Adjustable tungsten filament pinching device
By designing an adjustable power supply tungsten wire tipping device, the problem of unstable current during the tungsten wire tipping process was solved, achieving stability and safety in the tungsten wire tipping effect, and improving production efficiency and product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- ZHANGJIAKOU YUANSHI ADVANCED MATERIALS CO LTD
- Filing Date
- 2025-03-27
- Publication Date
- 2026-04-28
AI Technical Summary
Existing tungsten wire tipping devices cannot provide a constant current, resulting in inconsistent reaction intensity, unstable tipping effect, low wire threading efficiency, and safety hazards.
An adjustable power supply tungsten filament tipping device was designed, which can convert AC power to DC power and automatically adjust the output current according to the input parameters. It is equipped with a remote control module and protection functions to ensure the stability and safety of the electrolysis reaction.
It improves the quality and efficiency of tungsten wire tipping, reduces operational risks, enhances product qualification rate and production management level, and ensures the consistency and safety of tipping effects for tungsten wires of different specifications.
Smart Images
Figure CN224172913U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of diamond wire manufacturing, and in particular relates to an adjustable tungsten wire tipping device. Background Technology
[0002] With the rapid development of the photovoltaic industry, the demand for silicon wafer cutting is increasing. Against this backdrop, diamond wire has become a widely used cutting tool. Diamond wire is a high-strength, high-wear-resistant cutting wire made by electroplating a layer of diamond powder onto the surface of a steel wire substrate. It is mainly used in the solar photovoltaic industry for cutting hard and brittle materials such as monocrystalline silicon and polycrystalline silicon. In recent years, in order to further improve cutting efficiency and reduce costs, research on using tungsten wire as the main conductor of diamond wire has gradually attracted attention.
[0003] Tungsten wire, due to its high strength, high temperature resistance, and excellent conductivity, is an ideal choice for manufacturing high-performance diamond wire. The production process first requires a wire drawing process to process the tungsten raw material into fine wires of the required diameter. However, in practice, the tungsten wire tip is often too large to pass directly through the die for subsequent processing. Therefore, the tungsten wire tip must be sharpened before drawing to facilitate smooth die passage. Ideally, the sharpening effect requires the tungsten wire tip to both easily pass through the die and possess sufficient strength to prevent breakage during the stretching process.
[0004] Currently, commonly used tungsten filament tipping devices rely on a 150VA AC step-down transformer. This device reduces the AC 220V voltage to AC 24V output and achieves the tipping process of the tungsten filament by connecting it to a tipping cup. Since tipping is essentially a chemical reaction—the tungsten filament dissolving in an electrolyte—this process requires a stable current to ensure the smooth progress of the electrolytic reaction. However, the internal resistance of tungsten filaments of different diameters varies, and existing devices using a fixed voltage power supply cannot provide a constant current, leading to the following problems:
[0005] The intensity of the reaction varies: for tungsten wires of certain diameters, excessive current may cause violent chemical reactions, resulting in the risk of solution splashing and increasing the possibility of injury to operators.
[0006] The tipping effect is unstable: if the current is too low, there is almost no reaction, which prevents the tungsten wire tip from being effectively tipped, affecting the efficiency of subsequent die-cutting; while if the current is too high, the tungsten wire may be over-dissolved, which not only wastes raw materials, but may also reduce the mechanical properties of the tungsten wire.
[0007] Low wire drawing efficiency: Due to the above reasons, the entire wire drawing preparation process takes longer, reducing overall production efficiency.
[0008] In summary, existing tungsten wire tipping devices, due to their unreasonable power supply design, cannot meet the precise tipping requirements of tungsten wires of different specifications, thus limiting the application potential of tungsten wire as a diamond wire busbar. Therefore, developing a new tipping device capable of automatically adjusting voltage or current according to the diameter of the tungsten wire is particularly urgent. This would not only improve tipping quality but also significantly enhance operational safety and production efficiency. Utility Model Content
[0009] The purpose of this invention is to provide an adjustable tungsten wire tipping device to solve the technical problem.
[0010] To achieve the above objectives, the specific technical solution of the adjustable tungsten wire tipping device of this utility model is as follows:
[0011] An adjustable tungsten wire tipping device includes a device housing, an adjustable power supply, a tipping cup electrically connected to the adjustable power supply, and a wire guide wheel disposed on the device housing for the tungsten wire to pass through.
[0012] An electrolyte is placed inside the cup, the positive output terminal of the adjustable power supply is connected to the electrolyte inside the cup, and the negative output terminal of the adjustable power supply is connected to the device housing.
[0013] One end of the tungsten wire enters the tipping cup through the wire guide wheel, forming a complete circuit with the adjustable power supply, generating a constant current to carry out an electrolytic reaction to tip the tungsten wire.
[0014] As a further improvement of this utility model, the adjustable power supply converts AC power to DC power and automatically adjusts the output current according to the input parameters to adapt to the tipping requirements of tungsten wires of different specifications.
[0015] As a further improvement of this utility model, the adjustable power supply has a remote control module, which is connected to the controller via wired or wireless communication, and the controller enables remote monitoring and adjustment of the output of the adjustable power supply.
[0016] As a further improvement of this utility model, the cup includes a cup body and an electrode plate disposed inside the cup body. The cup body is made of corrosion-resistant insulating material. The electrode plate is connected to the positive output of the adjustable power supply. The shape of the electrode plate is adapted to the inside of the cup body to ensure uniform electric field distribution in the electrolyte.
[0017] As a further improvement of this utility model, the negative output terminal of the adjustable power supply is connected to the device housing via a mounting base.
[0018] As a further improvement of this utility model, the adjustable power supply includes a display input module, which is disposed on the surface of the device housing and displays the values of output voltage and output current in real time while inputting parameters.
[0019] As a further improvement of this utility model, the guide wheel includes a tension adjustment mechanism, which is used to adjust the tension of the tungsten wire on the guide wheel to ensure that the tungsten wire is in a suitable tension state.
[0020] As a further improvement of this utility model, the adjustable power supply has overvoltage protection, overcurrent protection and short circuit protection functions. The overvoltage protection mechanism cuts off the power output when the voltage exceeds a set threshold; the overcurrent protection function cuts off the power output when the current exceeds a set threshold; and the short circuit protection mechanism cuts off the power output when a short circuit is detected.
[0021] As a further improvement of this utility model, a cover plate is provided on the top of the cup body. When the cover plate is closed, it closes the opening of the cup body. When the cover plate is open, it is inclined and protrudes upward relative to the cup body, with the lower end extending into the interior of the cup body, effectively preventing the electrolyte generated by the violent reaction during the tipping process from splashing out.
[0022] Beneficial effects:
[0023] The adjustable power supply converts AC to DC and automatically adjusts the output voltage or current based on input parameters. This allows the device to easily handle the tipping requirements of tungsten wires of different specifications, ensuring a stable tipping process, greatly improving tipping quality, reducing poor tipping results caused by parameter mismatch, increasing production efficiency and product qualification rate, and ensuring the most suitable electrolytic reaction conditions for tungsten wires of different diameters and specifications. This not only improves tipping quality but also avoids problems caused by excessive or insufficient current, such as the risk of violent solution splashing or poor tipping results.
[0024] Equipped with a remote control module, it can connect to the controller via wired or wireless communication. Operators can remotely monitor and adjust the adjustable power output without being physically present at the equipment, facilitating production management and equipment debugging. It is particularly suitable for large-scale production scenarios, enabling centralized and intelligent control, improving overall production efficiency and management level. Whether via wired or wireless communication, it greatly enhances operational flexibility and convenience, reducing the need for operators to directly contact the equipment, thereby lowering risks.
[0025] The cup body of the tungsten wire tipping cup is made of corrosion-resistant and insulating material, effectively preventing the electrolyte from corroding the cup body and extending the service life of the tipping cup. The shape of the internal electrode plate is adapted to the cup body to ensure a uniform electric field distribution in the electrolyte, making the electrolysis reaction more stable and uniform, thereby improving the consistency of the tungsten wire tipping effect and enhancing product quality stability.
[0026] The adjustable power supply output negative terminal is connected to the equipment housing via the mounting base, ensuring a reliable electrical connection. Simultaneously, the power supply features overvoltage, overcurrent, and short-circuit protection functions. In the event of abnormal voltage or current or a short circuit, it can quickly cut off the power output, effectively protecting the equipment, reducing the risk of equipment damage, decreasing maintenance costs, and improving the safety and stability of the device's operation.
[0027] The cover plate on the top of the cup can effectively prevent foreign objects from entering the cup and affecting the tipping process when closed; when opened, it is tilted and the lower end extends into the cup body, which can prevent electrolyte from splashing out due to violent reactions during the tipping process, avoid injury to operators, and ensure the safety of the production environment.
[0028] The tension adjustment mechanism of the guide roller can precisely adjust the tension of the tungsten wire on the guide roller, ensuring that the tungsten wire is under appropriate tension when it enters the tipping cup. This helps maintain the stability of the tungsten wire position during the tipping process, improves tipping accuracy, reduces tipping deviation caused by improper tungsten wire tension, and further improves product quality. Attached Figure Description
[0029] Figure 1 This is a schematic diagram of an adjustable tungsten wire tipping device according to the present invention;
[0030] The markings in the diagram are as follows: 1. Equipment housing; 2. Adjustable power supply; 3. Tipping cup; 4. Wire guide wheel; 5. Tungsten wire; 6. Wire drawing die. Detailed Implementation
[0031] To enhance understanding of this utility model, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. These embodiments are only used to explain the present utility model and do not constitute a limitation on the scope of protection of the present utility model.
[0032] Implementation example:
[0033] like Figure 1 The adjustable tungsten wire tipping device shown here tipps one end of the tungsten wire 5 before drawing it, to facilitate the wire 5 passing through the drawing die 6. The tipping device includes a housing 1 that serves as the device's support, and an adjustable power supply 2, a tipping cup 3, and a wire guide roller 4 mounted on the housing 1. After passing through the wire guide roller 4, the tungsten wire 5 is tipped in the tipping cup 3 and then passes through the drawing die 6.
[0034] The adjustable power supply 2 converts AC to DC and is attached to the surface of the equipment housing via a display input module. In this embodiment, the display input module is a display screen with a parameter adjustment knob and a status display window. The output voltage and current are adjusted by adjusting the knob, with a maximum output of DC 36V and 5A. The status display window shows the output voltage and current values in real time, with a voltage accuracy of ±0.1V and a current accuracy of ±0.01A. The adjustable power supply also has a remote control module, which connects to a controller via wired or wireless communication. The controller enables remote monitoring and adjustment of the adjustable power supply output. Operators can remotely monitor and adjust the adjustable power supply output without being physically present at the equipment site, facilitating production management and equipment debugging. This is particularly suitable for large-scale production scenarios, enabling centralized and intelligent control and improving overall production efficiency and management level. The adjustable power supply features an overvoltage protection module. When the output voltage exceeds the preset safe voltage threshold (DC36V), the overvoltage protection module automatically cuts off the power output to prevent damage to the equipment or safety accidents caused by excessive voltage. The safe voltage threshold can be adjusted in the display input module according to actual needs. The overcurrent protection module activates quickly when the output current exceeds the preset safe current threshold (5A), reducing the output current or cutting off the power supply to avoid overheating or burnout caused by excessive current. The safe current threshold can be flexibly set through the display input module. The short-circuit protection module cuts off the power output within a very short time (less than 100ms) upon detecting a short circuit, preventing irreversible damage to the equipment from the short-circuit current and issuing an alarm signal via an audible and visual alarm.
[0035] The tipping cup 3 comprises a cup body and an electrode plate. The cup body, made of corrosion-resistant insulating material, holds the electrolyte, providing a reaction environment for tungsten filament tipping. The electrolyte within the cup body, along with the adjustable power supply and the tungsten filament, forms a complete circuit, generating a constant current for electrolysis to achieve tungsten filament tipping. The electrode plate, a conductive metal block, is located at the bottom of the cup body and connected to the positive output of the adjustable power supply. Its shape is adapted to the bottom of the cup, ensuring a uniform electric field distribution in the electrolyte, making the electrolysis reaction more stable and uniform, and improving the consistency of tungsten filament tipping and product quality stability. The cover plate is located at the top of the cup body and is flip-up, positioned inside the opening at the top. When closed, it seals the cup opening; when open, it protrudes upwards relative to the cup body at an angle, extending its lower end into the cup body. In the open state, the cover plate effectively prevents electrolyte splashing during the vigorous reaction, avoiding injury to operators and ensuring a safe production environment.
[0036] The guide roller 4, mounted on the equipment housing 1, guides the tungsten wire forward, ensuring its smooth entry into the tipping cup and guaranteeing an accurate transmission path within the device. This allows the tungsten wire to participate in the tipping process in a predetermined manner. After tipping, the tungsten wire can continue through the drawing die for the drawing process. The tension adjustment mechanism regulates the tension of the tungsten wire on the guide roller, maintaining it at a suitable tension level. This helps maintain the stability of the tungsten wire's position during tipping and drawing, preventing positional deviations due to improper wire tension, thereby improving tipping accuracy, reducing tipping deviations caused by tension issues, and enhancing product quality.
[0037] In this invention, the adjustable power supply 2 converts alternating current (AC) to direct current (DC) to provide power to the power circuit. Its positive output terminal is connected to the electrolyte in the tipping cup 3, and its negative output terminal is connected to the equipment housing via a mounting base. The tipping cup 3 contains electrolyte and has an electrode plate connected to the positive output terminal of the adjustable power supply, serving as the site of the electrolytic reaction. The tungsten wire 5 enters the tipping cup 3 via the wire guide wheel 4 on the equipment housing 1 and participates in the electrolytic reaction in the electrolyte. The negative terminal of the adjustable power supply 2 is connected to the equipment housing 1 via the mounting base, and the equipment housing 1 forms a complete circuit as part of the overall circuit. By forming a complete circuit and generating a constant current, the tungsten wire 5 undergoes an electrolytic reaction in the electrolyte, thereby achieving the purpose of tipping the tungsten wire and meeting the requirement of tipping the tungsten wire head in the wire drawing process so that it can pass through the mold. The adjustable power supply can automatically adjust the output voltage or current according to the input parameters, adapting the current in the circuit to the tipping requirements of tungsten wires of different specifications, ensuring the tipping quality and effect.
[0038] It is understood that this utility model has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this utility model. Furthermore, under the teachings of this utility model, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the protection scope of this utility model.
Claims
1. An adjustable tungsten wire tipping device, characterized in that, It includes a device housing, an adjustable power supply, a tipping cup electrically connected to the adjustable power supply, and a wire guide wheel disposed on the device housing for the tungsten filament to pass through; An electrolyte is placed inside the cup, the positive output terminal of the adjustable power supply is connected to the electrolyte inside the cup, and the negative output terminal of the adjustable power supply is connected to the device housing. One end of the tungsten wire enters the tipping cup through the wire guide wheel, forming a complete circuit with the adjustable power supply, generating a constant current to carry out an electrolytic reaction to tip the tungsten wire.
2. The adjustable tungsten wire tipping device according to claim 1, characterized in that, The adjustable power supply converts AC to DC and automatically adjusts the output current according to the input parameters to meet the tipping requirements of tungsten wires of different specifications.
3. The adjustable tungsten wire tipping device according to claim 1, characterized in that, The adjustable power supply has a remote control module, which is connected to the controller via wired or wireless communication. The controller enables remote monitoring and adjustment of the output of the adjustable power supply.
4. The adjustable tungsten wire tipping device according to claim 1, characterized in that, The cup includes a cup body and an electrode plate disposed inside the cup body. The cup body is made of corrosion-resistant insulating material. The electrode plate is connected to the positive output terminal of the adjustable power supply. The shape of the electrode plate is adapted to the interior of the cup body to ensure uniform electric field distribution in the electrolyte.
5. The adjustable tungsten wire tipping device according to claim 1, characterized in that, The negative output terminal of the adjustable power supply is connected to the device housing via a mounting base.
6. The adjustable tungsten wire tipping device according to claim 2, characterized in that, The adjustable power supply includes a display input module, which is disposed on the surface of the device housing and displays the values of output voltage and output current in real time while inputting parameters.
7. The adjustable tungsten wire tipping device according to claim 1, characterized in that, The guide roller includes a tension adjustment mechanism, which is used to adjust the tension of the tungsten wire on the guide roller to ensure that the tungsten wire is in a suitable tension state.
8. The adjustable tungsten wire tipping device according to claim 6, characterized in that, The adjustable power supply has overvoltage protection, overcurrent protection and short circuit protection functions. The overvoltage protection mechanism cuts off the power output when the voltage exceeds a set threshold; the overcurrent protection function cuts off the power output when the current exceeds a set threshold; and the short circuit protection mechanism cuts off the power output when a short circuit is detected.
9. The adjustable tungsten wire tipping device according to claim 4, characterized in that, The top of the cup is provided with a cover plate, which closes the opening of the cup when closed; when the cover plate is open, it is tilted and protrudes upward relative to the cup, with the lower end extending into the interior of the cup, effectively preventing the electrolyte from splashing out due to the violent reaction during the tipping process.