) above the electric heating rod (31). The upper end of the sealing cover (34) is equipped with an air pump (35). The air pump (35) is electrically connected to the control box (8). The output end of the air pump (35) is equipped with a delivery pipe (36). The output end of the delivery pipe (36) extends into the interior of the sealing cover (34).

3. The multi-level gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 1, characterized in that: The enclosed unit (5) includes an annular cylinder (51) installed outside two wire holes (4) on the inner wall of the low temperature solidification zone (21), the medium temperature shaping zone (22) and the high temperature curing zone (23). A positioning air pump (52) is provided at the upper end of the annular cylinder (51). The input end of the positioning air pump (52) extends into the curing box (1), and the output end of the positioning air pump (52) extends into the annular cylinder (51). Multiple exhaust pipes (53) connected to the annular cylinder (51) are evenly arranged on the inner wall of the annular cylinder (51).

4. The multi-level gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 3, characterized in that: The exhaust pipe (53) has a diffuser plate (54) installed at one end near the axis of the wire hole (4). The diffuser plate (54) has multiple equally spaced air outlets (55) on the side facing the wire hole (4).

5. The multi-level gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 1, characterized in that: The partition (2) has an air collection chamber (56) that is connected to the wire hole (4) inside. The outer wall of the air collection chamber (56) has multiple exhaust holes (57) that are connected to the outside evenly.

6. The multi-level gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 1, characterized in that: The roller pressing unit (6) includes multiple first U-shaped frames (61) installed in the low temperature solidification zone (21) and the high temperature curing zone (23). The first U-shaped frames (61) are fixedly installed on the bottom wall of the curing box (1) by a support frame. Two extrusion rollers (62) are rotatably arranged at the opening of the first U-shaped frame (61) for rolling the insulation coating on the outer wall of the cable. Multiple first U-shaped frames (61) are arranged clockwise with the axis of the wire hole (4) as the center. When the cable passes through the extrusion roller (62), the extrusion roller (62) on the multiple first U-shaped frames (61) can perform circumferential multi-angle roller pressing on the insulation coating of the cable outer wall, which is used to perform full-coverage roller pressing on the insulation coating without dead angles.

7. The multi-level gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 6, characterized in that: The outer wall of the extrusion roller (62) is fixedly fitted with a rubber cylinder (63). The diameter of the outer wall of the rubber cylinder (63) gradually decreases from both ends to the middle, which is used to increase the contact area with the insulating coating. The rubber cylinder (63) is easy to undergo elastic deformation to ensure close contact with the insulating coating.

8. The multi-level gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 6, characterized in that: Two sliding grooves are symmetrically opened on opposite sides of the two parallel sections of the first U-shaped frame (61). Adjusting blocks (64) are rotatably installed at both ends of the extrusion roller (62) through bearings. The adjusting blocks (64) are slidably installed in the sliding grooves. Double-headed screws (65) are rotatably installed on the two parallel sections of the first U-shaped frame (61). The double-headed screws (65) pass through the adjusting blocks (64) through threaded connections. The two double-headed screws (65) on the first U-shaped frame (61) are connected by a belt drive. The end of the double-headed screw (65) away from the first U-shaped frame (61) is provided with a positioning shaft (66). The positioning shaft (66) is installed on the inner wall of the curing box (1) through a shaft bracket (67). The inner walls of the low-temperature solidification zone (21) and the high-temperature curing zone (23) are both provided with drive motors (68) through motor mounts. The drive motors (68) are electrically connected to the control box (8). The drive motors (68) are connected to the end of any one of the positioning shafts (66) in the low-temperature solidification zone (21) and the high-temperature curing zone (23). The double-headed screws (65) between two adjacent first U-shaped frames (61) are connected by a belt drive. A universal coupling is installed between the double-headed screw (65) on the clockwise offset first U-shaped frame (61) and the positioning shaft (66) to facilitate the positioning shaft (66) to drive the double-headed screw (65) to rotate through the universal coupling.

9. The multi-level gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 1, characterized in that: The shaping unit (7) includes a support base (71) installed on the bottom wall of the medium-temperature shaping zone (22). Two guide rails (72) are symmetrically arranged on the upper end of the support base (71) along the width direction of the curing box (1). A reciprocating plate (73) is slidably arranged on the upper end of the two guide rails (72). Multiple second U-shaped frames (74) are installed on the upper end of the reciprocating plate (73) through a fixed seat. The multiple second U-shaped frames (74) are arranged clockwise with the axis of the wire hole (4) as the center. Limiting grooves (75) are opened on opposite sides of the two parallel sections of the second U-shaped frame (74). A linkage block (76) is slidably installed inside the limiting groove (75). A shaping roller (77) is rotatably arranged between two corresponding linkage blocks (76) through a bearing. The diameter of the shaping roller (77) gradually decreases from both ends to the middle. The shaping roller (77) can be rotated under the action of external force. A support spring rod (78) is installed between the linkage block (76) and the inner wall of the limiting groove (75).

10. The multi-stage gradient shaping and curing device for an electromagnetic wire insulation coating according to claim 9, characterized in that: The shaping unit (7) also includes a reciprocating screw (711) rotatably mounted on a support base (71). A positioning motor (712) connected to the reciprocating screw (711) is mounted on the upper end of the support base (71) through a motor cover. Both ends of the reciprocating plate (73) are equipped with reciprocating slides (731) sleeved outside the reciprocating screw (711) for cooperating with the reciprocating screw (711) to drive the reciprocating plate (73) to reciprocate.

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