A precisely controllable wire and cable extruder

Abstract

The utility model relates to the technical field of wire and cable generation, and disclose a kind of wire and cable extruder of precision control, including cylinder and PLC controller;The inner chamber of the cylinder is fixedly connected with outer layer heat preservation cover, the inner wall of the outer layer heat preservation cover is fixedly connected with inner layer nanometer ceramic heating layer, middle layer heat conduction copper pipe is embedded between the outer layer heat preservation cover with the inner layer nanometer ceramic heating layer, the middle layer heat conduction copper pipe overall presents spiral structure, the inner chamber of the middle layer heat conduction copper pipe is equipped with electric heating wire and filled with heat-conducting silicone grease, the surface of the inner layer nanometer ceramic heating layer is sprayed with far infrared coating, the axial of the cylinder is uniformly arranged with three temperature sensors, three the temperature sensors are respectively located the feeding end, middle and discharge end of cylinder, and each the temperature sensor is electrically connected with PLC controller.

Description

Technical Field

[0001] This utility model relates to the field of wire and cable manufacturing technology, specifically to a wire and cable extruder that can be precisely controlled. Background Technology

[0002] Wire and cable extruders are production equipment used to manufacture wires and cables. These machines are mainly used to extrude the insulation or sheathing material of wires and cables onto the outer diameter of the wires or cables through a specific die, thereby completing the insulation or sheathing process. The working principle is that the extruder uses a heated die to transform the cable wrapping material (such as PVC, PE and other plastics or rubber) into a specific shape through the extrusion process, accurately wrapping it around the outer layer of the wire to form insulation or sheath. Therefore, wire and cable extruders are one of the indispensable and important pieces of equipment in the modern wire and cable manufacturing industry. Chinese patent publication (publication number: CN219171623U) discloses an extruder for wire and cable production and processing, including a column, a first servo motor is fixedly connected through and fixedly connected to the middle of the left side of the column, a first screw rod is fixedly connected to the output end of the first servo motor and the first screw rod passes through the column, a heating plate is fixedly connected through and fixedly connected to the inside of the column, and a temperature sensor is fixedly connected to the middle of the top left side of the column. The aforementioned comparative documents mainly rely on a single cylindrical heating plate to heat the material. Although this method is simple and easy to implement, in practical applications, the heat conduction path of a single cylindrical heating plate is singular, resulting in significant radial temperature differences within the column. During the heating process, the material is prone to local over-melting or insufficient melting due to uneven heating, which in turn leads to defects such as thickness deviation and surface roughness in the extruded cable insulation or sheath layer. In view of this, the present invention solves the above-mentioned technical problems by proposing a wire and cable extruder that can be precisely controlled. Utility Model Content

[0003] To address the shortcomings of the aforementioned background technology, this utility model provides a technical solution for a precisely controllable wire and cable extruder. It reduces heat loss through an outer layer of nano-aerogel felt insulation, achieves uniform circumferential heat conduction with a middle layer of spiral heat-conducting copper tube and thermal grease, and heats the material through radiation with an inner layer of nano-ceramic heating layer with a far-infrared coating, thus reducing radial temperature differences. Simultaneously, PT100 temperature sensors are arranged at three axial ends of the cylinder, and a PLC controller adjusts the power of each heating section in real time, reducing temperature fluctuations, improving material melting uniformity, and lowering cable surface roughness.

[0004] This utility model provides the following technical solution: a precisely controllable wire and cable extruder, including a barrel and a PLC controller; an outer insulation sleeve is fixedly connected to the inner cavity of the barrel, an inner nano-ceramic heating layer is fixedly connected to the inner wall of the outer insulation sleeve, a middle heat-conducting copper tube is embedded between the outer insulation sleeve and the inner nano-ceramic heating layer, the middle heat-conducting copper tube has an overall spiral structure, the inner cavity of the middle heat-conducting copper tube is provided with an electric heating wire and filled with thermally conductive silicone grease, the surface of the inner nano-ceramic heating layer is sprayed with a far-infrared coating, three temperature sensors are evenly arranged axially on the barrel, the three temperature sensors are respectively located at the feed end, the middle and the discharge end of the barrel, and each temperature sensor is electrically connected to the PLC controller.

[0005] As a preferred technical solution of this utility model, a feed cylinder is fixedly connected to the surface of the cylinder, and a connecting shaft is rotatably connected to the inner cavity of the feed cylinder. Multiple sets of stirring blades are fixedly connected to the surface of the connecting shaft, and multiple serrated cutting edges are fixedly connected to one side of each stirring blade. The cutting edge angle of the serrated cutting edges is 45 degrees.

[0006] As a preferred embodiment of this utility model, the inner cavity of the cylinder is rotatably connected to a rotating shaft, the surface of the rotating shaft is fixedly connected to a spiral blade, the discharge end of the cylinder is fixedly connected to an extrusion port, and the extrusion port is detachably connected to the cylinder by bolts.

[0007] As a preferred embodiment of this utility model, a servo motor is fixedly connected to one end of both the connecting shaft and the rotating shaft, and a pressure sensor is installed near the extrusion port of the cylinder. Each servo motor and each pressure sensor are electrically connected to the PLC controller.

[0008] As a preferred embodiment of this utility model, a feeding pipe is fixedly connected to the surface of the feeding cylinder, and the feeding pipe is set at an angle to the horizontal plane of the feeding cylinder.

[0009] As a preferred embodiment of this utility model, the surface of the PLC controller is integrated with a touch screen, and two control buttons are fixedly connected to the surface of the PLC controller below the touch screen.

[0010] As a preferred embodiment of this invention, the temperature sensor is a PT100 platinum resistance temperature sensor, and the pressure sensor is a piezoresistive ceramic pressure sensor.

[0011] As a preferred embodiment of this utility model, the outer insulation sleeve is a nano-aerogel felt outer insulation sleeve, and the two control buttons are an emergency stop button and a system reset button.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. The outer layer of nano-aerogel felt insulation jacket reduces heat loss, the middle layer of spiral heat-conducting copper tube and thermal grease achieve circumferential uniform heat conduction, and the far-infrared coating of the inner nano-ceramic heating layer heats the material by radiation, reducing the radial temperature difference. At the same time, PT100 temperature sensors are arranged at the three ends of the cylinder axis, and the PLC controller adjusts the power of each heating section in real time, reducing temperature fluctuations, improving the uniformity of material melting, and reducing the surface roughness of the cable.

[0013] 2. Temperature sensor data is transmitted to the PLC controller in real time. The power of the electric heating wire is dynamically adjusted through a PID algorithm. When the temperature exceeds the threshold, the system automatically reduces the heating power to prevent the material from decomposing due to overheating, thereby reducing the scrap rate and improving production continuity. In addition, temperature control is linked with pressure-speed regulation. When temperature fluctuations affect the viscosity of the material, the pressure sensor feeds back to the servo motor, which automatically adjusts the screw speed ratio to ensure that the extrusion volume does not fluctuate, thus solving the problem of unstable extrusion caused by temperature deviation in the existing technology.

[0014] 3. The material is sheared and crushed by the 45-degree serrated blades of the stirring blades, and the extrusion and conveying by the spiral blades reduces the deviation of the crushed particle size and improves the uniformity of the residence time of the material in the cylinder, avoiding local over-melting caused by uneven particles and improving the utilization rate of raw materials. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is a cross-sectional view of the present invention; Figure 3 This is a schematic diagram of the serrated cutting edge structure of this utility model; Figure 4 This is a schematic diagram of the middle-layer heat-conducting copper tube structure of this utility model.

[0016] In the diagram: 1. Cylinder; 101. PLC controller; 2. Outer insulation jacket; 201. Inner nano-ceramic heating layer; 202. Middle heat-conducting copper pipe; 3. Feed cylinder; 301. Connecting shaft; 302. Stirring blade; 303. Serrated cutting edge; 4. Rotating shaft; 401. Spiral blade; 402. Extrusion port; 5. Servo motor; 6. Feeding pipe; 7. Touch screen; 701. Control button. Detailed Implementation

[0017] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0018] Please see Figure 1-4 As shown, a precisely controllable wire and cable extruder includes a barrel 1 and a PLC controller 101. An outer insulation sleeve 2 is fixedly connected to the inner cavity of the barrel 1. An inner nano-ceramic heating layer 201 is fixedly connected to the inner wall of the outer insulation sleeve 2. A middle heat-conducting copper tube 202 is embedded between the outer insulation sleeve 2 and the inner nano-ceramic heating layer 201. The middle heat-conducting copper tube 202 has a spiral structure. The inner cavity of the middle heat-conducting copper tube 202 is provided with an electric heating wire and filled with thermally conductive silicone grease. The surface of the inner nano-ceramic heating layer 201 is sprayed with a far-infrared coating. Three temperature sensors are evenly arranged axially on the barrel 1. The three temperature sensors are located at the feed end, the middle and the discharge end of the barrel 1, respectively. Each temperature sensor is electrically connected to the PLC controller 101. Based on real-time data from three temperature sensors, the PLC controller 101 independently adjusts the power of each heating section using a PID algorithm to form a closed-loop temperature control. The helix angle of the middle layer heat-conducting copper tube 202 is 30 degrees, the pitch is 20mm, and the thermal conductivity of the thermal grease is not less than 3.0W / (m•K). The inner nano-ceramic heating layer 201 has a thickness of 3mm, and the outer insulation sleeve 2 has a thickness of 15mm. A feed cylinder 3 is fixedly connected to the surface of the cylinder 1. A connecting shaft 301 is rotatably connected to the inner cavity of the feed cylinder 3. Multiple sets of stirring blades 302 are fixedly connected to the surface of the connecting shaft 301. Multiple serrated cutting edges 303 are fixedly connected to one side of each stirring blade 302. The cutting edge angle of the serrated cutting edges 303 is 45 degrees. The inner cavity of the cylinder 1 is rotatably connected to a rotating shaft 4, and a spiral blade 401 is fixedly connected to the surface of the rotating shaft 4. The discharge end of the cylinder 1 is fixedly connected to an extrusion port 402, and the extrusion port 402 is detachably connected to the cylinder 1 by bolts. A servo motor 5 is fixedly connected to one end of the connecting shaft 301 and the rotating shaft 4. A pressure sensor is installed on the cylinder 1 near the extrusion port 402. Each servo motor 5 and pressure sensor is electrically connected to the PLC controller 101. Based on the feedback signal from the pressure sensor, the PLC controller 101 dynamically adjusts the speed ratio of each servo motor 5 using a fuzzy control algorithm. A feeding pipe 6 is fixedly connected to the surface of the feeding cylinder 3, and the feeding pipe 6 is set at an angle to the horizontal plane of the feeding cylinder 3. The surface of the PLC controller 101 is integrated with a touch screen 7, and two control buttons 701 are fixedly connected to the surface of the PLC controller 101 below the touch screen 7. The touchscreen 7 is a 7-inch capacitive touchscreen; The PLC controller 101 has a built-in process formula database that can store at least 10 sets of production parameters for cables of different specifications. The temperature sensor is a PT100 platinum resistance temperature sensor, and the pressure sensor is a piezoresistive ceramic pressure sensor. The temperature sensor 8 has a measurement accuracy of ±0.1℃ and a response time of less than 100ms; The pressure sensor 9 has a measurement range of 0-200MPa and an accuracy of ±0.2%FS; The outer insulation sleeve 2 is a nano-aerogel felt outer insulation sleeve, and the two control buttons 701 are the emergency stop button and the system reset button, respectively.

[0019] Overall Workflow Overview This extruder achieves precise control of temperature, pressure, and extrusion volume during the wire and cable production process through an integrated system of "multi-layer heating closed-loop control + mechanical crushing and conveying + pressure-speed coordinated adjustment". After being crushed, the material enters the cylinder 1 for heating and melting, and is conveyed to the extrusion port 402 for forming through the spiral blades 401. At the same time, the PLC controller 101 adjusts each actuator in real time based on multi-sensor data to ensure extrusion accuracy.

[0020] Core System Working Principle Multi-layer heating and temperature closed-loop control Heating structure working logic: The electric heating wire inside the middle heat-conducting copper tube 202 generates heat when energized. The heat is conducted to the spiral copper tube through the thermal grease and then evenly transferred to the inner nano-ceramic heating layer 201. The far-infrared coating on its surface heats the material inside the cylinder by radiation. The outer insulation sleeve 2 (made of nano-aerogel felt) reduces heat loss, forming a three-layer insulation system.

[0021] Temperature closed-loop control: Three PT100 temperature sensors along the axis of the cylinder 1 monitor the temperature at the feed end, middle section, and discharge end, respectively. The data is transmitted to the PLC controller 101 in real time. The controller independently adjusts the power of each heating section through a PID algorithm: when the temperature of a certain section exceeds the set value, the power of the corresponding electric heating wire is reduced; otherwise, it is increased, so that the radial temperature difference is controlled within ±2℃ and the temperature fluctuation is ≤±1℃.

[0022] Material crushing and conveying system Feeding and crushing process: The material enters the feed cylinder 3 through the feeding pipe 6 (set at an angle to the horizontal plane). The connecting shaft 301 drives the stirring blade 302 to rotate. Its 45-degree serrated cutting edge 303 shears and crushes the material. The crushed material falls into the cylinder 1 and is conveyed forward by the spiral blade 401 on the rotating shaft 4, forming a squeezing and propulsive force.

[0023] Extrusion quantity coordinated control: A piezoresistive ceramic pressure sensor near the extrusion port 402 monitors the extrusion pressure in real time. The PLC controller 101 adjusts the speed ratio between the connecting shaft 301 and the rotating shaft 4) servo motor 5 according to the pressure deviation (threshold ±5%) through a fuzzy control algorithm to ensure that the extrusion volume fluctuation is ≤ ±0.5% and avoid material accumulation or material interruption.

[0024] Extrusion molding and cooling dimension control Extrusion and die head adjustment: The molten material is extruded through the extrusion port 402 (which is detachably connected by bolts for easy die replacement).

[0025] Intelligent control system and human-computer interaction PLC integrated control: The PLC controller 101 integrates real-time monitoring and control of parameters such as temperature, pressure, and speed. Through 10 preset process formulas (such as parameter combinations for different wire diameters and materials), it can achieve one-click switching of production modes. For example, when producing RVV2×1.5 specification cables, the PLC controller 101 automatically calls the corresponding heating temperature, screw speed, and other parameters.

[0026] Human-computer interaction interface: The 7-inch touchscreen displays real-time data curves and process parameters, supporting manual fine-tuning; the emergency stop button 701 and the system reset button 701 ensure rapid response in case of equipment malfunction, improving operational safety.

[0027] Key technology collaboration logic Temperature-pressure-speed linkage: Temperature sensor data affects heating power adjustment, and pressure sensor data is fed back to screw speed control, forming a closed-loop synergy of "stable temperature → stable material viscosity → small pressure fluctuations → uniform extrusion speed".

[0028] Crushing-Heating-Extrusion Matching: The pulverizing efficiency of the serrated blade 303 is matched with the conveying capacity of the spiral blade 401 to ensure that the material stays in the cylinder for a consistent time and avoid insufficient heating or over-melting caused by uneven pulverization.

[0029] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Additionally, in the accompanying drawings of this utility model, the fill patterns are merely for distinguishing layers and do not constitute any other limitation.

[0030] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A precisely controllable wire and cable extruder, comprising: Cylinder (1) and PLC controller (101); The features are as follows: an outer heat insulation sleeve (2) is fixedly connected to the inner cavity of the cylinder (1), an inner nano-ceramic heating layer (201) is fixedly connected to the inner wall of the outer heat insulation sleeve (2), a middle heat-conducting copper tube (202) is embedded between the outer heat insulation sleeve (2) and the inner nano-ceramic heating layer (201), the middle heat-conducting copper tube (202) is in a spiral structure, the inner cavity of the middle heat-conducting copper tube (202) is provided with an electric heating wire and filled with thermal grease, the surface of the inner nano-ceramic heating layer (201) is sprayed with a far-infrared coating, three temperature sensors are evenly arranged axially on the cylinder (1), the three temperature sensors are respectively located at the feed end, the middle and the discharge end of the cylinder (1), and each temperature sensor is electrically connected to the PLC controller (101).

2. The wire and cable extruder with precise control according to claim 1, characterized in that: The surface of the cylinder (1) is fixedly connected to a feed cylinder (3), and the inner cavity of the feed cylinder (3) is rotatably connected to a connecting shaft (301). The surface of the connecting shaft (301) is fixedly connected to multiple sets of stirring blades (302), and each stirring blade (302) has multiple serrated cutting edges (303) fixedly connected to one side. The cutting edge angle of the serrated cutting edges (303) is 45 degrees.

3. The wire and cable extruder with precise control according to claim 1, characterized in that: The inner cavity of the cylinder (1) is rotatably connected to a rotating shaft (4), and a spiral blade (401) is fixedly connected to the surface of the rotating shaft (4). The discharge end of the cylinder (1) is fixedly connected to an extrusion port (402), and the extrusion port (402) is detachably connected to the cylinder (1) by bolts.

4. The wire and cable extruder with precise control according to claim 2, characterized in that: A servo motor (5) is fixedly connected to one end of the connecting shaft (301) and the rotating shaft (4). A pressure sensor is installed on the cylinder (1) near the extrusion port (402). Each servo motor (5) and the pressure sensor are electrically connected to the PLC controller (101).

5. The wire and cable extruder with precise control according to claim 2, characterized in that: The surface of the feed cylinder (3) is fixedly connected to the feeding pipe (6), and the feeding pipe (6) is set at an angle to the horizontal plane of the feed cylinder (3).

6. The wire and cable extruder with precise control according to claim 1, characterized in that: The surface of the PLC controller (101) is integrated with a touch screen (7), and two control buttons (701) are fixedly connected to the surface of the PLC controller (101) below the touch screen (7).

7. The wire and cable extruder with precise control according to claim 4, characterized in that: The temperature sensor is a PT100 platinum resistance temperature sensor, and the pressure sensor is a piezoresistive ceramic pressure sensor.

8. The wire and cable extruder with precise control according to claim 6, characterized in that: The outer insulation sleeve (2) is a nano aerogel felt outer insulation sleeve, and the two control buttons (701) are the emergency stop button and the system reset button, respectively.

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