A stranding apparatus for wire production

Abstract

This utility model discloses a stranding device for wire production, relating to the technical field of wire and cable manufacturing equipment. The stranding device includes a frame with adjustable feet at the bottom and an inspection door on the left side. The top of the frame sequentially houses a drive motor, a flexible coupling, a left-direction fixed gear set, and a single-stage stranding chamber. The left-direction fixed gear set is connected to the single-stage stranding chamber via a connecting shaft. The output end of the single-stage stranding chamber is connected to a stranding rotor with a guide wire groove. A fixed-diameter stranding mold is located on the right side of the stranding rotor, and an annular ceramic guide wheel (with an inner ring enclosing the stranding rotor and a guide wire groove) is located on the left side. A diffuse reflection photoelectric sensor is located on the side of the guide wire groove. A U-shaped wire feeding frame bracket is located on the right side of the gear set mounting base. This wire stranding device simplifies power transmission, increases efficiency by 20%, ensures stranding accuracy (outer diameter error ±0.02mm), achieves single-wire tension control and rapid wire breakage positioning, and facilitates maintenance and type change. It is suitable for the production of 10mm² copper wire stranded conductors.

Description

Technical Field

[0001] This utility model relates to the field of wire and cable manufacturing equipment technology, and in particular to a stranding device for wire production. Background Technology

[0002] To accommodate the production needs of multiple specifications and multiple stranding directions, traditional stranding equipment generally incorporates redundant components such as stranding direction switching motors and pitch adjustment frequency converters. This results in power transmission paths exceeding 1.2m, with a transmission efficiency of only about 85%, leading to significant energy losses. Furthermore, the motor and gear set are often connected by rigid couplings, requiring extremely high installation precision (coaxiality error must be ≤0.02mm). Even minor installation deviations can easily cause severe vibrations, with equipment operating noise reaching up to 75dB. Moreover, the gear sets are often made of ordinary steel without quenching and strengthening treatment, resulting in meshing clearances that often exceed 0.05mm. After long-term use, the failure rate can reach as high as 3%, and frequent downtime for maintenance severely impacts production efficiency.

[0003] Patent application number CN201820858407.1 discloses a cable stranding machine that can solve the problem of loose stranding in cables. However, this solution does not address the issue that the wire guide components of traditional equipment are mostly independent metal wire guide wheels, which can only achieve "single-point guidance". Before the copper wire enters the stranding stage, radial deviation is likely to occur, resulting in insufficient concentricity guidance accuracy. Moreover, the friction coefficient of the metal wire guide wheel is as high as 0.3, which can easily cause scratches on the surface of the copper wire, affecting the conductivity of the conductor. In addition, the stranding die is mostly an adjustable structure, with the inner hole size adjusted by bolts to adapt to different specifications of products. However, the adjustment gap can easily lead to an outer diameter accuracy error of ±0.1mm in the finished product, and the surface quality compliance rate is only 90%. At the same time, the wire breakage detection mostly uses contact probe sensors, which not only pose a risk of about 3% copper wire scratches, but also have a response time of up to 0.5s. After the wire breaks, the machine cannot be stopped in time, which can easily produce a 1-3m wire-free strand. The material utilization rate is only below 95%, resulting in a large amount of copper wire waste.

[0004] Traditional stranding equipment often uses a tension control system designed for multiple wires to share a single tension device, which cannot achieve independent tension control for each wire. This results in tension fluctuations of up to ±10% across the five copper wires. Some wires may shrink or deform due to excessive tension (shrinkage > 0.05mm) or become loose and misaligned due to insufficient tension, affecting the concentricity of the stranded conductors. Furthermore, the equipment frame is often a fixed structure without adjustable feet, making it difficult to adapt to the unevenness of different workshop floors. During operation, it is prone to vibration due to tilting. Maintenance requires disassembling the enclosed shell to access the core components, with a single maintenance time exceeding one hour. When changing the adjustable stranding die, the inner hole size needs to be repeatedly calibrated, with a changeover time of more than 30 minutes. This makes it difficult to adapt to the pace of continuous batch production, increasing the operating and time costs of the equipment. Utility Model Content

[0005] The purpose of this invention is to at least solve one of the technical problems existing in the prior art, and to provide a stranding device for wire production that can solve the above-mentioned problems.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a stranding device for wire production, comprising a frame, four adjustable feet fixedly connected to the bottom of the frame, an inspection door fixedly connected to the left side of the frame via two hinges, the inspection door being fixed to the frame by a buckle, a motor base fixedly connected to the top left side of the frame, a drive motor fixedly connected to the motor base, a left-direction fixed gear set fixedly connected to the output end of the drive motor via a flexible coupling, a gear set mounting seat fixedly connected to the bottom of the left-direction fixed gear set, and the gear set mounting seat being fixedly connected to the frame.

[0007] Preferably, the output end of the left-hand fixed gear set is fixedly connected to a single-stage hinge chamber via a connecting shaft.

[0008] Preferably, the output end of the single-stage twisting chamber is fixedly connected to a twisting rotor, the twisting rotor is provided with five wire guide grooves, and a fixed-diameter twisting die is provided on the right side of the twisting rotor. The fixed-diameter twisting die is fixedly connected to the top of the frame through a twisting die bracket.

[0009] Preferably, an annular ceramic guide wheel is provided on the left side of the stranding rotor. The annular ceramic guide wheel is fixedly connected to the frame by a guide wheel bracket. The annular ceramic guide wheel is annular, and the stranding rotor is located in the inner ring of the annular ceramic guide wheel.

[0010] Preferably, the annular ceramic wire guide wheel is provided with five wire guide grooves, and a diffuse reflection photoelectric sensor is provided on one side of each wire guide groove. A wire feeding frame bracket is provided on the right side of the gear set mounting base, and the wire feeding frame bracket is fixedly connected to the top of the frame.

[0011] Preferably, the wire feeding frame support is U-shaped, and a single-layer fixed wire feeding frame is fixedly connected to the wire feeding frame support, and five wire feeding spools are fixedly connected to the single-layer fixed wire feeding frame.

[0012] Preferably, a wire-blocking disc is fixedly connected to the wire-feeding shaft, and five sets of pneumatic tensioners are arranged between the right side of the wire-blocking disc and the left side of the annular ceramic wire guide wheel.

[0013] Preferably, a tension wheel is rotatably connected to the pneumatic tensioner, and a tension sensor is fixedly connected to the top of the pneumatic tensioner.

[0014] Compared with the prior art, the beneficial effects of this utility model are:

[0015] (1) The stranding equipment for the production of this wire adopts a simplified transmission design of "drive motor-flexible coupling-left fixed gear set". The redundant stranding direction switching and pitch adjustment components of the traditional equipment are removed, which shortens the power transmission length from the traditional 1.2m to 0.6m, increases the transmission efficiency from 85% to 98%, and reduces energy consumption loss by 20%. At the same time, the flexible coupling adopts a rubber elastomer compensation structure, which can compensate for ±0.05mm coaxiality deviation, solving the problem of "high installation accuracy requirements and easy vibration" of the traditional rigid coupling. The equipment operating noise is reduced from 75dB to 60dB. The left fixed gear set is made of 45# steel quenched (HRC50-55) with a meshing gap ≤0.02mm. The component failure rate is reduced from the traditional 3% to less than 1%. Compared with the existing technology, it is more energy-efficient and more stable.

[0016] (2) The stranding equipment for producing this wire achieves “full circumferential limiting” through an annular ceramic wire guide wheel. Its annular structure wraps the stranding rotor in the inner ring, and the five wire guide grooves are precisely aligned with the wire guide grooves of the stranding rotor in a regular pentagonal shape. The concentricity guidance accuracy is improved by 60%, and the friction coefficient of the ceramic material is reduced from 0.3 of the traditional metal wheel to 0.15, avoiding scratches on the copper wire surface. On the other hand, the fixed aperture stranding die is made of WC-Co8 hard alloy (hardness HRA88-90), and the outer diameter accuracy error of the finished product is controlled within ±0.02mm (the error of the traditional adjustable die is ±0.1mm). The wear resistance life is increased from 30,000 hours to 100,000 hours. At the same time, the diffuse reflection photoelectric sensor realizes non-contact wire breakage detection, and the response time is shortened from 0.5s to 0.1s. The waste of empty stranding without wire is reduced to within 0.1m, and the material utilization rate is increased to more than 99.8%. Compared with the existing technology, the finished product accuracy, surface quality and material utilization rate are significantly better than traditional equipment.

[0017] (3) The stranding equipment for wire production is equipped with independent pneumatic tension units for each of the five copper wires. Through the closed-loop control of preset 8-10N air pressure and tension sensor, the tension fluctuation range is reduced from the traditional ±10% to ±5%, and the tension deviation of the five copper wires is ≤±2%, avoiding the stretching deformation (diameter reduction ≤0.02mm) or loosening and deviation of the copper wires. In addition, the bottom of the equipment frame is equipped with adjustable feet (levelness error ≤0.1mm / m) to ensure stable operation. The maintenance door on the left side is fixed by hinges and buckles. Opening it allows access to the core components, reducing maintenance time by 50%. The design of the fixed aperture stranding mold also shortens the changeover time from more than 30 minutes to less than 5 minutes. Compared with the existing technology, it not only ensures the tension stability of the stranding process, but also greatly reduces the time cost of equipment maintenance and production changeover, and is more suitable for batch continuous production needs. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0019] Figure 1 This is a schematic diagram of a stranding device for wire production according to the present invention;

[0020] Figure 2 The right side is a schematic diagram of a stranding device for wire production according to this utility model;

[0021] Figure 3 This utility model Figure 2 Enlarged view of point A in the middle;

[0022] Figure 4 This utility model Figure 2 Enlarged diagram of point B in the middle.

[0023] Reference numerals: 1. Frame; 2. Inspection door; 3. Hinge; 4. Adjustable foot; 5. Drive motor; 6. Motor base; 7. Flexible coupling; 8. Left-hand fixed gear set; 9. Gear set mounting base; 10. Pay-off frame bracket; 11. Single-layer fixed pay-off frame; 12. Stranding die bracket; 13. Fixed aperture stranding die; 14. Pneumatic tensioner; 15. Single-stage stranding chamber; 16. Stranding rotor; 17. Annular ceramic guide wheel; 18. Guide wheel bracket; 19. Pay-off shaft; 20. Wire stop plate; 21. Connecting shaft; 22. Tension wheel; 23. Tension sensor; 24. Diffuse reflection photoelectric sensor. Detailed Implementation

[0024] This section will describe in detail the specific embodiments of the present utility model. The preferred embodiments of the present utility model are shown in the accompanying drawings. The purpose of the drawings is to supplement the textual description with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present utility model, but they should not be construed as limiting the scope of protection of the present utility model.

[0025] In the description of this utility model, it should be understood that the directional descriptions, such as up, down, front, back, left, right, etc., indicate the directional or positional relationship based on the directional or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0026] In the description of this utility model, terms such as greater than, less than, and exceeding are understood to exclude the stated number, while terms such as above, below, and within are understood to include the stated number. The use of terms like "first" and "second" is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the quantity or sequence of the indicated technical features.

[0027] In the description of this utility model, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this utility model in conjunction with the specific content of the technical solution.

[0028] Please see Figure 1-4 This utility model provides a technical solution: a stranding device for wire production, including a frame 1, four adjustable feet 4 fixedly connected to the bottom of the frame 1, two hinges 3 fixedly connected to the left side of the frame 1, an inspection door 2 fixedly connected to the other end of the hinges 3, the inspection door 2 being fixed to the frame 1 by a buckle, a motor base 6 fixedly connected to the top left side of the frame 1, a drive motor 5 fixedly connected to the motor base 6, an elastic coupling 7 fixedly connected to the output end of the drive motor 5, a left-direction fixed gear set 8 fixedly connected to the elastic coupling 7, a gear set mounting seat 9 fixedly connected to the bottom of the left-direction fixed gear set 8, the gear set mounting seat 9 being fixedly connected to the frame 1, a single-stage stranding chamber 15 fixedly connected to the output end of the left-direction fixed gear set 8, and a connecting shaft 21 fixedly connected between the left-direction fixed gear set 8 and the single-stage stranding chamber 15;

[0029] The "motor-coupling-fixed gear set" design removes all redundant adjusting components, retaining only the left-hand fixed transmission path. The power transmission length is shortened from the traditional 1.2m to 0.6m, the transmission efficiency is increased from 85% to 98%, and energy loss is reduced by 20%. At the same time, the flexible coupling 7 in the component adopts a rubber elastomer compensation structure, which can compensate for coaxiality deviation of ±0.05mm, solving the problems of "high installation accuracy requirements and easy vibration" of traditional rigid couplings. The equipment operating noise is reduced from 75dB to 60dB, and the gear set is made of 45# steel with quenching treatment (HRC50-55), with a meshing clearance ≤0.02mm. The component failure rate is reduced from the traditional 3% to less than 1%.

[0030] A stranding rotor 16 is fixedly connected to the output end of the single-stage stranding chamber 15. Five wire guide grooves are provided on the stranding rotor 16. A fixed-diameter stranding mold 13 is provided on the right side of the stranding rotor 16. A stranding mold support 12 is fixedly connected to the fixed-diameter stranding mold 13. The stranding mold support 12 is fixedly connected to the top of the frame 1.

[0031] The fixed-diameter stranding die 13 uses WC-Co8 cemented carbide with a custom fixed diameter (4.5mm ± 0.02mm). On the one hand, the "fixed diameter" eliminates the need for adjustment components in traditional adjustable dies, avoiding diameter fluctuations caused by adjustment gaps. The finished product's outer diameter accuracy error is controlled within ±0.02mm (compared to ±0.1mm for traditional adjustable dies). On the other hand, the cemented carbide contains 8% cobalt and has a hardness of HRA88-90. Compared to traditional steel dies, its wear life is increased from 30,000 hours to 100,000 hours. Furthermore, the inner hole undergoes ultra-precision grinding, improving the inner wall smoothness by 3 times, reducing extrusion scratches during copper wire stranding, and increasing the finished product's surface quality compliance rate from 90% to 99.5%.

[0032] A ring-shaped ceramic wire guide wheel 17 is provided on the left side of the stranded rotor 16. The ring-shaped ceramic wire guide wheel 17 is fixedly connected to a wire guide wheel bracket 18, which is fixedly connected to the frame 1. The ring-shaped ceramic wire guide wheel 17 is ring-shaped, and the stranded rotor 16 is located in the inner ring of the ring-shaped ceramic wire guide wheel 17. The ring-shaped ceramic wire guide wheel 17 is provided with five wire guide grooves. A diffuse reflection photoelectric sensor 24 is provided on one side of each wire guide groove. The diffuse reflection photoelectric sensor 24 does not need to be in direct contact with the copper wire. It identifies the broken wire by reflecting the 660nm red visible light signal, completely eliminating the risk of contact scratch (the scratch rate of traditional probes is about 3%, while this design is 0%). At the same time, the sensor corresponds one-to-one with the wire guide groove, and the detection distance is accurately set to 6mm. The wire breakage response time is shortened from the traditional 0.5s to 0.1s, and it can directly locate the specific broken wire guide groove (traditional sensors can only alarm as a whole and need to check each wire one by one). The fault handling efficiency is improved by 80%.

[0033] The annular ceramic wire guide wheel 17 completely incorporates the stranding rotor 16 into the inner ring. The five wire guide slots are precisely aligned with the wire guide slots of the stranding rotor 16 in a regular pentagonal shape, upgrading from "single-point guidance" to "full-circumferential limiting". This completely eliminates radial deviation of the copper wire before it enters the stranding stage, improving concentricity guidance accuracy by 60%. At the same time, the annular ceramic wire guide wheel 17 is made of high-smoothness alumina ceramic (Ra≤0.2μm). Compared with traditional metal wire guide wheels, the coefficient of friction is reduced from 0.3 to 0.15. This not only avoids scratches on the surface of the copper wire, but also reduces the temperature rise of the copper wire caused by friction (temperature rise≤5℃). This solves the pain points of traditional metal wheels being "easy to wear and easy to damage the wire", extending the service life of the parts to more than 50,000 hours (compared to only 15,000 hours for traditional metal wheels).

[0034] A wire feeding frame bracket 10 is provided on the right side of the gear set mounting base 9. The wire feeding frame bracket 10 is fixedly connected to the top of the frame 1. The wire feeding frame bracket 10 is U-shaped. A single-layer fixed wire feeding frame 11 is fixedly connected to the wire feeding frame bracket 10. Five wire feeding shafts 19 are fixedly connected to the single-layer fixed wire feeding frame 11. A wire guide plate 20 is fixedly connected to the wire feeding shaft 19. Five sets of pneumatic tensioners 14 are provided between the right side of the wire guide plate 20 and the left side of the annular ceramic wire guide wheel 17. A tension wheel 22 is rotatably connected to the pneumatic tensioner 14. A tension sensor 23 is fixedly connected to the top of the pneumatic tensioner 14.

[0035] The pneumatic tensioner 14 adopts an independent pneumatic tension unit, with each of the five copper wires equipped with a pneumatic tensioner 14. By preset 8-10N air pressure (adapted to the rigidity of 2mm copper wire), combined with the V-groove of the tension wheel 22 (groove angle 60°, groove bottom radius 1.05mm), "independent tension control of a single wire" is achieved, reducing the tension fluctuation range from the traditional ±10% to ±5%. At the same time, the tension wheel 22 is made of wear-resistant POM material (Shore hardness 60±5A), which improves the aging resistance by 2 times compared to the traditional rubber wheel, and the inner wall of the wheel groove is polished to avoid "wire jamming and indentation" of the copper wire during tension adjustment.

[0036] Working principle: Before starting the equipment, the initial preparation is completed: five rolls of 2mm copper wire are respectively mounted on the five wire feeding shafts 19 of the single-layer fixed wire feeding frame 11. The copper wire is led out from the inside of the wire guide plate 20 at the top of the wire feeding shaft 19, passes through the tension wheel 22 of the corresponding pneumatic tensioner 14, passes through the guide groove of the annular ceramic wire guide wheel 17, and finally embeds into the guide groove of the twisting rotor 16 in the single-stage twisting chamber 15. At the same time, it is confirmed that the fixed diameter twisting die 13 and the axis of the twisting rotor 16 are aligned to ensure smooth wire feeding. During this process, the five wire feeding shafts 19 of the single-layer fixed wire feeding frame 11 are precisely arranged in a regular pentagon. With the limiting effect of the wire guide plate 20, the initial deviation of the copper wire is avoided from the source. Compared with the general wire feeding frame, the wire feeding adjustment time is reduced by more than 30%.

[0037] After the equipment is started, the drive motor 5 on the motor seat 6 on the top left of the frame 1 is powered on and runs. The power at its output end is transmitted to the left fixed gear set 8 through the flexible coupling 7. The flexible coupling 7 can compensate for the coaxiality deviation of ±0.05mm, avoiding vibration and noise caused by installation errors between the motor and the gear set. Under the stable support of the bottom gear set mounting seat 9, the left fixed gear set 8 converts the power into stable left rotation power according to the preset reduction ratio (adapted to the 2mm copper wire stranding speed), and then transmits it to the single-stage stranding chamber 15 through the connecting shaft 21, driving the stranding rotor 16 to rotate synchronously to the left. The entire power transmission system has no redundant stranding direction switching and pitch adjustment components, and the structural simplification is improved by 40%.

[0038] When the stranding rotor 16 rotates, its five guide grooves pull five copper wires in a leftward spiral motion around the central axis, initially achieving single-layer concentric stranding. During this process, the copper wires led out by the pay-off shaft 19 maintain precise tension through the pneumatic tensioner 14. The pneumatic tensioner 14 is preset with an air pressure value adapted to 2mm copper wire (corresponding to 8-10N tension). The tension wheel 22 applies uniform pressure to the copper wires, and the tension sensor 23 at the top monitors the tension changes in real time. If the tension fluctuation exceeds ±5%, the tension sensor 23 immediately feeds back a signal to the control system to adjust the air pressure of the pneumatic tensioner 14, preventing the copper wires from being stretched and deformed (diameter reduction ≤0.02mm) or loosened and deviated. Compared with the general tension system, independent pneumatic control ensures that the tension deviation of the five copper wires is ≤±2%.

[0039] The annular ceramic wire guide wheel 17 is fixed to the frame 1 by the wire guide wheel bracket 18. Its annular structure wraps the stranded rotor 16 in the inner ring. The five wire guide grooves on its surface are precisely aligned with the wire guide grooves of the stranded rotor 16. The high smoothness of the ceramic material (Ra≤0.2μm) reduces the coefficient of friction of the copper wire to 0.15, avoiding scratches on the surface of the copper wire. At the same time, the diffuse reflection photoelectric sensor 24 on one side of each wire guide groove continuously monitors the status of the copper wire. If a copper wire breaks, the diffuse reflection photoelectric sensor 24 triggers a signal within 0.1s, which links the equipment to stop and activates the audible and visual alarm. Compared with traditional contact sensors, the non-contact design eliminates the risk of scratches and improves the wire breakage response speed by 80%.

[0040] The copper wires, after being stranded by the stranding rotor 16, form a concentric spiral structure and then enter the fixed-diameter stranding die 13 at the output end of the single-stage stranding chamber 15. The fixed-diameter stranding die 13 is made of WC-Co8 hard alloy material (wear resistance life ≥100,000 hours). The copper wires are shaped and calibrated by a customized inner hole (adapted to a 10mm² finished product cross-section) to ensure that the outer diameter of the finished product is stable at 4.5mm±0.02mm. Compared with the adjustable stranding die, the fixed-diameter design shortens the changeover time to less than 5 minutes.

[0041] Finally, the processing of the copper wire concentric stranded conductor is completed. Throughout the process, the adjustable feet 4 at the bottom of the frame 1 can adjust the level of the equipment (level error ≤ 0.1mm / m) to ensure stable operation of the equipment. The left-side maintenance door 2 (fixed by hinge 3 and buckle) facilitates the maintenance of internal components in the later stage. Opening the maintenance door 2 allows direct access to the core components, reducing maintenance time by 50% compared to the closed structure.

[0042] Structural Description:

[0043] Frame 1: As the core load-bearing structure of the equipment, it is welded from Q235 carbon steel profiles. The overall shape is a rectangular frame with a length of 1800mm, a width of 800mm, and a height of 1500mm. The surface is treated with silver-gray powder coating. It provides a stable installation benchmark for all functional components (such as drive motor, single-stage twisting chamber, etc.). The rigid frame (bending strength ≥200MPa) supports the total weight of the equipment (approximately 800kg). At the same time, the internal wiring channel (width 50mm × height 30mm) is reserved to hide wires and air pipes and avoid exposure and damage to the wiring.

[0044] Inspection door 2: As a maintenance access component on the left side of the equipment, it is made of Q235 steel plate (5mm thick) and has an overall rectangular structure. Rubber sealing strips are added to the edges. It is connected to the left side of the frame 1 by two hinges 3 and adopts a snap-on fixing structure, providing a convenient access for later equipment maintenance: opening the snap allows direct access to the power components, gear sets and other core components inside the frame without disassembling the frame. Compared with the closed structure, it reduces maintenance time by 50%. At the same time, the rubber sealing strips can prevent dust from entering the equipment and ensure the cleanliness of the components.

[0045] Hing 3: As a rotating support component for inspection door 2, it is made of 304 stainless steel (3mm thick) and stamped. It has a standard hinge structure. Two M5 bolt holes (30mm apart) are opened at both ends. One end is fixed to the left column of frame 1 with M5×10mm bolts, and the other end is welded to the edge of inspection door 2, providing a fulcrum for the rotation and opening of inspection door 2, ensuring that the inspection door can be opened flexibly (opening angle ≥90°). At the same time, the 304 stainless steel material has excellent rust resistance, avoiding jamming or corrosion after long-term use, and ensuring the convenience of maintenance operations.

[0046] Adjustable foot 4: As a component for leveling and stabilizing the equipment, it adopts a combination structure of "M16 screw + round rubber pad". The screw is made of 45# steel and the rubber pad is made of natural rubber. The top of the rubber pad is welded to the bottom of the screw. It is connected to the pre-set M16 threaded holes at the four corners of the bottom of the frame 1 through the screw, providing the equipment with leveling function: rotating the screw can change the height of the foot (adjustment range ±50mm), so that the levelness error of the frame 1 is ≤0.1mm / m, adapting to the difference in flatness of different workshop floors, avoiding vibration caused by equipment tilting, and ensuring the twisting accuracy and component stability;

[0047] Drive motor 5: As the power output source of the equipment, it is made of cast iron shell (material is HT200 gray cast iron) and has a cylindrical structure. The tail is integrated with a black plastic cooling fan (material is ABS, diameter is 80mm). The output shaft is made of 45# steel and the shaft end has a keyway with a width of 8mm and a depth of 10mm. The rated power is 1.5kW and the rated speed is 1450r / min. It is fixed to the motor base 6 with 4 M10×25mm bolts to provide basic rotational power for the equipment. After being powered on, the power is transmitted to the subsequent flexible coupling 7 through the output shaft. Since the equipment does not require pitch adjustment, the motor adopts a fixed speed design, and the redundant frequency converter module is removed to reduce energy consumption and failure risk.

[0048] Motor mount 6: As a fixed support component for the drive motor 5, it is made of Q235 steel plate (10mm thick) and machined into an L-shaped structure. The surface is milled (flatness error ≤0.1mm). Four M12 bolt holes are opened on the top, and the bottom is fixed to the top left area of ​​the frame 1 by four M12×30mm internal hex bolts. It provides rigid support for the drive motor 5 and ensures that the motor shaft is coaxial with the subsequent flexible coupling 7 and the left fixed gear set 8 (coaxiality error ≤0.05mm), so as to avoid vibration and noise caused by motor misalignment during power transmission.

[0049] Flexible coupling 7: As the power transmission connection component between drive motor 5 and left-direction fixed gear set 8, it is composed of a rubber elastomer (material is nitrile rubber, Shore hardness 60±5A) and 45# steel flange. The whole structure is cylindrical. The flanges at both ends are respectively opened with shaft holes adapted to the output shaft of drive motor 5 and the input shaft of left-direction fixed gear set 8. Keyways are opened in the shaft holes (adapted to the corresponding shaft end keyways). It is fixed to the output shaft of drive motor 5 and the input shaft of left-direction fixed gear set 8 respectively by key connection. It compensates for installation errors and buffers vibration: it can allow coaxiality deviation of ±0.05mm, solves the problem of "high installation accuracy requirements and easy vibration transmission" of traditional rigid couplings, reduces the equipment operating noise from 75dB to 60dB, and protects the motor and gear set from impact damage.

[0050] Left-direction fixed gear set 8: As the power reduction and direction fixing component of the equipment, it is made of 45# steel and processed into a rectangular metal box. The surface of the box is milled (flatness error ≤0.1mm). It encapsulates two sets of spur gears (20 teeth for the driving gear and 40 teeth for the driven gear, module 2.5, tooth surface hardened, hardness HRC50-55). The left side has an input shaft hole (diameter 25mm, adapted to the flexible coupling 7 for connection) and the right side has an output shaft hole (diameter 30mm, adapted to the connecting shaft 21 for connection). The bottom is fixed to the gear set mounting seat 9 by 4 M10×20mm bolts to achieve speed reduction and torque increase and fixed left-direction transmission: the speed of the drive motor is reduced from 1450r / min to 725r / min (adapted to the 2mm copper wire stranding requirement), and the stranding direction switching component is removed, only the left-direction transmission path is retained, the structural simplification is improved by 40%, and the failure rate is reduced from the traditional 3% to less than 1%;

[0051] Gear set mounting base 9: As a fixed support component for the left-facing fixed gear set 8, it is made of Q235 steel plate (12mm thick) and machined into a rectangular structure. The surface is milled (flatness error ≤0.1mm / m). Four M10 bolt holes are opened on the top, and the bottom is fixed to the top of the frame 1 by six M10×25mm bolts, providing stable support for the left-facing fixed gear set 8. The rigid mounting surface ensures that the gear set axis is coaxial with the motor 5 and the single-stage winding chamber 15, avoiding the increase of meshing clearance due to vibration during gear set operation, and ensuring power transmission efficiency (increased to 98%).

[0052] Cable feeder bracket 10: As a fixed support component for the single-layer fixed cable feeder 11, it is made of Q235 steel plate (thickness 8mm) and processed into a U-shaped structure. After rust removal treatment, the surface is sprayed with gray anti-rust paint. Five M8 bolt holes are opened on the top crossbeam, and the bottom is fixed to the top right side of the frame 1 (right side of gear set mounting seat 9) by six M8×20mm bolts. It provides stable support for the single-layer fixed cable feeder 11. The U-shaped structure can bear the single-layer fixed cable feeder 11 and five rolls of copper wire (total weight ≤250kg), ensuring that the cable feeder does not tilt during the cable feeding process and providing a stable reference for the initial cable routing of the copper wire.

[0053] Single-layer fixed wire feeding frame 11: As the mounting carrier for wire feeding spools 19, it is made of Q235 steel plate (20mm thick) into a circular metal disc structure. The surface is chrome-plated (plating thickness 5μm, surface finish Ra≤0.8μm). Five wire feeding spool holes are machined on the disc surface in a regular pentagonal pattern. It is fixed to the top of the wire feeding frame bracket 10 by five M8×25mm bolts. The disc surface is kept horizontal (horizontal error ≤0.1mm), providing a fixed installation position for the five wire feeding spools 19. The five spool holes are arranged in a regular pentagonal pattern to ensure that the five wire feeding spools 19 are arranged with one in the center and four on the periphery. This avoids the initial deviation of the copper wire from the source. Compared with general wire feeding frames, it reduces the wire routing adjustment time by more than 30%. Moreover, the single-layer design removes the layer adjustment components, making the structure more streamlined.

[0054] The stranding die bracket 12 serves as a fixed support component for the fixed-diameter stranding die 13. It is made of Q235 steel plate (12mm thick) and machined into a U-shaped structure. The surface is milled (flatness error ≤0.1mm). A circular mounting hole is opened at the top, and the bottom is fixed to the top of the frame 1 (located on the right side of the stranding rotor 16) by four M10×25mm bolts. It provides rigid support for the fixed-diameter stranding die 13, ensuring that the inner hole of the stranding die is coaxial with the axis of the stranding rotor 16 (coaxiality error ≤0.03mm). This avoids the stranding die from offset, which would result in an irregular cross-section of the finished product. At the same time, the U-shaped structure facilitates the disassembly and replacement of the stranding die, reducing the changeover time to less than 5 minutes.

[0055] Fixed-aperture stranding die 13: As a shaping and calibration component after copper wire stranding, it is made of WC-Co8 hard alloy material and processed into a circular cylindrical structure. A through inner hole (diameter 4.5mm±0.02mm) is opened in the middle. The entrance end of the inner hole has a 15° tapered chamfer (chamfer length 2mm). The inner wall is ultra-fine ground (surface finish Ra≤0.8μm). A 45# steel fixing seat is installed on the outside. Two M8 set screw holes (symmetrically distributed) are opened on the side of the fixing seat. It is fixed to the top of the stranding die bracket 12 by set screw locking. It restricts the aperture of the copper wire stranded after stranding rotor 16: ensuring that the outer diameter of the finished product is stable at 4.5mm±0.02mm (suitable for 10mm² cross-section requirements). The hard alloy material increases the wear resistance life from the traditional 30,000 hours to 100,000 hours, improves the inner wall smoothness by 3 times, reduces copper wire extrusion scratches, and achieves a finished product surface quality compliance rate of 99.5%.

[0056] Pneumatic tensioner 14: As the core component for copper wire tension control, it is made of aluminum alloy (model 6061-T6) and processed into a rectangular structure with an anodized surface. It has an air pressure adjustment knob on the front, a 6mm quick air pipe interface (brass material, chrome plated) on the side, an M6 threaded hole on the top (for tension sensor 23 installation), and a tension wheel mounting shaft (stainless steel material, 8mm diameter) at the bottom. It is fixed to the top of the frame 1 (located between the right side of the wire guide plate 20 and the left side of the annular ceramic wire guide wheel 17) by an L-shaped bracket (aluminum alloy material, 5mm thickness). It is aligned with the wire feeding shaft 19 and the wire guide wheel groove to provide precise tension control for the copper wire: by preset 8-10N air pressure, uniform pressure is applied to the copper wire to achieve "independent tension control of a single wire". The tension fluctuation range is reduced from the traditional ±10% to ±5%, avoiding copper wire stretching deformation (diameter reduction ≤0.02mm) or loosening and deviation.

[0057] Single-stage stranding chamber 15: As a closed working space component for copper wire stranding, it is made of 304 stainless steel (3mm thick) and processed into a cylindrical chamber body. Circular flanges are welded to both ends. Six M12 bolt holes (200mm apart) are evenly opened on the flanges. The input end is fixed to the connecting shaft 21 through the flanges, and the output end is connected to the stranding rotor 16. It is installed in the middle area of ​​the top of the frame 1 to provide a closed space for copper wire stranding: the inside accommodates the stranding rotor 16. The closed chamber body prevents flying wires during copper wire stranding. At the same time, the observation window allows the operator to check the stranding status in real time and avoid the failure to detect abnormalities in time.

[0058] The stranding rotor 16, as the core actuator for copper wire stranding, is made of 45# steel and its surface is hardened (hardness HRC45-50). It has five wire guide grooves along the axial direction, which are distributed in a regular pentagonal pattern (center spacing 100mm). The inner wall is polished (surface finish Ra≤0.4μm). One end is fixed to the output end of the single-stage stranding chamber 15 by a key connection, and the whole is located in the inner ring of the annular ceramic wire guide wheel 17. It rotates synchronously under the drive of the left-hand fixed gear set 8. The five wire guide grooves respectively pull five copper wires to make a left-hand spiral motion around the central axis, initially forming a single-layer concentric stranding structure. The precise arrangement of the wire guide grooves ensures that the concentricity deviation during copper wire stranding is ≤0.08mm.

[0059] Annular ceramic wire guide wheel 17: As a guiding and limiting component for the copper wire before it enters the stranding stage, it is made of 99% pure alumina ceramic material and processed into an annular structure. The surface is polished (smoothness Ra≤0.2μm). Five wire guide grooves are opened in a regular pentagon shape. A 304 stainless steel flange is welded to the outside. It is fixed to the top of the frame 1 (located between the right side of the pneumatic tensioner 14 and the left side of the single-stage stranding chamber 15) by the wire guide wheel bracket 18. The stranding rotor 16 is completely inside it, providing precise guidance and limiting for the copper wire. The annular structure achieves "full circumferential limiting". The five wire guide grooves are precisely aligned with the wire guide grooves of the stranding rotor 16, improving the concentricity guidance accuracy by 60%. It completely eliminates radial deviation of the copper wire before it enters the stranding stage. The ceramic material has a low coefficient of friction (reduced from 0.3 to 0.15 of the traditional metal wheel), avoiding scratches on the copper wire. At the same time, it reduces frictional temperature rise (≤5℃), and extends the service life of the parts to more than 50,000 hours (compared to only 15,000 hours of the traditional metal wheel).

[0060] Guide wheel bracket 18: As a fixed support component for the annular ceramic guide wheel 17, it is made of 304 stainless steel (thickness 3mm) and processed into a U-shaped structure. The surface is brushed (smoothness Ra≤1.6μm). There are 3 M8 bolt holes on the top (to fit the outer flange of the annular ceramic guide wheel 17, hole spacing 120mm), and 4 M8×20mm bolts on the bottom.

[0061] Pay-off spool 19: As the mounting carrier component for copper wire rolls, it is made of 45# steel (diameter 48mm × length 300mm) and chrome-plated. The top is welded with a wire-blocking disc 20, which is fixed in the pay-off spool hole (hole diameter 50mm) of the single-layer fixed pay-off frame 11 by interference fit. The axis is perpendicular to the surface of the pay-off frame disc (perpendicularity error ≤0.1mm). It provides an installation position for the copper wire rolls: each pay-off spool can hold one 2mm copper wire roll (maximum weight ≤50kg). The chrome-plated surface reduces the frictional resistance when the copper wire roll is paid off, ensuring uniform copper wire lead-out speed and avoiding copper wire stretching and deformation due to friction. At the same time, the vertical installation structure prevents the copper wire roll from shifting axially.

[0062] Wire guide plate 20: As a limiting and protective component for copper wire coil, it is made of Q235 steel plate (thickness 5mm) and processed into a circular structure (diameter 120mm). After rust removal treatment, the surface is sprayed with gray anti-rust paint and the edges are rounded (rounded corner radius 2mm). It is fixed to the top of the wire feeding shaft 19 by welding and is perpendicular to the axis of the wire feeding shaft (perpendicularity error ≤0.1mm). It plays a limiting role for the copper wire coil on the wire feeding shaft 19: preventing the copper wire coil from axially shifting or falling off during the wire feeding process. The rounded edges avoid scratching the surface of the copper wire and ensure the smoothness of the copper wire when it is drawn out from the wire feeding shaft. It works with the wire feeding shaft 19 to form a stable wire feeding unit.

[0063] Connecting shaft 21: As the power transmission component between the left-direction fixed gear set 8 and the single-stage hinge chamber 15, it is made of 45# steel and chrome-plated. Keyways are opened at both ends. One end is fixed to the output shaft of the left-direction fixed gear set 8 by a key connection, and the other end is fixed to the input end of the single-stage hinge chamber 15 by a flange, so as to achieve precise power transmission: the left-direction rotation power output by the left-direction fixed gear set 8 is transmitted to the single-stage hinge chamber 15. The short path design reduces power loss, the chrome-plated surface improves wear resistance and extends service life, and at the same time ensures that there is no obvious vibration during power transmission, ensuring the stable rotation of the hinge rotor 16.

[0064] Tension wheel 22: As the tension transmission and copper wire guiding component of pneumatic tensioner 14, it is made of POM material and processed into a circular structure with a polished surface (smoothness Ra≤0.8μm). The wheel groove has a V-shaped structure, and the wheel axle is made of 304 stainless steel. It is connected to the bottom of pneumatic tensioner 14 through the rotation of the wheel axle. The wheel groove fits in close with the copper wire, transmitting tension and guiding the copper wire. The V-shaped groove fits tightly in close with the copper wire, ensuring that the pressure of pneumatic tensioner 14 is evenly transmitted to the copper wire, achieving precise tension control. POM material is wear-resistant and anti-aging (2 times more anti-aging than traditional rubber wheels), avoiding "wire jamming and indentation" of the copper wire during tension adjustment, and ensuring the surface quality of the copper wire.

[0065] Tension sensor 23: As a real-time monitoring component for copper wire tension, it is made of 304 stainless steel with laser-engraved range markings on the surface. It integrates a strain gauge (sensitivity 2mV / V) and has M6 threaded connectors at both ends. One end is fixed to the top of the pneumatic tensioner 14 by the thread, and the other end is connected to the support of the tension wheel 22. The output line is a 2m long shielded cable (5mm diameter, anti-interference) connected to the equipment control system to monitor the copper wire tension in real time. When the copper wire tension acts on the tension wheel 22, the tension is transmitted to the sensor through the support. The strain gauge deforms and outputs an electrical signal (0-5V voltage signal) proportional to the tension. If the tension fluctuation exceeds ±5%, it is immediately fed back to the control system to adjust the air pressure of the pneumatic tensioner 14, forming a closed-loop control to ensure that the tension deviation of the 5 copper wires is ≤±2%, avoiding the copper wire from being stretched, deformed, or loosened.

[0066] Diffuse reflection photoelectric sensor 24: As a copper wire breakage detection and protection component, it adopts an ABS plastic shell, integrates a red visible light emitting lens and a receiving lens on the front, a wiring terminal on the side, and a green working indicator light and a red alarm indicator light on the top. It is fixed to the top of the frame 1 by a Z-shaped metal bracket (304 stainless steel, 3mm thick), located on one side of the guide groove of the annular ceramic guide wheel 17. The lens axis is perpendicular to the copper wire (6mm spacing), realizing non-contact wire breakage detection: After power-on, the emitting lens continuously emits light. When the copper wire is normal, the light is diffusely reflected by the copper wire and captured by the receiving lens, outputting a normal signal (green light on). When the copper wire is broken, there is no reflected light, and the sensor immediately outputs an alarm signal (red light on), which triggers the equipment to stop and activates the audible and visual alarm. This completely eliminates the risk of scratches associated with traditional contact sensors, reduces the wire breakage response time from 0.5s to 0.1s, and can locate the specific wire breakage guide groove, improving fault handling efficiency by 80%.

[0067] The embodiments of the present utility model have been described in detail above with reference to the accompanying drawings. However, the present utility model is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present utility model.

Claims

1. A stranding apparatus for the production of electric wires comprising a frame (1), characterized in that: The bottom of the frame (1) is fixedly connected with four adjustable feet (4), and the left side of the frame (1) is fixedly connected with an inspection door (2) via two hinges (3). The inspection door (2) is fixed to the frame (1) by a buckle. A motor base (6) is fixedly connected to the top left side of the frame (1). A drive motor (5) is fixedly connected to the motor base (6). A left-direction fixed gear set (8) is fixedly connected to the output end of the drive motor (5) through a flexible coupling (7). The bottom of the left-facing fixed gear set (8) is fixedly connected to a gear set mounting base (9), which is fixedly connected to the frame (1).

2. A stranding apparatus for wire production according to claim 1, characterized in that: The output end of the left-facing fixed gear set (8) is fixedly connected to a single-stage hinge chamber (15) via a connecting shaft (21).

3. A stranding apparatus for wire production according to claim 2, characterized in that: The output end of the single-stage twisting chamber (15) is fixedly connected to a twisting rotor (16). Five wire guide grooves are provided on the twisting rotor (16). A fixed-diameter twisting mold (13) is provided on the right side of the twisting rotor (16). The fixed-diameter twisting mold (13) is fixedly connected to the top of the frame (1) through a twisting mold bracket (12).

4. A stranding apparatus for wire production according to claim 3, characterized in that: The stranded rotor (16) is provided with an annular ceramic guide wheel (17) on the left side. The annular ceramic guide wheel (17) is fixedly connected to the frame (1) through the guide wheel bracket (18). The annular ceramic guide wheel (17) is annular, and the stranded rotor (16) is located in the inner ring of the annular ceramic guide wheel (17).

5. A stranding apparatus for wire production according to claim 4, characterized in that: The annular ceramic wire guide wheel (17) is provided with five wire guide grooves, and a diffuse reflection photoelectric sensor (24) is provided on one side of each wire guide groove. A wire feeding frame bracket (10) is provided on the right side of the gear set mounting base (9), and the wire feeding frame bracket (10) is fixedly connected to the top of the frame (1).

6. A stranding apparatus for wire production according to claim 5, characterized in that: The wire feeding frame bracket (10) is U-shaped, and a single-layer fixed wire feeding frame (11) is fixedly connected to the wire feeding frame bracket (10). Five wire feeding shafts (19) are fixedly connected to the single-layer fixed wire feeding frame (11).

7. A stranding apparatus for wire production according to claim 6, characterized in that: A wire guide plate (20) is fixedly connected to the wire feeding shaft (19), and five sets of pneumatic tensioners (14) are arranged between the right side of the wire guide plate (20) and the left side of the annular ceramic wire guide wheel (17).

8. A stranding apparatus for wire production according to claim 7, characterized in that: A tension wheel (22) is rotatably connected to the pneumatic tensioner (14), and a tension sensor (23) is fixedly connected to the top of the pneumatic tensioner (14).

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