Copper slot wire production device
The integrated design of the copper channel wire production equipment solves the complexity and quality problems caused by material transfer in traditional segmented production, realizing efficient and continuous copper channel wire manufacturing and improving electrical conductivity and mechanical properties.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-14
- Publication Date
- 2026-04-07
AI Technical Summary
In the traditional copper channel wire manufacturing process, the segmented production mode makes material transfer susceptible to external influences, increases operational complexity and cost, and affects electrical conductivity and mechanical properties.
The copper channel production unit achieves integrated continuous production, integrating a vacuum induction furnace, horizontal continuous casting machine, extrusion die, annular drying device, online torsion device, flaw detection device, and take-up device. Combined with intelligent control, it realizes zero-interruption production from liquid copper to finished copper channel.
It improves the quality and production efficiency of copper channel lines, reduces energy consumption, ensures production continuity and high product quality, and reduces oxidation and impurity contamination problems.
Smart Images
Figure CN224096459U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to copper slot wire production and manufacturing technical field, specifically, relate to a copper slot wire production device. BACKGROUND
[0002] In modern high-voltage transmission network and advanced power system, superconducting cable becomes a promising technology due to its extremely low energy loss, high transmission capacity and compact system design. As an indispensable part of superconducting cable, the manufacturing technology of copper slot wire directly affects the current-carrying capacity, mechanical stability and long-term reliability of the cable. The design and manufacture of copper slot wire require high geometric precision, excellent electrical conductivity and stable torsion structure to match the performance requirements of superconducting layer and the overall design requirements of the cable.
[0003] In the manufacturing process of high-purity and high-uniformity copper slot wire, the traditional manufacturing process is a segmented production mode, including smelting, continuous casting, rolling, drawing, extrusion, torsion, detection and winding. Under this mode, after each process is completed, the copper material needs to be transferred from one device to the next, which not only increases the complexity of operation and production cost, but more importantly, the material is easily affected by the external environment during the transfer process, such as oxidation and impurity contamination, which seriously affects the electrical conductivity and mechanical properties of the copper slot wire. SUMMARY
[0004] The main purpose of the utility model is to provide a copper slot wire production device, which can realize the integrated continuous production of copper slot wire, ensure the continuity of copper slot wire production, reduce production cost and improve the quality of copper slot wire.
[0005] In order to achieve the above purpose, according to one aspect of the utility model, a copper slot wire production device is provided, which comprises:
[0006] A vacuum induction furnace is used for smelting copper;
[0007] A horizontal continuous casting machine is arranged at the outlet side of the vacuum induction furnace, which is used for continuously casting the molten copper after smelting into a copper rod;
[0008] An extrusion die is arranged at the downstream side of the horizontal continuous casting machine, which is used for continuously extruding the copper rod to form a multi-slot copper slot wire in one step;
[0009] A ring-shaped drying device is arranged at the copper slot wire outlet end of the extrusion die, which is used for drying the copper slot wire extruded by the extrusion die;
[0010] An online torsion device is arranged downstream of the ring-shaped drying device, which is used for torsion of the dried copper slot wire;
[0011] The flaw detection device is arranged downstream of the online twisting device, and is used for detecting flaws of the copper slot wire after twisting and marking qualified products and substandard products;
[0012] The take-up device is used for coiling the qualified copper slot wire.
[0013] Further, the annular blow-drying device comprises an annular air cover and a plurality of air nozzles arranged on the inner circumferential side of the annular air cover, the plurality of air nozzles are arranged at intervals along the circumferential direction of the annular air cover, and the air outlets of the air nozzles face the copper slot wire.
[0014] Further, the air nozzles are arranged in an inclined manner along the axial direction of the copper slot wire, and the air outlets of the air nozzles face the incoming direction of the copper slot wire.
[0015] Further, the included angle between the central axis of the air nozzle and the central axis of the copper slot wire is 30°-60°.
[0016] Further, the rear end of the annular air cover is connected with a hot air generator and a blower through an air pipe, and an air volume adjusting valve is arranged on the air pipe.
[0017] Further, a drain groove is arranged at the bottom of the annular air cover, and the copper slot wire production device further comprises a waste water collecting tank, and the bottom of the drain groove is communicated with the waste water collecting tank.
[0018] Further, the copper slot wire production device further comprises a gradient cooling device, the gradient cooling device is arranged at the wire outlet end of the extrusion die and is located on the upstream side of the annular blow-drying device, and the gradient cooling device comprises cooling sections with gradually decreasing cooling temperatures along the running direction of the copper slot wire.
[0019] Further, the cooling sections comprise a first cooling section, a second cooling section and a third cooling section, the temperature control range of the first cooling section is 280-320℃, the temperature control range of the second cooling section is 140-160℃, and the temperature control range of the third cooling section is 20-30℃.
[0020] Further, the cooling sections comprise a first cooling section, a second cooling section and a third cooling section, the first cooling section comprises a first cooling tank, an arc-shaped flow guide plate and a cooling pipe, the first cooling tank contains cooling water, the arc-shaped flow guide plate is arranged on the inner wall of the first cooling tank, the second cooling section comprises a second cooling tank, a spiral flow guide groove and a cooling pipe, the second cooling tank contains cooling water, and the spiral flow guide groove is arranged on the inner wall of the second cooling tank, and the third cooling section comprises a third cooling tank, the third cooling tank is provided with a honeycomb buffer plate, and the third cooling tank contains cooling water.
[0021] Further, the online twisting device comprises a driving twisting roller, a driven twisting roller, a tension detection module and a tension adjusting mechanism, the driven twisting roller controls the copper tank wire to adhere to the driving twisting roller, the tension detection module is used for detecting the tension of the copper tank wire, and the tension adjusting mechanism adjusts the driving twisting roller and the driven twisting roller according to the tension detected by the tension detection module.
[0022] The technical scheme of the utility model is applied, the copper tank wire production device integrates the vacuum smelting, horizontal continuous casting, continuous extrusion, online twisting, flaw detection and take-up processes in the copper wire production in one continuous production line, realizes the "zero interruption" production from liquid copper to finished copper tank wire through the continuous production process and intelligent control technology, not only eliminates the low-efficiency links such as material transfer, repeated heating and cooling and reprocessing in the traditional segmented production mode, but also adds the annular drying process and the online twisting process according to the special requirements of the copper tank wire production, combines the efficient defect detection and automatic rejection mechanism, can realize the integrated continuous production of the copper tank wire, guarantees the continuity of the copper tank wire production, realizes the high-quality and high-efficiency production of the copper tank wire for superconducting cables, greatly reduces the energy consumption, shortens the production cycle and guarantees the production quality of the copper tank wire. BRIEF DESCRIPTION OF DRAWINGS
[0023] The drawings accompanying the specification of the utility model form part of the utility model and are used to provide further understanding of the utility model, the illustrative embodiments of the utility model and the description thereof are used to explain the utility model, and do not constitute improper limitation on the utility model. In the drawings:
[0024] Figure 1 The structure schematic view of the copper tank wire production device of the embodiment of the utility model is shown;
[0025] Figure 2 The structure schematic view of the online twisting device of the copper tank wire production device of the embodiment of the utility model is shown;
[0026] Figure 3 The structure schematic view of the annular blowing device of the copper tank wire production device of the embodiment of the utility model is shown;
[0027] Figure 4 The side view structure diagram of the annular blowing device of the copper tank wire production device of the embodiment of the utility model is shown; and
[0028] Figure 5 The structure schematic view of the gradient cooling device of the copper tank wire production device of the embodiment of the utility model is shown.
[0029] Among them, the above-mentioned drawings include the following signs:
[0030] 1, vacuum induction furnace; 2, horizontal continuous casting machine; 3, extrusion die; 4, annular blow-drying device; 5, on-line twisting device; 6, flaw detection device; 7, take-up device; 8, annular air hood; 9, tuyere; 10, air pipe; 11, hot air generator; 12, air blower; 13, drainage groove; 14, waste water collection box; 15, gradient cooling device; 16, first cooling section; 17, second cooling section; 18, third cooling section; 19, first cooling tank; 20, arc-shaped flow guide plate; 21, cooling pipe; 22, second cooling tank; 23, spiral flow guide groove; 24, third cooling tank; 25, honeycomb buffer plate; 26, driving twisting roller; 27, driven twisting roller; 28, driving motor; 29, speed reducer; 30, angle detection mechanism. DETAILED DESCRIPTION
[0031] It should be noted that the embodiments in the present application and the features in the embodiments can be combined with each other without conflict. The present application will be described in detail below with reference to the drawings and in combination with the embodiments.
[0032] In combination with the drawings, Figures 1 to 5 As shown in the drawings, the present application provides a copper slot wire production device, comprising: a vacuum induction furnace 1 for melting copper; a horizontal continuous casting machine 2 arranged at the outlet side of the vacuum induction furnace 1 for continuously casting the molten copper after melting into a copper rod; an extrusion die 3 arranged at the downstream side of the horizontal continuous casting machine 2 for continuously extruding the copper rod to form the copper rod into a multi-slot copper slot wire in one step; an annular blow-drying device 4 arranged at the copper slot wire outlet end of the extrusion die 3 for blow-drying the copper slot wire extruded by the extrusion die 3; an on-line twisting device 5 arranged downstream of the annular blow-drying device 4 for twisting the copper slot wire after blow-drying; a flaw detection device 6 arranged downstream of the on-line twisting device 5 for detecting the copper slot wire after twisting and marking the qualified products and substandard products; and a take-up device 7 for coiling and taking up the qualified copper slot wire.
[0033] In the present embodiment, the vacuum induction furnace 1 melts the copper raw material, effectively removes gas and impurities, and ensures the high purity of the copper material. The horizontal continuous casting machine 2 continuously casts the molten copper into a uniform copper rod, laying a foundation for subsequent finishing. The copper rod then enters the extrusion die 3 and is formed into a copper slot wire with a specific slot structure in one step by the extrusion die 3, eliminating the repeated drawing, heat treatment and other links in the traditional multi-pass processing process, greatly saving time and energy, and improving production efficiency.
[0034] In order to further optimize the organizational structure of the copper slot line, improve its electrical performance and mechanical stability, the embodiment is configured with a ring-shaped blow-drying device 4 after the extrusion die 3, which can quickly remove the moisture on the surface and in the slot of the copper slot line, prevent oxidation and die rust, thereby significantly reducing the defect rate in production and improving the product yield. The copper slot line after blow-drying enters the online twisting device 5, which, through a precisely controlled tension adjustment mechanism, ensures that the twisting angle of each meter of copper slot line is uniform, avoiding the problem of local distortion or stress concentration commonly seen in traditional twisting processes, and enhancing the mechanical strength of the copper slot line and the overall consistency after twisting.
[0035] Subsequently, the copper slot line enters the flaw detection device 6, which uses flaw detection technology to detect defects, accurately identifies internal cracks, pores, inclusions and other defects, and real-time marks and automatically rejects the copper slot line with defects, greatly improving the efficiency and accuracy of inspection, reducing the misjudgment rate, and ensuring that the final product meets strict quality standards. Finally, the take-up device 7 is responsible for coiling the copper slot line that passes the flaw detection, forming a standard coiled finished product for storage and transportation. The entire take-up process also follows the principles of high efficiency and accuracy to ensure the quality and consistency of the finished product.
[0036] The copper slot line production device of the embodiment integrates the processes of vacuum melting, horizontal continuous casting, continuous extrusion, online twisting, flaw detection, and take-up in a continuous production line. Through continuous production processes and intelligent control technology, it realizes "zero interruption" production from liquid copper to finished copper slot line. Not only does it eliminate the inefficient links such as material transfer, repeated heating and cooling, and reprocessing in traditional segmented production mode, but also adds a ring-shaped blow-drying process and an online twisting process to meet the special needs of copper slot line production. Combined with efficient defect detection and automatic rejection mechanism, it can realize integrated continuous production of copper slot line, ensure the continuity of copper slot line production, and achieve high-quality and efficient production of superconducting cable copper slot line, greatly reducing energy consumption, shortening production cycle, and ensuring copper slot line production quality.
[0037] In one embodiment, the ring-shaped blow-drying device 4 includes a ring-shaped air hood 8 and a plurality of air nozzles 9 arranged on the inner circumferential side of the ring-shaped air hood 8. The air nozzles 9 are arranged at intervals along the circumference of the ring-shaped air hood 8, and the air outlets of the air nozzles 9 face the copper slot line.
[0038] In the present embodiment, the annular drying device 4 is integrated with an annular air cover 8 and a plurality of air nozzles 9 arranged on the inner circumferential side thereof. The air nozzles 9 are uniformly distributed along the circumferential direction of the annular air cover 8, and the air outlets thereof are oriented to align with the copper slot. This design ensures that the surface of the copper slot and the inside of the slot are quickly dried after cooling, effectively avoiding the problem of oxidation caused by residual moisture and affecting the subsequent twisting process. The combination of the annular air cover 8 and the air nozzles 9 achieves full-range and dead-angle-free blowing and drying of the cooled copper slot, thereby improving the surface cleanliness and internal structural stability of the product, reducing mechanical damage and mold wear caused by moisture, and indirectly optimizing the production yield. In terms of operation, by precisely controlling the blowing direction and intensity of the air nozzles 9 and the air flow distribution of the annular air cover 8, the surface of the copper slot can be dried while ensuring that there is no water accumulation in the slot, providing ideal conditions for subsequent processing. In addition, the design of the annular air cover 8 and the air nozzles 9 not only enhances the drying effect, but also simplifies the drying process, improves production efficiency, and significantly enhances the continuity and automation level of the entire production device.
[0039] In one embodiment, the air nozzles 9 are arranged in multiple groups, and the air nozzles 9 in each group are spaced along the circumferential direction of the annular air cover 8. The air nozzles 9 in each group are spaced along the axial direction of the annular air cover 8, which can further improve the drying efficiency and effect of the annular drying device 4 on the surface of the copper slot.
[0040] In one embodiment, the air nozzles 9 are arranged obliquely along the axial direction of the copper slot, and the air outlets of the air nozzles 9 are oriented towards the incoming direction of the copper slot.
[0041] In the present embodiment, the air nozzles 9 are arranged obliquely along the axial direction of the copper slot, and the air outlets of the air nozzles 9 are oriented towards the incoming direction of the copper slot. This design ensures that the contact angle between the hot air and the surface of the copper slot is optimized, effectively improving the drying efficiency and uniformity. When the cooled copper slot enters the annular drying device 4, the hot air is sprayed from the inclined air nozzles 9 at a specific angle, covering not only the outer surface of the copper slot but also the inside of the slot, achieving comprehensive drying of the surface and the inside of the slot. Since the air outlets of the air nozzles 9 are oriented towards the incoming direction of the copper slot, the hot air can form a stable air flow along the axial direction of the copper slot during its passage through the drying device, helping to blow out the residual moisture from the slot and causing the residual moisture to move towards the incoming direction rather than the outgoing direction. This ensures the drying effect of the copper slot and avoids blowing the moisture on the copper slot out of the annular drying device in the outgoing direction, which would result in ineffective drying of the copper slot.
[0042] In one embodiment, there can be multiple annular drying devices 4 arranged at intervals along the conveying direction of the copper slot, which can achieve continuous segmental drying of the copper slot, further improving the drying effect of the copper slot.
[0043] In one embodiment, the included angle between the central axis of the tuyere 9 and the central axis of the copper slot line is 30°-60°.
[0044] In this embodiment, the included angle between the central axis of the tuyere 9 and the central axis of the copper slot line is 30°-60°. The setting of this angle ensures that the hot air blowing can cover the surface of the copper slot line and the area inside the slot in the most effective way. By adjusting to this specific angle range, the hot air can not only be blown directly to the surface of the copper slot line, but also accurately enter the space inside the slot through the inclined air holes, accelerating the evaporation and discharge of moisture. This design utilizes the principle of fluid dynamics, so that the tuyere 9 can provide the best wind direction and wind pressure for the complex geometry of the copper slot line during the blow-drying process, thereby significantly improving the blow-drying efficiency, ensuring the dry state of the copper slot line in the subsequent processing steps, avoiding the oxidation problem caused by moisture residue and mold corrosion during twisting, and thereby improving the yield and production continuity of the product.
[0045] In one embodiment, the rear end of the annular air shield 8 is connected with a hot air generator 11 and a blower 12 through an air pipe 10, and the air pipe 10 is provided with an air volume adjusting valve.
[0046] In this embodiment, the rear end of the annular air shield 8 is connected with a hot air generator 11 and a blower 12 through an air pipe 10, and the air pipe 10 is provided with an air volume adjusting valve, which can perform efficient blow-drying treatment on the cooled copper slot line. The hot air generator 11 provides hot air at a constant temperature, and the blower 12 ensures that the hot air blows evenly on the surface of the copper slot line and the space inside the slot at a suitable speed. Through the precise control of the air volume adjusting valve, the air volume can be adjusted in real time to adapt to the different state requirements of the copper slot line during the blow-drying process. This design not only effectively removes the moisture on the surface and inside of the copper slot line, but also prevents the oxidation and mold corrosion problems that may occur in subsequent processing, while controlling the wind temperature reduces the stress caused by sudden cooling and heating, significantly improving the quality and production efficiency of the product.
[0047] The hot air generator 11 is used to heat the air delivered by the blower 12, including a heating device, the heating power is 3kW, and the wind temperature is 50℃-60℃.
[0048] In one embodiment, the bottom of the annular air shield 8 is provided with a drainage groove 13, and the copper slot line production device further comprises a wastewater collection tank 14, and the bottom of the drainage groove 13 is communicated with the wastewater collection tank 14.
[0049] In this embodiment, the bottom of the annular air hood 8 is provided with a drainage groove 13. When the annular drying device blows the surface of the copper tank wire, the water on the surface of the copper tank wire will be blown off. After the water falls on the bottom of the annular air hood 8, it will be collected by the drainage groove 13, and then enter the waste water collection tank 14 through the drainage groove, avoiding the accumulation of water in the annular air hood 8, and ensuring the effective collection of the residual water on the surface of the copper tank wire after cooling. The waste water collection tank 14 is connected to the bottom of the drainage groove 13, forming a complete water discharge path, avoiding the problem of residual water on the surface of the copper tank wire after cooling when entering the subsequent process, thereby preventing the oxidation of the surface of the copper tank wire and the corrosion of the twisting mold, while reducing the stress concentration caused by water, significantly improving the yield of the product. The use of the drainage groove 13 and the waste water collection tank 14 can ensure the timely removal of water during production.
[0050] The drainage groove can be a groove structure recessed from the bottom of the annular air hood 8, which makes better use of the collection and discharge of water flow.
[0051] By setting the annular drying device 4, the copper tank wire can be dried for 5s~8s, and the water content on the surface of the copper tank wire is <0.5%, and there is no residual water in the tank.
[0052] In one embodiment, the copper tank wire production device further comprises a gradient cooling device 15, which is arranged at the wire outlet end of the extrusion mold 3 and located on the upstream side of the annular drying device 4. The gradient cooling device 15 comprises cooling sections with gradually decreasing cooling temperatures along the running direction of the copper tank wire.
[0053] In this embodiment, the copper tank wire production device comprises a gradient cooling device 15, which is arranged at the wire outlet end of the extrusion mold 3 and located on the upstream side of the annular drying device 4. The gradient cooling device 15 is composed of multiple cooling sections with gradually decreasing cooling temperatures along the running direction of the copper tank wire, which ensures the gradual transition of the copper tank wire from high temperature to room temperature, avoiding internal structural defects caused by rapid cooling. The temperature gradient change during cooling can promote the uniform refinement of copper internal grains, improve electrical conductivity, reduce stress concentration, and reduce the generation of micro-cracks, creating ideal material conditions for subsequent online twisting and flaw detection processes. By this cooling method, not only the microstructure of the copper tank wire is optimized, but also the continuity and efficiency of the entire production process are significantly improved.
[0054] In one embodiment, the cooling sections include a first cooling section 16, a second cooling section 17, and a third cooling section 18. The temperature control range of the first cooling section 16 is 280℃~320℃, the temperature control range of the second cooling section 17 is 140℃~160℃, and the temperature control range of the third cooling section 18 is 20℃~30℃.
[0055] In this embodiment, the cooling section includes a first cooling section 16, a second cooling section 17 and a third cooling section 18, which control different temperature ranges of the copper busbar during the cooling process respectively, to ensure that the cooling rate and cooling effect of the copper busbar meet the production requirements. The temperature control range of the first cooling section 16 is set to 280℃-320℃, and the cooling goal of this section is to rapidly cool the copper busbar from high temperature to about 300℃ to avoid unnecessary stress of the heat conductor during the cooling process, and to provide a stable temperature basis for the subsequent cooling steps. Subsequently, the copper busbar enters the second cooling section 17, which has a temperature control range of 140℃-160℃. By reducing the cooling speed, the copper busbar achieves a slow cooling effect in the medium and low temperature range, further ensuring the uniformity of the internal organization and preventing grain coarsening. Finally, the copper busbar enters the third cooling section 18, which has a temperature control range of 20℃-30℃, to achieve the final cooling from room temperature and ensure that the copper busbar has good physical and mechanical properties in subsequent processing. The entire gradient cooling process is accurately controlled according to the characteristics of the copper busbar, and the temperature and cooling speed of each cooling section are strictly set to achieve the best cooling effect, thereby significantly improving the production quality and efficiency of the copper busbar, reducing energy consumption, and improving product consistency.
[0056] In one embodiment, the cooling section includes a first cooling section 16, a second cooling section 17 and a third cooling section 18, the first cooling section 16 includes a first cooling tank 19, an arc-shaped flow guide plate 20 and a cooling pipe 21, the first cooling tank 19 contains cooling water, the arc-shaped flow guide plate 20 is arranged on the inner wall of the first cooling tank 19, the second cooling section 17 includes a second cooling tank 22, a spiral flow guide groove 23 and a cooling pipe 21, the second cooling tank 22 contains cooling water, and the spiral flow guide groove 23 is arranged on the inner wall of the second cooling tank 22, the third cooling section 18 includes a third cooling tank 24, the third cooling tank 24 is provided with a honeycomb buffer plate 25, and the third cooling tank 24 contains cooling water.
[0057] In this embodiment, the cooling section is composed of the first cooling section 16, the second cooling section 17 and the third cooling section 18, aiming to realize the segmented gradient cooling of the copper busbar. The first cooling section 16 is cooled by the cooling water in the first cooling tank 19, combined with the arc-shaped flow guide plate 20 to guide the water flow, the water flow speed is 0.8 m / s, the cooling time is 15-20 s, so as to quickly reduce the temperature of the copper busbar to 300℃, which effectively avoids the abnormal growth of the grains at high temperature. Subsequently, the copper busbar enters the second cooling tank 22 of the second cooling section 17, which is provided with a spiral flow guide groove 23 to prolong the water flow path and ensure that the temperature of the copper busbar is further reduced to 150℃, the water flow speed is 0.5 m / s, the cooling time is 20 s-25 s, which is beneficial to the stability of the internal organization. Finally, the copper busbar is in the third cooling tank 24 of the third cooling section 18, which is gently reduced to room temperature through the moderating effect of the honeycomb buffer plate 25, avoiding the micro-cracks caused by rapid cooling. The honeycomb buffer plate 25 can slow down the flow speed of the cooling water and increase the turbulent effect of the cooling water by using the honeycomb structure thereon, thereby improving the heat exchange efficiency between the cooling water and the copper busbar. In the third cooling section 18, the water flow speed is 0.3 m / s, and the cooling time is 25 s-30 s. In the whole cooling process, the temperature control is fine, which avoids the problems of grain coarsening and cracking commonly seen in traditional cooling methods, and ensures the uniformity of the copper busbar organization and the improvement of the electrical conductivity. The cooling pipe 21 can adjust the temperature of the cooling water, so that the temperature of the cooling water is maintained in the preset temperature range, ensuring that each cooling section can realize accurate temperature control, thereby optimizing the production efficiency and product quality.
[0058] In one embodiment, the cooling pipe 21 contains refrigerant, which can accurately adjust the temperature of the cooling water by using the efficient and wide-range temperature adjustment characteristics of the refrigerant.
[0059] The refrigerant in the cooling pipe 21 is spaced apart from the cooling water, and the two adopt different circulating pipelines and are isolated from each other, only realizing heat exchange and not flowing between the media.
[0060] In one embodiment, the online twisting device 5 includes a driving twisting roller 26, a driven twisting roller 27, a tension detection module and a tension adjusting mechanism. The driven twisting roller 27 controls the copper busbar to be attached to the driving twisting roller 26, the tension detection module is used to detect the tension of the copper busbar, and the tension adjusting mechanism adjusts the driving twisting roller 26 and the driven twisting roller 27 according to the tension detected by the tension detection module.
[0061] In this embodiment, when the online twisting device 5 integrates the driving twisting roller 26 and the driven twisting roller 27, the two work together to ensure the fit and tension control of the copper slot wire during the twisting process. The driven twisting roller 27 is designed with a floating bearing seat, which can flexibly adjust the position according to the instantaneous deformation of the copper slot wire, so that it closely fits the driving twisting roller 26, avoiding uneven twisting caused by processing gap. The tension detection module includes a tension sensor installed on the bearing seat of the driven twisting roller 27, which monitors the tension change of the copper slot wire during the twisting process in real time, and the signal is directly transmitted to the PID controller for data processing. The tension adjusting mechanism is connected with the lifting cylinder of the driven twisting roller 27 through the servo motor, and according to the real-time tension deviation feedback by the tension detection module, the PID controller automatically adjusts the speed of the driving twisting roller 26 or the pressure of the driven twisting roller 27, to ensure the accurate control of the twisting angle per meter and the uniform distribution of internal stress of the copper slot wire during the twisting process.
[0062] This technical solution can effectively solve the problems of uneven twisting angle and local stress concentration caused by fixed tension in traditional twisting equipment, ensuring the geometric precision and mechanical properties of the twisted copper slot wire, and improving the continuity of the production process and the yield of finished products. Of course, in other embodiments not shown, different tension detection and adjustment methods can be used, such as monitoring tension through optical fiber sensors, or using hydraulic cylinders instead of air cylinders for pressure adjustment, to adapt to different production needs and improve the response speed and control accuracy of the system.
[0063] In one embodiment, the online twisting device 5 further includes a driving motor 28 and a speed reducer 29, the driving twisting roller 26 is driven connected through the speed reducer 29 and the driving motor 28 to form a driving twisting mechanism, the driven twisting roller 27 is driven connected through the speed reducer 29 and the driving motor 28 to form a driven twisting mechanism, the driven twisting mechanism is located on the upstream side of the driving twisting mechanism, and an angle detection mechanism 30 is arranged on the downstream side of the driving twisting mechanism to detect the twisting angle of the copper slot wire.
[0064] In one embodiment, the flaw detection device is an ultrasonic flaw detection device, which comprises a scraping and lubricating unit, a flaw detection probe assembly, and a defect processing unit. The scraping and lubricating unit comprises a clamping sleeve, a polyurethane scraping sleeve is installed in the sleeve, a ring-shaped cavity is opened in the interior of the scraping sleeve, and a lubricating oil pipe is connected through a micro-hole to realize the synchronous performance of "scraping + lubricating", thereby reducing the interference of copper scraps. The flaw detection probe assembly adopts a ring-shaped probe seat, 6 5MHz ultrasonic probes are uniformly arranged, the distance between the probes and the surface of the copper slot line is 1mm, and the spring floating mechanism is self-adaptive to the jumping of the copper slot line. The defect processing unit comprises a defect identification module, which is linked with a PLC, the identification accuracy is >99.5%, an automatic rejection mechanism, which comprises a cylinder pushing cutter, the response time is <0.5s, and a defect marker, such as a laser marker, the marking position deviation is <1mm. Through the adoption of the above-mentioned ultrasonic flaw detection device, the flaw detection speed can be synchronized with the production speed, the misjudgment rate is <0.5%, and the defect detection rate is >99%.
[0065] The working process of the copper slot wire production device is as follows: firstly, the material is smelted in the vacuum induction furnace 1, the high-purity copper raw material is heated and melted in the furnace to remove impurities and gas. Then, the molten copper is continuously cast into a copper rod with a diameter of 16 mm through the horizontal continuous casting machine 2, and the surface of the copper rod is smooth and dense. The copper rod is then transported to the extrusion die 3, and after continuous extrusion, it is once formed into a multi-slot copper slot wire with a specified slot shape. The extruded copper slot wire directly enters the gradient cooling device 15 through the sealed channel. In the first cooling section 16, the cooling water flows through the arc-shaped guide plate 20 in the first cooling tank 19 through the cooling pipe 21, effectively guiding the water flow, so that the copper slot wire is quickly cooled to about 300 DEG C. Then, the copper slot wire enters the second cooling section 17, and the cooling water in the second cooling tank 22 increases the path length through the spiral guide groove 23, further reducing the temperature of the copper slot wire to 150 DEG C. Finally, in the third cooling section 18, the cooling water in the third cooling tank 24 is cooled to room temperature through the moderating effect of the honeycomb buffer plate 25, avoiding micro-cracks caused by rapid cooling. The cooled copper slot wire then enters the annular drying device 4, and the hot air generated by the hot air generator 11 and the air blower 12 is delivered to the inclined air nozzle 9 in the annular air hood 8 through the air pipe 10. The central axis of the air nozzle 9 forms an angle of 30 DEG ~ 60 DEG with the central axis of the copper slot wire, ensuring that the hot air can fully cover the surface and the slot of the copper slot wire, realizing efficient drying. The drainage tank 13 at the bottom of the annular air hood 8 collects the dripping water, which is uniformly treated through the connection with the waste water collection tank 14. The dried copper slot wire then enters the online twisting device 5, and the cooperation of the driving twisting roller 26 and the driven twisting roller 27, as well as the real-time monitoring and adjustment of the tension detection module and the tension adjusting mechanism, ensures the uniform tension of the copper slot wire during the twisting process, avoiding local stress concentration. The twisted copper slot wire immediately receives the detection of the ultrasonic flaw detection device 6, which can accurately identify internal cracks, pores, inclusions and other defects, and automatically mark or reject unqualified products. Finally, the qualified copper slot wire is coiled by the automatic take-up machine to form a standard coil of finished product, and the entire production process realizes "zero interruption" production from liquid copper to finished copper slot wire, significantly improving production efficiency and product quality, while reducing energy consumption and optimizing the continuity and controllability of the production process.
[0066] Obviously, the above-described embodiments are only a part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor should belong to the scope of protection of the present application.
[0067] It is to be understood that the terminology used herein is for the purpose of describing specific embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, devices, components and / or combinations thereof, but do not preclude the presence or addition of one or more other features, steps, operations, devices, components and / or combinations thereof.
[0068] The preferred embodiments of the present application have been described above with the aid of drawing only for purposes of example and variation, and it should be understood that the present application can be practiced otherwise without departing from the spirit and principles of the present application. The present application is thus not limited to the embodiments described above, but encompasses any and all modifications within the spirit and scope of the present application.
Claims
1. A copper channel wire production apparatus, characterized in that, include: A vacuum induction furnace (1) is used for smelting copper; A horizontal continuous casting machine (2) is set on the outlet side of the vacuum induction furnace (1) for continuously casting molten copper into copper rods. The extrusion die (3) is set on the downstream side of the horizontal continuous casting machine (2) for continuously extruding the copper rod so that the copper rod is formed into a multi-groove copper groove line in one step. An annular drying device (4) is provided at the copper channel wire outlet end of the extrusion die (3) for drying the copper channel wire extruded by the extrusion die (3); An online twisting device (5) is located downstream of the annular drying device (4) and is used to twist the dried copper channel wire. The flaw detection device (6) is located downstream of the online torsion device (5) and is used to detect flaws in the copper channel wire after it has been torsioned and to mark qualified products and defective products. The winding device (7) is used to coil and wind up the qualified copper channel wire.
2. The copper channel wire production apparatus according to claim 1, characterized in that, The annular drying device (4) includes an annular hood (8) and a plurality of nozzles (9) disposed on the inner periphery of the annular hood (8). The plurality of nozzles (9) are arranged at intervals along the circumference of the annular hood (8), and the air outlets of the nozzles (9) face the copper groove line.
3. The copper channel wire production apparatus according to claim 2, characterized in that, The nozzle (9) is inclined along the axial direction of the copper channel line, and the air outlet of the nozzle (9) faces the material inlet direction of the copper channel line.
4. The copper channel wire production apparatus according to claim 3, characterized in that, The angle between the central axis of the nozzle (9) and the central axis of the copper groove is 30°~60°.
5. The copper channel wire production apparatus according to claim 2, characterized in that, The rear end of the annular hood (8) is connected to a hot air generator (11) and a blower (12) via a duct (10), and the duct (10) is equipped with an air volume regulating valve.
6. The copper channel wire production apparatus according to claim 5, characterized in that, The bottom of the annular hood (8) is provided with a drainage trough (13), and the copper trough production device also includes a wastewater collection tank (14), the bottom of which is connected to the wastewater collection tank (14).
7. The copper channel wire production apparatus according to claim 1, characterized in that, The copper channel production device also includes a gradient cooling device (15), which is located at the outlet end of the extrusion die (3) and upstream of the annular drying device (4). The gradient cooling device (15) includes a cooling section with a gradually decreasing cooling temperature along the traveling direction of the copper channel.
8. The copper channel wire production apparatus according to claim 7, characterized in that, The cooling section includes a first cooling section (16), a second cooling section (17) and a third cooling section (18). The temperature control range of the first cooling section (16) is 280℃~320℃, the temperature control range of the second cooling section (17) is 140℃~160℃, and the temperature control range of the third cooling section (18) is 20℃~30℃.
9. The copper channel wire production apparatus according to claim 7, characterized in that, The cooling section includes a first cooling section (16), a second cooling section (17), and a third cooling section (18). The first cooling section (16) includes a first cooling tank (19), an arc-shaped guide plate (20), and a cooling pipe (21). The first cooling tank (19) contains cooling water, and the arc-shaped guide plate (20) is disposed on the inner wall of the first cooling tank (19). The second cooling section (17) includes a second cooling tank (22), a spiral guide groove (23), and a cooling pipe (21). The second cooling tank (22) contains cooling water, and the spiral guide groove (23) is disposed on the inner wall of the second cooling tank (22). The third cooling section (18) includes a third cooling tank (24), and a honeycomb buffer plate (25) is disposed inside the third cooling tank (24). The third cooling tank (24) contains cooling water.
10. The copper channel wire production apparatus according to claim 1, characterized in that, The online torsion device (5) includes an active torsion roller (26), a driven torsion roller (27), a tension detection module, and a tension adjustment mechanism. The driven torsion roller (27) controls the copper channel wire to adhere to the active torsion roller (26). The tension detection module is used to detect the tension of the copper channel wire. The tension adjustment mechanism adjusts the active torsion roller (26) and the driven torsion roller (27) according to the tension detected by the tension detection module.