Film wrapping machine for film wrapping wire shaping

Abstract

The utility model discloses a film coating machine for shaping film-coated wires, which is characterized in that a film coating mechanism is mounted on a main machine body, a discharging mechanism is positioned below the film coating mechanism, and a winding mechanism is arranged above a film coating head; the wire passing barrel is located at the film covering mechanism and vertically arranged on the path, pointing to the winding mechanism, of the discharging mechanism, the tensioning piece is fixed under the wire passing barrel, the bottom end of the metal wire is fixedly connected to the tensioning piece, and the top end of the metal wire and the wire to be covered with the film jointly penetrate through an inner cavity of the wire passing barrel. In the film covering process, the metal wire and the tensioning piece are synchronously wrapped to form a composite structure, and the metal wire cannot move upwards along with the wire in the winding stage due to the fact that the bottom end is fixed to the tensioning piece, so that the metal wire is automatically pulled away from the covering layer, the surface tension of the wire can be effectively adjusted, and the defect that the wire is too high in hardness after film covering is avoided. And a pure mechanical adjusting mechanism does not need external energy input or complex algorithm control, so that the equipment manufacturing cost is reduced, and the failure risk of electronic elements in a high-frequency vibration or dust environment is avoided.

Description

Technical Field

[0001] This utility model relates to the field of wire manufacturing equipment technology, and in particular to a coating machine for shaping film-coated wires. Background Technology

[0002] In the production and processing of film-coated wires, stable control of wire tension is a crucial step in ensuring coating quality. Insufficient tension or large fluctuations can easily lead to defects such as wrinkles, misalignment, or loosening of the coating layer, severely affecting the product's appearance and insulation performance. Conversely, excessive tension may cause wire stretching deformation, excessive wire stiffness that fails to meet usage requirements, or even breakage under normal force, resulting in production interruptions. Therefore, the proper design of the tension adjustment mechanism directly impacts production efficiency and product yield.

[0003] Traditional coating machines often employ mechanical tension controllers or a combination of electronic sensors and servo motors for adjustment. For example, dynamic tension adjustment is achieved through complex lever structures, spring buffer assemblies, or closed-loop feedback systems. However, such structures have significant drawbacks: firstly, mechanical adjustment mechanisms rely on multi-stage transmission devices, resulting in a bulky structure and limited adjustment accuracy, especially prone to response lag under high-speed winding and unwinding conditions; secondly, while intelligent adjustment systems based on electronic sensors can improve accuracy, they require costly control modules, servo drive units, and supporting software, leading to high overall equipment costs and demanding high operator skill levels. Furthermore, the long-term wear of numerous moving parts in existing mechanisms exacerbates tension fluctuations, requiring frequent maintenance and calibration, further increasing production costs. Therefore, existing technologies require improvement and enhancement. Utility Model Content

[0004] In view of the shortcomings of the prior art, the purpose of this utility model is to provide a coating machine for shaping film-coated wires, so as to solve the problem of complex tension mechanism of the coating machine in the prior art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a coating machine for shaping film-coated wires, comprising a main body, a feeding mechanism, a coating mechanism, a winding mechanism, and a tension adjustment mechanism: the coating mechanism is mounted on the main body, the feeding mechanism is located below the coating mechanism, and the winding mechanism is arranged above the coating head; the tension adjustment mechanism includes a wire guide spool, a metal wire, and a tensioning member, the wire guide spool is located at the coating mechanism and is vertically arranged on the path from the feeding mechanism to the winding mechanism, the tensioning member is fixed directly below the wire guide spool, the bottom end of the metal wire is fixedly connected to the tensioning member, and the top end of the metal wire and the wire to be coated pass through the inner cavity of the wire guide spool together.

[0006] In one embodiment of the present invention, a surrounding panel is further included, the surrounding panel being fixed to the main body, and the film covering mechanism being located inside the surrounding panel.

[0007] The beneficial effects of the above embodiments are as follows: the enclosure is fixed to the main body and surrounds the film covering mechanism, which can effectively isolate external dust or foreign objects from entering the film covering area, reduce the risk of film material contamination, and at the same time prevent operators from accidentally touching high temperature or moving parts, thereby improving equipment safety and the cleanliness of the production environment.

[0008] In one embodiment of the present invention, at least one pair of pressure rollers are further included. The pressure rollers are rotatably mounted on the main body, and the surface of the pressure rollers is provided with anti-slip texture.

[0009] The beneficial effects of the above embodiments are as follows: the anti-slip texture is set on the surface of the pressure roller, which increases the contact friction with the wire, prevents the wire from slipping or deviating during high-speed conveying, ensures the straightness and stability of the coating path, further reduces abnormal tension fluctuations, and improves the uniformity of coating.

[0010] In one embodiment of this utility model, the anti-slip texture is a grid pattern.

[0011] The beneficial effects of the above embodiments are as follows: the grid-type anti-slip texture design makes the friction distribution on the surface of the pressure roller more uniform, avoids local deformation of the wire under pressure, and reduces the problem of concentrated wear of the anti-slip texture due to long-term use, thus extending the service life of the pressure roller and maintaining the durability of the anti-slip performance.

[0012] In one embodiment of this utility model, the spacing between the pressure rollers is adjusted by an electric push rod, which is connected to a PLC controller via a signal. The PLC controller integrates a wire diameter adaptive algorithm module.

[0013] The beneficial effects of the above embodiments are as follows: the spacing between the pressure rollers is adjusted in conjunction with the electric push rod and the PLC controller. Combined with the wire diameter adaptive algorithm module, it can match the coating requirements of different specifications of wires in real time, realize intelligent dynamic adjustment, reduce manual intervention, and improve the versatility of equipment and production efficiency.

[0014] In one embodiment of this utility model, the metal wire is a galvanized steel wire.

[0015] The beneficial effects of the above embodiments are as follows: using galvanized steel wire as the tension regulating metal wire, its surface coating can effectively resist the erosion of the metal wire by humid or corrosive environments, extend the service life and reduce the cost of frequent replacement, while ensuring the stability and reliability of tension feedback.

[0016] In one embodiment of this utility model, the tensioning member is a detachable clamp, and the galvanized steel wire is vertically fixed inside the wire spool by the detachable clamp.

[0017] The beneficial effects of the above embodiments are as follows: the detachable clamp design makes the installation and replacement of galvanized steel wire convenient, and allows for quick maintenance without disassembling other parts, reducing downtime. At the same time, it ensures the vertical fixing accuracy of the metal wire in the wire spool and avoids tension adjustment failure due to installation deviation.

[0018] In one embodiment of the present invention, the coating mechanism includes a coating wheel, a film tray and a driving device. The coating wheel is driven to rotate by the driving device to perform the coating operation on the wire. The film tray is fixed on the coating wheel.

[0019] The beneficial effects of the above embodiments are as follows: the coating roller and the film material tray are integrated on the drive device, and the continuous and stable release of the film material is achieved by rotation drive. The film material tray can be adapted to different specifications of film rolls, reducing the material change time. The high-precision control of the drive device ensures that the coating speed and the winding speed are synchronized, further improving the uniformity and adhesion of the coating layer thickness.

[0020] As described above, the coating machine for shaping film-coated wires of this utility model has the following beneficial effects: during the coating process, the two are wrapped synchronously to form a composite structure, while during the winding stage, the metal wire cannot move upward with the wire because its bottom end is fixed to the tensioning member, thus automatically being pulled out from the coating layer, which can effectively adjust the tension on the surface of the wire and avoid the defect of excessive hardness of the wire after coating; the purely mechanical adjustment mechanism does not require external energy input or complex algorithm control, which reduces the equipment manufacturing cost and avoids the risk of failure of electronic components in high-frequency vibration or dust environment. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of the coating machine for shaping film-coated wires provided by this utility model;

[0023] Figure 2 This is a partial structural schematic diagram of the coating machine for shaping film-coated wires provided by this utility model.

[0024] Component designation explanation

[0025] 1. Main body; 2. Feeding mechanism; 3. Coating mechanism; 31. Coating roller; 32. Film material tray; 4. Winding mechanism; 5. Tension adjustment mechanism; 51. Wire guide spool; 52. Metal wire; 53. Tensioning component; 6. Side panel; 7. Pressure roller. Detailed Implementation

[0026] This utility model provides a coating machine for shaping film-coated wires. To make the purpose, technical solution and effects of this utility model clearer and more explicit, the following describes this utility model in further detail with reference to the accompanying drawings and embodiments.

[0027] In the description of this utility model, it should be understood that the terms "up, down, left, right" and other indicating directions or positional relationships are based on the directions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and should not be construed as limiting this utility model; in addition, the terms "installation" and "connection" should be interpreted broadly, and those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0028] Please see Figure 1 and Figure 2 This utility model provides a coating machine for shaping film-coated wires, including a main body 1, a feeding mechanism 2, a coating mechanism 3, a winding mechanism 4, a tension adjustment mechanism 5, and auxiliary functional components. The main body 1 adopts a frame-type welded structure, and its working surface is provided with mounting guide rails perpendicular to the base surface. The coating mechanism 3 is movably mounted on the longitudinal guide rails of the main body 1 via a slider assembly. The feeding mechanism 2 is set on a support platform below the coating mechanism 3, and the winding mechanism 4 is positioned in the space above the coating mechanism 3 via a cantilever beam structure.

[0029] Furthermore, the tension adjustment mechanism 5 consists of a guide assembly and a tension feedback assembly. Specifically, it includes a wire guide spool 51, a metal wire 52, and a tensioning member 53. The wire guide spool 51 is made of 304 stainless steel tubing, and its inner diameter is 1.2-1.5 times the diameter of the wire to be coated. It is vertically installed on the transmission path between the coating mechanism 3 and the winding mechanism 4. The metal wire 52 is preferably galvanized steel wire with a diameter of 0.8 mm. Its bottom end extends into the adjustable fixing groove of the tensioning member 53, and its top end is free. In particular, the tensioning member 53 is a quick clamp with a butterfly locking nut. Its base is fixed to the mounting hole of the main body 1 by a threaded connection to achieve vertical tensioning of the galvanized steel wire.

[0030] To ensure a clean production environment and operational safety, this invention incorporates protective components. Specifically, it includes a surrounding panel 6, which is fixed to the main body 1, with the film-coating mechanism 3 located inside the surrounding panel 6. The surrounding panel 6, fixed to the main body 1 and enclosing the film-coating mechanism 3, effectively isolates external dust or foreign objects from entering the film-coating area, reducing the risk of film contamination. It also prevents operators from accidentally touching high-temperature or moving parts, thus improving equipment safety and the cleanliness of the production environment.

[0031] For material transfer control, pressure rollers 7 are also included. These consist of two sets of pressure rollers 7 with laser-engraved grid-like anti-slip textures on their surfaces. The axes of the pressure rollers 7 are arranged perpendicular to the wire transport direction. Each set of pressure rollers 7 is mounted on the main body 1 via a guide rod with a linear bearing. The spacing adjustment mechanism between the two pressure rollers 7 is driven by an electric push rod with a stroke of 150mm, which is connected to the PLC controller. The PLC controller's built-in wire diameter adaptive algorithm module collects wire linear velocity data fed back from the encoder, combines it with a preset material deformation coefficient, calculates in real time, and outputs control commands to the electric push rod, achieving precise dynamic adjustment of the pressure roller spacing 7.

[0032] The specific implementation of the coating mechanism 3 includes: a coating wheel 31 driven by a servo motor, the wheel surface of which is provided with a replaceable polyurethane coating layer; a film material tray 32 adopts a quick-change chuck structure, which is suitable for film rolls of 300-600mm specifications; the drive device integrates a high-precision photoelectric encoder, which forms a closed-loop control system with the magnetic powder brake of the winding mechanism 4 to ensure that the synchronization error between the film release linear speed and the winding linear speed is controlled within ±0.5%.

[0033] In summary, this invention, a coating machine for shaping film-coated wires, utilizes the synchronous movement characteristics of the metal wire 52 and the wire to be coated within the winding drum 51 to achieve adaptive tension adjustment during the coating process. Compared to traditional coating machines that rely on complex mechanical transmissions or high-precision electronic control, this technology eliminates redundant components such as multi-stage transmission devices, sensors, and servo motors. Tension control is achieved solely through the co-linear wrapping and separation actions of the metal wire 52 and the wire during the coating stage, significantly simplifying the mechanical structure. In practical applications, the metal wire 52 and the wire pass through the inner cavity of the winding drum 51 together. During the coating process, they are synchronously wrapped to form a composite structure. During the winding stage, the metal wire 52, because its bottom end is fixed to the tensioning member 53, cannot move upwards with the wire, thus automatically being pulled out of the coating layer. This process, through the physical separation of the metal wire 52 and the wire, changes the coating tension on the surface of the finished product, making the finished product more flexible and optimizing the user experience.

[0034] Furthermore, the vertical arrangement of the wire guide spool 51 optimizes the straightness of the wire coating path, reduces bending friction caused by the traditional horizontal guide wheel structure, and further reduces the probability of abnormal tension. The fixed position design of the tensioning member 53 ensures linear and controllable tension feedback of the metal wire 52 during the withdrawal process, avoiding the problem of reduced adjustment accuracy caused by fatigue deformation of the spring buffer mechanism. The overall structure of this mechanism is compact, with no easily damaged moving parts. Maintenance only requires periodic inspection of the wear condition of the metal wire 52 and the wire guide spool 51, significantly reducing maintenance costs. Therefore, this utility model effectively overcomes the various shortcomings of the prior art and has high industrial application value.

[0035] It is understood that those skilled in the art can make equivalent substitutions or changes based on the technical solution and inventive concept of this utility model, and all such substitutions or changes should fall within the protection scope of this utility model.

Claims

1. A film wrapping machine for shaping a film-wrapped wire, characterized by The coating mechanism (3) is installed on the main body (1), the unwinding mechanism (2) is located below the coating mechanism (3), and the winding mechanism (4) is arranged above the coating head. The tension adjusting mechanism (5) comprises a wire passing barrel (51), a wire (52) and a tensioning piece (53), the wire passing barrel (51) is located at the coating mechanism (3) and vertically arranged on the path of the unwinding mechanism (2) pointing to the winding mechanism (4), the tensioning piece (53) is fixed below the wire passing barrel (51), the bottom end of the wire (52) is fixedly connected to the tensioning piece (53), and the top end of the wire (52) and the wire to be coated pass through the inner cavity of the wire passing barrel (51) together.

2. The film wrapping machine for shaping a film-wrapped wire according to claim 1, wherein The fence (6) is fixed on the main body (1), and the coating mechanism (3) is located on the inner side of the fence (6).

3. The film wrapping machine for shaping a film-wrapped wire according to claim 1, wherein At least one pair of pressing rollers (7) are rotatably arranged on the main body (1), and the surface of the pressing roller (7) is provided with anti-skid lines.

4. The film wrapping machine for shaping a film-wrapped wire according to claim 3, wherein The anti-skid lines are grid type.

5. The film wrapping machine for shaping a film wrapped wire according to claim 3, wherein The spacing between the pressing rollers (7) is adjusted by an electric push rod, the electric push rod is signal connected with a PLC controller, and the PLC controller is integrated with a wire diameter self-adaptive algorithm module.

6. The film wrapping machine for shaping a film-wrapped wire according to claim 1, wherein The wire (52) is a galvanized steel wire.

7. The film wrapping machine for shaping a film wrapped wire according to claim 5, wherein The tensioning piece (53) is a detachable clamp, and the galvanized steel wire is vertically fixed in the wire passing barrel (51) through the detachable clamp.

8. The film wrapping machine for shaping a film wrapped wire according to claim 1, wherein The coating mechanism (3) comprises a coating wheel (31), a film material tray (32) and a driving device, the coating wheel (31) is driven to rotate by the driving device to perform the coating operation of the wire, and the film material tray (32) is fixed on the coating wheel (31).

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