A copper wire doubling machine

Abstract

The utility model discloses a copper wire and silk machine, including, the integration base is installed with a plurality of branch support respectively on the integration base, install the silk bearing structure on the branch support, install the winding up gather silk structure on the integration base, the utility model relates to the technical field of power cable harness equipment, and the present application realizes the intelligent management of whole process through intelligent tension control system, precision displacement synchronous control, self -lubricating wear -resistant structure and structural winding forming design, and effectively solves the core problem such as traditional craft slack uneven, surface defect, low efficiency, improves silk and silk roll quality stability and production efficiency.

Description

Technical Field

[0001] This utility model relates to the technical field of power supply cable harness equipment, specifically a copper wire paralleling machine. Background Technology

[0002] Traditional copper wire paralleling processes suffer from multiple technical bottlenecks: In terms of tension control, reliance on mechanical springs or fixed counterweights prevents real-time dynamic adjustment; the lack of independent tension monitoring when multiple copper wires are parallel can easily lead to slack or overstretching of individual strands, resulting in uneven stress in the coil; regarding winding uniformity, insufficient displacement accuracy of the fixed wire guide or manual slide rail, mismatch with the winding hub speed, causes "stepped" winding of the copper wires, with interlayer misalignment exceeding 5°, leading to wrinkles on the coil surface; and in the lubrication and wear-resistance process, manual application of lubricant results in uneven application and wire contamination, and ordinary metal pulleys... Severe wear exacerbates surface damage to the copper wire; the lack of a spiral guide groove in the winding and forming structure makes the copper wire prone to lateral movement, resulting in uneven or collapsed edges of the coil, large fluctuations in internal porosity, and affecting subsequent processing performance. This invention achieves intelligent management of the entire process through an intelligent tension control system, precise displacement synchronous control, a self-lubricating and wear-resistant structure, and a structured winding and forming design. It effectively solves the core problems of uneven tension, surface defects, and low efficiency in traditional processes, and improves the stability of the coiled wire quality and production efficiency. In view of this, in-depth research was conducted on the above problems, which led to the development of this invention. Utility Model Content

[0003] To achieve the above objectives, this utility model provides the following technical solution: a copper wire paralleling machine, comprising an integrated base, on which several branch supports are respectively installed, and on which a wire splitting bearing structure is installed; and on which a winding and gathering paralleling structure is installed on the integrated base, the winding and gathering paralleling structure comprising a winding main hub, the winding main hub being mounted on the integrated base; an electric slide rail being mounted on the integrated base; an electric slider being mounted on the electric slide rail; a copper wire gathering limiting frame being mounted on the electric slider; and several copper wire auxiliary lubrication balls being mounted on the copper wire gathering limiting frame.

[0004] Preferably, the wire-bearing structure includes a branch frame suspension frame, which is mounted on the branch support. A telescopic spring is provided on the branch frame suspension frame. A pair of spring-to-spring electromagnets are respectively provided on the telescopic spring. A tension adjustment bracket is provided on the telescopic spring. A fitting pulley is provided on the tension adjustment bracket. A branch copper wire hub bracket is provided on the branch support.

[0005] Preferably, the tension adjustment bracket is equipped with a dual-axial displacement sensor, which forms a closed-loop control system with the spring electromagnet; the surface of the contact pulley is provided with a nano-level ceramic coating, and the coating surface is provided with micro oil guide grooves to realize the self-lubricating function when the copper wire contacts the pulley.

[0006] Preferably, the slot of the copper wire gathering and limiting frame adopts a gradually tapered design, and the diameter of the slot inlet is 1.2-1.5 times the diameter of the outlet; the copper wire auxiliary lubrication ball is made of tungsten carbide alloy, the ball surface is provided with spiral oil guiding texture, and the ball is elastically connected to the inner wall of the frame through a micro spring to realize dynamic adjustment of contact pressure;

[0007] Preferably, the electric slide rail is equipped with a laser displacement sensor, which monitors the displacement of the copper wire winding limiting frame in real time and achieves speed synchronization control with the rotary encoder of the winding main hub; ensuring that the interlayer misalignment angle of the multiple copper wires is accurate during the winding process;

[0008] Preferably, the integrated base has a built-in intelligent tension control module. The module collects the tension data of each branch copper wire and adjusts the current intensity of the corresponding electromagnet between the springs in real time to keep the tension fluctuation of each copper wire within a reasonable range. The surface of the winding main hub is provided with a spiral wire guide groove. The depth of the wire guide groove is 1.1-1.3 times the diameter of the copper wire, and the groove spacing is 2-3 times the diameter of the copper wire to ensure that there is no crossover after the wires are wound together.

[0009] Beneficial effects

[0010] This utility model provides a copper wire doubling machine. It has the following advantages: Compared with existing technologies, this copper wire doubling machine achieves intelligent management of the entire process through an intelligent tension control system, precise displacement synchronous control, a self-lubricating and wear-resistant structure, and a structured winding and forming design. This effectively solves core problems such as uneven tension, surface defects, and low efficiency in traditional processes, improving the stability of doubling and winding quality and production efficiency. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the main cross-sectional structure of a copper wire twisting machine according to the present invention.

[0012] Figure 2 This is a schematic diagram of the electric slider structure of the copper wire twisting machine described in this utility model.

[0013] Figure 3 This is a schematic diagram of the copper wire bundling and limiting frame structure of the copper wire paralleling machine described in this utility model.

[0014] Figure 4 for Figure 1A magnified view of the letter "A" in the diagram.

[0015] In the diagram: 1. Integrated base; 2. Branch bracket; 3. Rewinding main hub; 4. Electric slide rail; 5. Electric slider; 6. Copper wire winding limit frame; 7. Copper wire auxiliary lubrication ball; 8. Branch frame suspension frame; 9. Telescopic spring; 10. Spring-interlocking electromagnet; 11. Tension adjustment bracket; 12. Fitting pulley; 13. Branch copper wire hub bracket. Detailed Implementation

[0016] Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0017] Those skilled in the art should connect all electrical components and their compatible power supplies in this case via wires. Appropriate controllers and encoders should be selected according to the actual situation to meet control requirements. The specific connection and control sequence should refer to the working principle described below, where the electrical components are connected in sequence. The detailed connection methods are well-known in the art. The following mainly introduces the working principle and process, and will not describe the electrical control further.

[0018] Example

[0019] Please see Figure 1-4 Bottlenecks in traditional tension control technology

[0020] Static tension adjustment defects: Traditional wire winding machines mostly use mechanical springs or fixed counterweights to adjust tension, which cannot achieve real-time dynamic adjustment. For example, when the tension of the branched copper wires changes abruptly due to fluctuations in wire diameter and temperature during high-speed winding, the traditional mechanical structure responds with lag, which can easily cause the single strand of copper wire to loosen or be overstretched, resulting in uneven internal stress in the wire winding package.

[0021] Multi-strand tension out of control: When multiple copper wires are parallel, traditional equipment lacks an independent tension monitoring and adjustment unit. Abnormal tension in a single strand will affect the overall wire twisting effect, leading to problems such as edge warping and interlayer misalignment.

[0022] Shortcomings in winding uniformity technology

[0023] Insufficient displacement control precision: Traditional wire winding machines often use fixed wire guide frames or manually adjustable slide rails, which cannot achieve precise synchronization with the rotational speed of the winding hub. For example, when the displacement speed of the electric slider does not match the rotational speed of the main winding hub, the copper wire will form "step-like" winding marks on the surface of the hub, resulting in uneven density of the wire winding cross-section.

[0024] Lack of interlayer misalignment control: Due to the lack of precision detection devices such as laser displacement sensors, traditional equipment cannot calibrate the movement trajectory of the copper wire winding limit frame in real time, resulting in interlayer misalignment angles of ≥5° during the winding process of multiple copper wires, which ultimately leads to defects such as wrinkles and cross-over on the roll surface.

[0025] Limitations of Lubrication and Wear Resistance Technology

[0026] Defects of passive lubrication: Traditional wire drawing processes rely on manual, periodic application of lubricant, which can lead to uneven application and contamination of the copper wire surface. For example, if the surface of the contact pulley lacks a self-lubricating coating, significant frictional heat will be generated when the copper wire passes through at high speed, resulting in oxidation of the wire surface and a decrease in strength.

[0027] Wear-resistant parts suffer severe damage: Ordinary metal pulleys are prone to wear grooves under long-term high-load operation, which not only aggravates the damage to the copper wire surface, but also requires frequent replacement of parts, affecting production efficiency.

[0028] Defects in winding and forming structure

[0029] Lack of wire guide groove design: Traditional winding hubs are mostly smooth cylindrical surfaces, and multiple copper wires are prone to lateral movement during winding, resulting in uneven edges of the coil, or even "collapsed edges".

[0030] Uncontrollable coil density: Due to the lack of guiding structures such as spiral guide grooves, copper wires are prone to random stacking during winding, resulting in large fluctuations in the internal porosity of the coil and affecting subsequent processing performance.

[0031] Technological Breakthrough Path of This Invention

[0032] To address the aforementioned shortcomings in the technical field, this invention achieves a technological breakthrough through the following innovations:

[0033] Intelligent tension control system: It forms a closed-loop control through a dual-axial displacement sensor and an electromagnet between the spring, and combines the intelligent tension control module to adjust the current intensity in real time, so as to control the tension fluctuation within a reasonable range and realize the independent and dynamic adjustment of the tension of multiple copper wires.

[0034] Precision displacement synchronization control: The laser displacement sensor and rotary encoder work together to ensure that the moving speed of the electric slider is precisely synchronized with the rotation speed of the winding hub. Combined with the gradient conical slot design, the interlayer misalignment angle is controlled within a reasonable range.

[0035] Self-lubricating and wear-resistant structure: The pulley surface is fitted with a nano-level ceramic coating and micro-oil guide grooves, combined with the spiral oil guide pattern design of tungsten carbide alloy balls, to achieve continuous self-lubrication between the copper wire and the contact parts, and significantly reduce the coefficient of friction.

[0036] Structured winding and forming: The surface of the winding main hub is equipped with a spiral guide groove. By precisely controlling the groove depth (1.1-1.3 times the diameter of the copper wire) and the groove spacing (2-3 times the diameter of the copper wire), it is ensured that there is no cross-over or overlap after the wires are wound and formed, and the surface flatness error is greatly reduced.

[0037] Through the synergistic effect of the above technical solutions, this invention realizes intelligent management of the entire process from copper wire guidance and tension control to uniform winding, effectively solving the core problems of uneven tension, surface defects and low efficiency in traditional wire winding process, and significantly improving the quality stability and production efficiency of wire winding.

[0038] Therefore, this application protects a copper wire bundling machine. First, multiple branch copper wire spools to be combined are fixed to branch copper wire spool brackets 13. Then, each branch copper wire is attached to its corresponding contact pulley 12. Next, the copper wire is passed through the slot of the copper wire bundling limiting frame 6. At this time, the copper wire naturally attaches to the copper wire auxiliary lubrication balls 7 set in the slot of the copper wire bundling limiting frame 6. Then, the copper wire is neatly wound onto the main winding hub 3. The above operations are repeated until all branch copper wires are initially installed. Then, the main winding hub 3 is started to rotate. At this time, the electric slide rail 4 on the integrated base 1 rotates, causing the electric slider 5 to slowly move, thereby driving the copper wire bundling limiting frame 6 to move synchronously. This linkage design allows multiple strands of copper wire to be evenly and smoothly wound onto the surface of the main winding hub 3, forming a neat... The coiling effect is achieved by using a pair of spring-electromagnets 10 within the telescopic spring 9 to generate precise electromagnetic repulsion, which pushes the tension adjustment bracket 11 and the contact pulley 12 to fit tightly and gently squeeze the surface of the copper wire. This intelligent tension control system can monitor the tension state of each copper wire in real time and automatically adjust the squeezing force to ensure that each copper wire is always kept in the optimal tension range. Ultimately, through the synergistic work of dynamic tension adjustment and precise displacement control, multiple branch copper wires can form a flat, tight, wrinkle-free, and abnormal coiled roll on the winding main hub 3, which not only ensures the winding quality but also avoids the uneven tension problem commonly found in traditional coiling processes. The entire design cleverly integrates mechanical transmission and electromagnetic control technology, realizing intelligent management of the entire process from copper wire guidance and tension control to uniform winding.

[0039] In summary, the operating process and principle system of the copper wire winding machine of this invention are based on intelligent management of the entire process, specifically including the following links and technical supplements: First, multiple branch copper wire spools are fixed to the branch copper wire spool bracket 13. The copper wire is guided by the tension adjustment bracket 11 of the branch frame suspension frame 8, and is initially guided and self-lubricated by the contact pulley 12 (with a nano-level ceramic coating and micro oil guide grooves on the surface). Subsequently, the copper wire is inserted into the gradually tapered slot of the copper wire winding limiting frame 6. The tungsten carbide alloy balls (with spiral oil guide texture on the surface) connected elastically on the inner wall dynamically adjust the contact pressure under the action of micro springs, and cooperate with the auxiliary lubrication balls to achieve low-friction wire threading. In the winding stage, the winding main hub 3 starts to rotate, and the electric slide rail 4 of the integrated base 1 synchronously drives the electric slider 5, which drives the copper wire winding limiting frame 6 to move at a suitable speed. The laser displacement sensor monitors the displacement in real time and forms a speed closed-loop control with the rotary encoder to ensure that the interlayer misalignment angle is appropriate and to achieve uniform and smooth winding. In terms of tension control, a closed-loop system is formed by a dual-axial displacement sensor and an electromagnet 10 between springs. The intelligent tension control module collects tension data of each branch of copper wire and dynamically adjusts the current intensity of the electromagnet to keep tension fluctuations within a reasonable range. The spiral guide groove on the surface of the main winding hub 3 guides the copper wires to arrange them in a regular pattern, avoiding crossover. In addition, the system is supplemented with a temperature monitoring module, which monitors the frictional heat of the copper wires in real time through an infrared sensor and links a cooling fan to prevent oxidation. It also integrates a fault diagnosis system to automatically warn of abnormal electromagnets and sensor malfunctions. The entire set of equipment achieves full automation from copper wire guidance, intelligent tension adjustment, precise displacement synchronization to structured forming through deep integration of mechanical transmission, electromagnetic control and intelligent algorithms. This effectively solves the problems of uneven tension, surface defects and low efficiency in traditional wire winding processes, and significantly improves the stability of wire winding quality and production efficiency.

[0040] 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 copper wire paralleling machine, comprising: an integrated base, wherein a plurality of branch supports are respectively installed on the integrated base, a wire splitting bearing structure is installed on the branch supports, and a winding and gathering paralleling structure is installed on the integrated base, characterized in that... The winding and gathering wire structure includes a winding main hub, which is mounted on the integrated base. An electric slide rail is mounted on the integrated base, an electric slider is mounted on the electric slide rail, a copper wire winding limiting frame is mounted on the electric slider, and a plurality of copper wire auxiliary lubrication balls are mounted on the copper wire winding limiting frame.

2. The copper wire twisting machine according to claim 1, characterized in that, The wire-bearing structure includes a branch frame suspension frame, which is mounted on the branch support. A telescopic spring is provided on the branch frame suspension frame. A pair of inter-spring electromagnets are respectively provided on the telescopic spring. A tension adjustment bracket is provided on the telescopic spring. A fitting pulley is provided on the tension adjustment bracket. A branch copper wire hub bracket is provided on the branch support.

3. A copper wire twisting machine according to claim 2, characterized in that, The tension adjustment bracket is equipped with a dual-axial displacement sensor, which forms a closed-loop control system with the spring electromagnet; the surface of the contact pulley is coated with a nano-level ceramic coating, and the coating surface is provided with micro oil guide grooves to achieve self-lubrication when the copper wire contacts the pulley.

4. A copper wire twisting machine according to claim 3, characterized in that, The slot of the copper wire gathering and limiting frame adopts a gradually tapered design, and the diameter of the slot inlet is 1.2-1.5 times the diameter of the outlet. The copper wire auxiliary lubrication ball is made of tungsten carbide alloy, and the surface of the ball is provided with a spiral oil guiding pattern. The ball is elastically connected to the inner wall of the frame through a micro spring to achieve dynamic adjustment of the contact pressure.

5. A copper wire twisting machine according to claim 4, characterized in that, The electric slide rail is equipped with a laser displacement sensor, which monitors the displacement of the copper wire winding limiting frame in real time and achieves speed synchronization control with the rotary encoder of the winding main hub; ensuring that the interlayer misalignment angle of the multiple copper wires is accurate during the winding process.

6. A copper wire twisting machine according to claim 5, characterized in that, The integrated base has a built-in intelligent tension control module. The module collects the tension data of each branch copper wire and adjusts the current intensity of the corresponding electromagnet between the springs in real time to keep the tension fluctuation of each copper wire within a reasonable range. The surface of the winding main hub is provided with a spiral wire guide groove. The depth of the wire guide groove is 1.1-1.3 times the diameter of the copper wire, and the groove spacing is 2-3 times the diameter of the copper wire, to ensure that there is no crossover after the wires are wound together.

Images