Coating device for applying at least one layer of a coating material to a wire

Abstract

Coating device (2) for applying at least one layer of a coating material to a wire (3), comprising: - a base body (7); - a support roller (8) for supporting and conveying the wire (3) in a wire conveying direction (5); - a base plate (10), wherein the base plate (10) is arranged on the base body (7); - a coating bank (11) arranged on the base plate (10) with: - an application unit (6) for applying coating material to the wire (3) and for removing excess coating material from the wire (3); - at least one collection basin (13) for collecting removed excess coating material; - at least one sliding device (14) arranged on the base plate (10) with an adjusting screw (15) for moving the coating bank (11) parallel to the support roller axis (9) along the base plate (10);and / or - a leveling device (16) for leveling the base plate (10), wherein the base plate (10) has a threaded bore (17) with an internal thread, wherein the leveling device (16) has at least one leveling screw (18).

Description

[0001] The invention relates to a coating device for applying at least one layer of a coating material to a wire, comprising: a base body; a support roller for supporting and conveying the wire in a wire conveying direction, wherein the support roller is rotatably mounted about a support roller axis, the support roller axis being connected to the base body; a base plate arranged downstream of the support roller in the wire conveying direction, the base plate being arranged on the base body; at least one coating station arranged on the base plate with: at least one application unit for applying coating material to the wire and for removing excess coating material from the wire, the application unit having at least one application opening for the wire; at least one collection basin for collecting removed excess coating material, the application unit being arranged on or in the collection basin;wherein the wire rests on the support roller in its intended state and at least one application opening is passed through it.

[0002] Furthermore, the invention relates to a device for producing coated wires, comprising a coating device for applying at least one layer of a coating material and an oven for solidifying the applied layer, wherein the oven is arranged in the wire conveying direction downstream of the at least one application unit.

[0003] The invention further relates to a method for producing coated wires.

[0004] Suitable devices and systems for the production of coated wires, such as enamelled wires, with coating equipment are already known from the prior art. Enamelled wires are understood to be enamel-insulated metal wires, for example, made of copper or aluminum. Due to the enamel coating, good insulation of an electrical conductor from an adjacent conductor or the winding support can be achieved. Coated wires, such as enamelled wires, are used in particular for the production of electrical windings, which serve for current conduction, voltage conversion, field generation, and field deflection. These windings are therefore, in turn, a central component of electric motors, transformers, and generators. Not least due to the rise of e-mobility, both the demand for and the requirements for coated wires are increasing.The coatings known in the prior art consist essentially of film-forming resins and solvents.

[0005] Such systems include, among other things, a unit for applying an insulating coating material and an oven for curing the applied layer. The wire is typically conveyed through the system by means of one or more support and / or deflection rollers.

[0006] A device and a method for processing a wire with a coating device are known, for example, from EP 2 930 723 B1. Liquid lacquer is applied to a wire by means of the coating device. Dissolved polymers in the lacquer chemically crosslink after application and characterize the hardening process of the lacquer. The lacquer is applied via conically shaped wiping nozzles, which are continuously supplied with fresh lacquer by means of a feed pump. A lacquer film of a preset thickness is then evenly applied to the wire surface. An oven is provided for drying the lacquer.

[0007] An inline process plant for the production of enamelled wire is known, for example, from DE 3 118 830 A1.

[0008] A multi-stage furnace system for the production of enamelled wires is known, for example, from AT 284 931 B.

[0009] Typically, bare wire is supplied as a continuous length on a spool or produced by drawing it from a raw material and then fed into the system. A roller is also provided, on which the wire rests and by which it is fed. A coating unit, usually comprising one or more coating stations, is typically used to apply the coating material. Each coating station has a basin for the material to be applied, as well as one or more devices for wetting the wire and removing excess coating material, such as a coating nozzle. The wire is completely coated with the material. Excess coating material is then typically wiped off the wire to achieve the most homogeneous layer possible. The wire, along with the coating, is then conveyed into an oven to dry, cure, and solidify the coating material.The coating process can be repeated several times to achieve the desired layer thickness or a sequence of different materials. Typically, several parallel wires or wire sheets are processed, with each wire or wire sheet being fed to one of the (parallel) devices for wetting the wire or wire sheet and removing excess coating material.

[0010] Generally, coating systems are divided into vertical and horizontal systems. In vertical systems, the wire is conveyed vertically during coating, while in horizontal systems, the wire is conveyed (predominantly) horizontally during coating. While horizontal systems offer advantages over vertical systems in terms of improved accessibility and maintainability, lower operating costs, lower energy consumption, and higher throughput, the cross-sectional area of ​​coated wires produced on horizontal systems is limited.

[0011] A key requirement for coated wires is a homogeneous coating thickness, which is often difficult or impossible to achieve due to the widely varying thicknesses and geometries of the bare wires and the different properties and desired coating thicknesses. For example, if the wire is not guided centrally through the application unit and / or stripping unit, the resulting coating will be asymmetrical or oval. In the subsequent oven drying process, an inhomogeneously thick coating can lead to insufficient or uneven curing, skin formation, blistering, and residual solvent content. Furthermore, this can result in dielectric breakdown and partial discharges, particularly in areas of insufficient coating thickness. Such dielectric breakdowns can damage or even cause the failure of large assemblies, leading to serious consequences.

[0012] Systems for the production of coated wires must therefore be precisely calibrated to the cross-section and material of the respective wire, the coating material, the coating thickness, and other parameters such as the wire feed speed. Existing systems are difficult and comparatively expensive to adapt to changing requirements. Furthermore, settings are often difficult to reproduce. This is particularly disadvantageous when process parameters (e.g., the geometry of a bare wire) change frequently. Adding to the complexity, mechanical stresses on individual critical components of such a system, for example, due to vibrations, cannot be completely ruled out during operation.This can result in the system settings being unstable and needing to be readjusted after some time to achieve sufficient homogeneity of the layer thickness.

[0013] It is therefore an object of the invention to mitigate or completely eliminate the disadvantages of the prior art. In particular, it is an object of the invention to provide a coating device for applying at least one layer of a coating material to a wire, and a device for producing coated wires with a coating device that can be flexibly and reproducibly adjusted to different properties of the wire to be coated using simple means and that ensures high temporal stability.

[0014] This problem is solved by a coating device of the type mentioned above, comprising at least one sliding device arranged on the base plate with an adjusting screw for moving the coating bank parallel to the support roller axis along the base plate; and / or a leveling device for leveling the base plate normal to the wire feed direction and normal to the support roller axis, wherein the base plate has at least one threaded bore with an internal thread, wherein the leveling device has at least one leveling screw, wherein an external thread of the leveling screw interacts with the internal thread of the threaded bore, and wherein the leveling screw is detachably connected to the base body.

[0015] The problem is also solved by a device for producing coated wires with a coating device according to the invention.

[0016] The problem is further solved by a method for producing coated wires with a device according to the invention, comprising the steps: Conveying the wire with the support roller in the wire conveying direction towards the application unit; applying a layer of the coating material to the wire using the application unit; drying and / or curing the coating material in the oven.

[0017] The coating device for applying at least one layer of a coating material to the wire has a base body. The base body can be, for example, a frame or a framework. The base body can, for example, be a housing. The base body can, for example, be designed to be permanently mounted on a floor, such as in an industrial building.

[0018] For example, the base body is not moved in its intended state (i.e., particularly during the coating of the wire). The base body can therefore, for example, define reference coordinates. The base body can, for example, be made of metal, particularly aluminum or steel. The base body can have a cladding.

[0019] The coating device has a support roller for supporting and conveying the wire in a wire conveying direction, the support roller being rotatably mounted about a support roller axis. The support roller axis is preferably perpendicular to the wire conveying direction. The support roller can, for example, have a smooth surface. The support roller can be configured to deposit several wires or wire coatings parallel to one another and convey them in the wire conveying direction. The wire conveying direction can be essentially in a horizontal plane. The support roller axis can also be in the horizontal plane. The support roller axis is connected to the base body. The support roller axis can, for example, be detachably connected to the base body. For example, the vertical position of the support roller axis can be adjustable, for instance, to adjust the height of the wire.

[0020] In the wire conveying direction, downstream of the support roller, a base plate is arranged, the base plate being mounted on the base body. The base plate can, for example, be made of a metal, in particular aluminum or steel. The base plate can, for example, have a length of 121 mm in the wire conveying direction. The width of the base plate can be 450 mm. The thickness of the base plate can, for example, be 12 mm.

[0021] At least one coating station is arranged on the base plate. The at least one coating station has at least one application unit for applying coating material to the wire and for removing excess coating material from the wire, wherein the application unit has at least one application feedthrough for the wire.

[0022] The application unit is designed to wet the wire with the coating material and wipe off excess material to create a homogeneous coating layer on the wire. The application unit may include at least one wetting unit for applying the coating material. The wetting unit may have a base body with a wetting passage for the wire. The wetting passage may be the application passage itself or an application passage. The base body of the wetting unit may be a single piece or multiple pieces. In its intended state, a main axis of the wetting passage may be oriented in the wire feed direction, so that the wire is fed through the wetting passage. The wetting passage may, for example, have a constant cross-section perpendicular to the wire feed direction.The wetting unit can be connected to and supplied with a reservoir or tank containing coating material. The wetting feedthrough can, for example, be flooded with liquid coating material. The wetting unit can then completely coat the wire with coating material.

[0023] Additionally, the application unit can have at least one stripping unit for removing excess coating material from the wire, wherein the stripping unit comprises a stripping unit base and a stripping feedthrough for the wire. The stripping feedthrough can be the application feedthrough or an application feedthrough. The stripping unit can be arranged downstream of the wetting unit in the wire conveying direction. The stripping unit base can be one-piece or multi-piece. A principal axis of the stripping feedthrough can, in its intended state, lie in the wire conveying direction, so that the wire is conveyed through the wetting feedthrough. The stripping feedthrough can, for example, have a constant cross-section perpendicular to the wire conveying direction. Preferably, the cross-section of the stripping feedthrough is tapered in the wire conveying direction. The stripping unit can be designed as a coating stripping nozzle.

[0024] The coating material is liquid during wetting and can therefore be dried and / or cured. The coating material can be, for example, a lacquer, in particular a wire lacquer. The wire lacquer can, for example, comprise polymers dissolved in a solvent, in particular an organic solvent mixture. The wire can, for example, comprise copper and / or aluminum. The uncoated wire can be referred to as bare wire. The wire has a principal axis and a cross-section perpendicular to the principal axis. The cross-section can, for example, be round, in particular circular or oval. Alternatively, the cross-section of the wire can be rectangular, in particular square. A cross-sectional area of ​​the wire can, for example, be between 0.02 mm² and 15 mm², in particular between 0.2 mm² and 8 mm². The diameter of a round wire can, for example, be between 0.15 mm and 4.3 mm, in particular between 0.15 mm and 4.3 mm.The width of a flat wire can be between 50 mm and 3.20 mm. The width of a flat wire can, for example, be between 1 mm and 7 mm. The thickness of a flat wire (normal to its width) can, for example, be between 0.8 mm and 2 mm. The aspect ratio between the width and thickness of a flat wire can, for example, be between 1 and 8.

[0025] The coating station has at least one collection basin for catching excess coating material that is wiped off, with the application unit being arranged on or in the collection basin. The excess coating material wiped off by the application unit can be collected in the basin. In its intended state, the wire rests on the support roller and is guided through the at least one application feedthrough.

[0026] In its intended state, the wire rests on the support roller and can, for example, be passed through the wetting feedthrough and the wiping feedthrough, each of which forms an application feedthrough.

[0027] The main axis of the wetting feedthrough can coincide with the main axis of the stripping feedthrough, i.e., the main axis of the wetting feedthrough and the main axis of the stripping feedthrough can lie on a (common) straight line. This straight line is preferably a tangent to the support roller, so that the wire, in its intended state and ideally within the coating device, lies on this straight line.

[0028] According to the invention, the coating device has a sliding device and / or a leveling device.

[0029] The base plate can be equipped with at least one sliding device with an adjusting screw for moving the coating bank parallel to the support roller axis along the base plate. The coating bank can be detachably and / or movably connected to the base plate. The sliding device can be connected to the base plate and / or the coating bank. The coating bank can be connected to the base plate by means of the sliding device. The sliding device is designed to move the coating bank along the base plate and parallel to the support roller axis. The (at least one) application unit is thus also moved parallel to the support roller axis. By moving the coating bank, the position of the at least one application feedthrough can be adjusted to ensure that the wire passes centrally through the application feedthrough in a direction parallel to the support roller axis.The paint bench can be continuously moved using the adjustment screw. For example, turning the adjustment screw can result in a defined movement of the paint bench. Similarly, a specific position of the adjustment screw can correspond to a precisely defined position of the paint bench.

[0030] The leveling device is designed to level the base plate perpendicular to the wire feed direction and perpendicular to the support roller axis. For this purpose, the base plate has at least one threaded bore with an internal thread, and the leveling device includes at least one leveling screw. An external thread of the leveling screw engages with the internal thread of the threaded bore, and the leveling screw is detachably connected to the base body. By turning the leveling screw, the relative position of the base plate to the leveling screw can be adjusted, as the external thread of the leveling screw engages with the internal thread of the threaded bore in the base plate. This allows a position, for example, a height, of the base plate to be set relative to the base body, since the leveling screw has a defined position relative to the base body that remains unchanged simply by turning the leveling screw.The coating device can have at least two, and in particular exactly three or exactly four, leveling devices to allow, for example, the tilting of the base plate. This enables more precise adjustment of the coating device to the respective process parameters and conditions.

[0031] The sliding and / or leveling device allows for particularly easy adjustment of the position and / or alignment of the base plate or coating bench, including the application unit, perpendicular to the wire feed direction. This ensures a centered passage of the wire through the application opening and consequently a homogeneous coating thickness. The adjustment can be made especially easily, precisely, reproducibly, and stably using the adjusting screw and / or leveling screw.

[0032] In particular, if both a leveling device and a shifting device are provided, a corresponding adjustment in any direction normal to the wire feed direction is possible.

[0033] The leveling screw optionally has a main axis, wherein the leveling screw has a through-hole, the main axis of the leveling screw coinciding with the main axis of the through-hole, and wherein the leveling screw is detachably connected to the base body by means of a locking screw, the locking screw passing through the through-hole. For example, the base body may have a locking bore into which the locking screw engages. The locking screw can be used to prevent or release rotation of the leveling screw. By fixing the leveling screw with the locking screw, a position of the base plate can therefore be fixed, and, for example, an unintentional change of position, such as due to vibrations, can be prevented. To change the position of the base plate, the locking screw can be loosened to allow rotation of the leveling screw.After adjusting the position of the base plate by turning the leveling screw, the locking screw can then be locked to fix the set position.

[0034] The fixing screw can have a first stop element, and the leveling screw can have a second stop element, wherein the first stop element is positively and releasably connected to the second stop element. For example, the fixing screw can have a fixing screw head connected to a substantially cylindrical fixing screw body. An end of the fixing screw head facing the fixing screw body can form the first stop element. The leveling screw can have the second stop element at an end facing the base body within the bore. By tightening the fixing screw, the first stop element (for example, formed by the fixing screw head) is fixed to the second stop element and positively connected to it. This fixes the fixing screw to the base body in such a way that the fixing screw cannot be turned.The positive connection can be released by loosening the locking screw. Since the locking screw passes through the leveling screw, its diameter is smaller than the diameter of the leveling screw. Contact between the first and second stop elements, combined with turning the locking screw, can transfer torque from the locking screw to the leveling screw. In an unfavorable scenario, this could lead to unintended adjustment of the leveling screw. Because the locking screw passes through the leveling screw, its diameter is smaller than the diameter of the leveling screw. This geometry results in a relatively small torque being transferred from the locking screw to the leveling screw, insufficient to cause unwanted movement or adjustment of the leveling screw.

[0035] A washer with a convex curvature can optionally be placed between the leveling screw and the base plate. This allows the leveling screw to tilt, causing one of its main axes to deviate from the main axis of the fixing screw. This allows the base plate to tilt relative to the base body. The convex curvature can be located on either the upper surface facing the leveling screw or the lower surface of the washer opposite the upper surface and facing the base body.

[0036] The sliding device can, for example, have a first wedge and a second wedge cooperating with the first wedge, wherein the first wedge is connected to the paint bench and the second wedge is movably connected to the base plate, wherein a distance of the second wedge to the base plate is adjustable, wherein the first wedge cooperates with the second wedge in such a way that the distance of the second wedge to the base plate determines a position of the first wedge parallel to the support roller axis.

[0037] The first wedge and the second wedge can each have wedge surfaces arranged parallel to each other. The wedge surface of the first wedge can at least partially abut the wedge surface of the second wedge. A cross-section of the first wedge perpendicular to the wedge surface and a cross-section of the second wedge perpendicular to the wedge surface each form an acute angle. The first wedge and the second wedge can be moved relative to each other along their wedge surfaces. Using the first and second wedges, a particularly precise and stable adjustment of the paint bench's position is possible. The adjusting screw can engage with the base plate. Optionally, a spring can be provided to counteract a normal force exerted by the adjusting screw. The spring can, for example, be wound around a cylindrical body of the adjusting screw and positioned between the base plate and the second wedge.

[0038] The distance of the second wedge to the base plate can be adjusted, for example, by means of the adjusting screw. By means of the interacting wedges, a force acting through the adjusting screw, in particular a normal force on a principal extension plane of the base plate, can be redirected, in particular by 90°, so that the paint bench is moved parallel to the support roller axis.

[0039] Optionally, a guide element can be provided to guide the second wedge, wherein the guide element is immovably and preferably permanently connected to the base plate. The guide element can have a rail for guiding the second wedge.

[0040] The coating device can have several coating stations arranged sequentially, i.e., in series, in the wire feed direction. The entirety of the coating stations of the coating device can be referred to as a coating unit. Several coating stations can optionally share a common base plate.

[0041] For example, a tilt sensor can be provided, designed to detect the tilt angle of the base plate in the wire feed direction and / or perpendicular to the wire feed direction. The tilt sensor can be, for example, optical, capacitive, or piezoelectric. The tilt sensor can also be referred to as an inclinometer or tilt sensor. The tilt sensor can be located, for example, on the base body or on the base plate. Using the tilt sensor, the orientation of the base plate, and thus the paint bench, can be determined. A measured value can be output and / or stored. By measuring the tilt, a particularly precise adjustment can be made, and previous settings can be easily reproduced.

[0042] The coating device can, for example, include a distance sensor configured to detect the position of the coating bank along a straight line parallel to the support roller axis. The distance sensor can be, for example, an optical or a capacitive sensor. The distance sensor can also be configured to detect the height of the base plate (and the associated collection basins). The height can be a distance, in particular a perpendicular distance, between the base plate and the base body. This distance can be set, for example, using the leveling device. The height can be determined, for example, at two opposite sides of the base plate. From this, for example, an inclination of the base plate perpendicular to the wire feed direction can be determined.

[0043] The distance sensor can, for example, be attached to the base unit and configured to detect the distance to the paint bench. This makes determining the position of the paint bench particularly easy.

[0044] Optionally, an extension element can be arranged on the collection basin, with the distance sensor configured to detect the distance to this extension element. The extension element can be detachably connected to the collection basin. Contamination from scraped-off coating material may occasionally occur in the immediate vicinity of the collection basin. This scraped-off coating material can impair or damage the distance sensor. The extension element increases the distance between the distance sensor and the collection basin, thus preventing any potential impairment or damage particularly easily and efficiently. Due to the known geometry and arrangement of the extension element on the collection basin, the distance between the distance sensor and the collection basin can be calculated from the distance between the distance sensor and the extension element.

[0045] A device for producing coated wires comprises a coating device according to the invention for applying at least one layer of a coating material, and an oven for solidifying the applied layer, wherein the oven is arranged in the wire conveying direction after the at least one application unit.

[0046] The oven is arranged downstream of the at least one application unit in the wire feed direction. The oven is designed to heat the wire together with the coating material applied by the application unit in order to dry and cure the coating material. The temperature inside the oven can be, for example, between 300°C and 800°C, and in particular between 450°C and 700°C. Under normal operating conditions, the wire does not rest on anything in the application unit or in the oven. The wire rests on the support roller and on another roller located downstream of the oven. Therefore, the wire does not rest on anything as long as liquid (i.e., not yet cured) coating material is present on the wire. In particular, the wire does not rest on the stripping unit within the stripping passage.Only a portion of the liquid coating material on the wire can come into contact with the application unit's wiper, thus removing excess coating material. The coating layer thickness on a wire can, for example, range from 10 µm to 40 µm. The wire can be fed in the wire feed direction at speeds between 8 m / min and 200 m / min.

[0047] The method for producing coated wires using a device according to the invention comprises the following steps: Conveying the wire with the support roller in the wire conveying direction towards the application unit; applying a layer of the coating material to the wire using the application unit; drying and / or curing the coating material in the oven.

[0048] During the production of the coated wires, the position of at least one coating bench and the position of the support roller axis are kept constant. The respective position is adjusted and set before the production of the coated wires to the specific wire design, in particular its deflection, as well as other process parameters, such as the conveying speed and the specific coating material.

[0049] The invention will be explained in more detail below with reference to figures, to which it is not, however, limited. The figures show: Fig. 1 schematically a device for the production of coated wires with a coating device and an oven; Fig. 2 schematically a section of a coating device for applying at least one layer of a coating material to a wire; Fig. 3 and Fig. 4 Each schematically shows a section of the coating device. Fig. 2 ; Fig. 5 schematically an exploded view of a section of the coating device Fig. 2 , the shifting device is not shown in favor of showing the leveling devices; Fig. 6A schematically a partial sectional view of a leveling device with a leveling screw made of Fig. 5 ; Fig. 6B-E Schematic detail views of the leveling screw with the fixing screw made of Fig. 6A ; Fig. 7 schematically a front view of the coating device Fig. 5 Fig. 8 schematically an exploded view of another section of the coating device Fig. 2 , the leveling devices are not shown in favor of showing the sliding device; Fig. 9 schematic view of the section of the coating device Fig. 8 in a composite state; Fig. 10 schematically the sliding device Fig. 9 in detail; Fig. 11 schematically a larger section of the coating device Fig. 9 ; and Fig. 12 schematically a front view of the in Fig. 8 depicted section.

[0050] Fig. 1 Figure 1 schematically shows a device 1 for the production of coated wires with a coating device 2 for applying at least one layer of a coating material to a wire 3 and an oven 4 for solidifying the applied layer, wherein the oven 4 is arranged in a wire conveying direction 5 after at least one application unit 6.

[0051] The coating device 2 for applying at least one layer of the coating material to the wire 3 has a base body 7 and a support roller 8 for supporting and conveying the wire 3 in the wire conveying direction 5, wherein the support roller 8 is rotatably mounted about a support roller axis 9. The support roller axis 9 is connected to the base body 7. In the wire conveying direction 5 downstream of the support roller 8 is a base plate 10 (see Fig. 2 The base plate 10 is arranged on the base body 7. At least one coating bench 11 is arranged on the base plate 10; in this example, three coating benches 11 (alternatively also referred to as "coating bench levels") are provided. Each coating bench 11 has at least one application unit 6 for applying coating material to the wire 3 and for removing excess coating material from the wire 3, the application unit 6 having at least one application opening 12 for the wire 3. Each coating bench 11 also has at least one collection basin 13 for collecting removed excess coating material, the application unit 6 being arranged on or in the collection basin 13. In the intended state, the wire 3 rests on the support roller 8 and passes through the at least one application opening 12.

[0052] The base plate 10 has at least one sliding device 14 (see, for example, details). Figuren 8 bis 11 ) with an adjusting screw 15 for moving the paint bench 11 parallel to the support roller axis 9 along the base plate 10. Furthermore, a leveling device 16 (see, for example, details) is arranged. Fig. 6 ) for leveling the base plate 10 normal to the wire conveying direction 5 and normal to the support roller axis 9, wherein the base plate 10 has at least one threaded bore 17 (see Fig. 6 ) with an internal thread, wherein the leveling device 16 has at least one leveling screw 18, wherein an external thread of the leveling screw 18 interacts with the internal thread of the threaded bore 17, wherein the leveling screw 18 is detachably connected to the base body 10.

[0053] The application units 6 are arranged serially (i.e., one after the other) in the wire conveying direction 5 to sequentially apply layers of the coating material or different coating materials to the wire 3. In this simplified embodiment, the application units 6 are each arranged in a (schematically shown) collecting basin 13 for the coating material, with each collecting basin 13 and one application unit 6 forming a coating station 11. The three coating stations 11 are arranged on the base plate 10. The three coating stations 11 on the base plate 10 together form a so-called coating vessel. The oven 4 is arranged downstream of the coating vessel in the wire conveying direction.

[0054] In this example, wire 3 is ideally represented as a horizontal straight line. In this embodiment, this line lies in a horizontal plane. The device 1 is designed as a horizontal system because wire 3, or the wires or wire coverings, are guided essentially horizontally, particularly during coating, drying, and curing.

[0055] In this exemplary embodiment, a deflection roller 19 is provided in front of or below the support roller 8 for deflecting the wire 3.

[0056] A method for producing coated wires using device 1 comprises the following steps: Conveying the wire 3 with the support roller 8 in the wire conveying direction 5 towards the application unit 6 or application units 6; applying a layer of the coating material to the wire 3 by means of the application unit 6 (see Fig. 2 ); Drying and / or curing of the coating material in oven 4.

[0057] Fig. 2 Figure 1 schematically shows a section of a coating device 2 for applying at least one layer of a coating material to the wire 3. The support roller 8 and the application unit 6 are not shown; see Figure 2 for further details. Figur 1 In this embodiment, the coating device has three base plates 10, each arranged on the base body 7. A coating bank 11 with a collection basin 13 for collecting excess coating material is arranged on each base plate 10. Two sliding devices 14, arranged symmetrically with respect to a vertical plane in which the wire feed direction 5 lies, are arranged on each of the three base plates 10. Each sliding device has an adjusting screw 15 for moving the coating bank 11 parallel to the support roller axis 9 (see figure). Fig. 1 ) along the base plate 10.

[0058] In addition, each base plate has 10 four leveling devices 16 (see, for example, for details). Fig. 6 ) for leveling the base plate 10 normal to the wire feed direction 5 (see Fig. 1 ) and normal to the support roller axis 9 (see Fig. 1 ) provided.

[0059] Fig. 3 and Fig. 4 Each figure schematically shows a view of a section of the coating device 2. Fig. 2 The coating device 2 has a distance sensor 21 configured to detect the position of the paint bank 11 along a straight line parallel to the support roller axis 9. The distance sensor 21 is attached to the base body 7 and configured to detect a distance to the paint bank 11, specifically a distance to the collection basin 13 of the paint bank 11. An extension element 22 is arranged on the collection basin 13, and the distance sensor 21 is configured to detect a distance to the extension element 22. The extension element 22 has an elongated hole 23 into which a screw 24 engages to limit the maximum deflection of the extension element 22 parallel to the support roller axis 9 (i.e., in the direction of the distance sensor 21). The extension element 22 is fixedly connected to the collection basin 13.The geometry and dimensions of the extension element 22 are known, so that the distance of the distance sensor 21 to the collection basin 13 can be calculated from the (measured) distance of the extension element 22 to the distance sensor 21. The relative position of the distance sensor to the support roller axis 9 is also known, so that the distance of the distance sensor 21 to the collection basin 13 allows a conclusion to be drawn about the position of the paint bench 11 along a straight line parallel to the support roller axis 9. The distance sensor 21 is configured to detect a distance in a direction parallel to the support roller axis 9. In this example, the distance sensor 21 is further configured to detect a height of the base plate 10 and the associated collection basin 13. The height in this case is a distance from the base plate 10 to the base body 7, which can be adjusted by means of the leveling devices 16.From the height that can be measured on two sides of the base plate 10, an inclination of the base plate 10 normal to the wire conveying direction 5 can be determined.

[0060] Fig. 5 schematically shows an exploded view of a section of the coating device. Fig. 2 , the shifting device 14 is not shown in favor of illustrating the leveling devices 16. There are four leveling devices 16 for leveling the base plate 10 perpendicular to the wire feed direction 5 (see Fig. 1 ) and normal to the support roller axis 9 (see Fig. 1 The leveling devices 16 are provided in this example for leveling (i.e., adjusting or setting) the vertical alignment of the base plate 10. The base plate has a threaded bore 17 for each leveling device 16, with each threaded bore 17 having an internal thread. The leveling device 16 has a leveling screw 18, with an external thread of the leveling screw 18 engaging with the internal thread of the threaded bore 17. The leveling screw 18 is (in its intended state; i.e., during the coating of a wire 2 with coating material) detachably connected to the base body 7.

[0061] Fig. 6A schematically shows a partial sectional view of a leveling device 16 made of Fig. 5 . The Figuren 6B, 6C, 6D und 6E further detailed views of the leveling screw 18 including the fixing screw 27 are shown. Fig. 6A . Fig. 6B und 6C Each shows a side view. Figur 6D shows a sectional view and Figur 6E a top view.

[0062] The leveling screw 18 has a main axis 25 (in this case, the main axis 25 is vertically oriented), and the leveling screw 18 has a through-hole 26, wherein the main axis 25 of the leveling screw 18 coincides with a main axis of the through-hole 26. In its intended state, the leveling screw 18 is detachably connected to the base body 7 by means of a locking screw 27, the locking screw 27 passing through the through-hole 26. The base body has a bore 28 into which the locking screw 27 engages. The locking screw 27 can be tightened or loosened through the through-hole, for example, using a screwdriver. The leveling screw 18 can be force-fitted and detachably connected to the base body 7 by means of the locking screw 27.

[0063] The fixing screw 27 has a first stop element 40 for this purpose (see Fig. 6D ; the head of the fixing screw 27) is located, wherein the leveling screw 18 has a second stop element 41. The first stop element 40 is positively and releasably connected to the second stop element 41.

[0064] When the locking screw 27 is loosened, the leveling screw 18 can be rotated about its main axis 25. However, even with the locking screw 27 loosened, the leveling screw 18 remains in contact with the base body, meaning that the relative position of the leveling screw 18 to the base body is defined and constant. The interaction of the external thread of the leveling screw 18 with the internal thread of the threaded bore 17 in the base plate 10 raises or lowers the base body 7, depending on the direction of rotation. By rotating the leveling screw 18, the vertical position of the base plate 10 can be adjusted. Once the desired position is reached, the locking screw 17 is tightened to secure the leveling screw 18 to the base body 7 and thus prevent further rotation.

[0065] By means of the four leveling devices 16, not only can the height of the base plate 10 be adjusted, but also a tilting angle can be adjusted by turning the leveling screws 18, for example, into different (matched and suitable) positions.

[0066] A washer 39 is located between the leveling screw 18 and the base plate 10 (see in particular the sectional view in Fig. 6D )arranged wherein the washer 39 has a convex curvature to simplify the setting of such a tilting angle.

[0067] Fig. 7 schematically shows a front view of the coating device 2. Fig. 5 The base plate 10 is arranged on the base body 7 by means of the leveling devices 16. The leveling devices 16 allow the base plate 10, and thus the collection basin 13 and the paint bench 11, to be positioned vertically.

[0068] Fig. 8 schematically shows an exploded view of another section of the coating device 2. Fig. 2 , wherein the leveling devices 16 are not shown in favor of showing the displacement device 14.

[0069] The shifting device 14 has a first wedge 29 and a second wedge 30 that interacts with the first wedge 29, wherein the first wedge 29 is connected to the paint bench 11 (in this example, specifically to the collection basin 13) and the second wedge 30 is movably connected to the base plate 10. The distance of the second wedge 30 to the base plate 10 is adjustable, the first wedge 29 interacting with the second wedge 30 in such a way that the distance of the second wedge 30 to the base plate 10 determines a position of the first wedge 29 parallel to the support roller axis 9.

[0070] The distance of the second wedge 30 to the base plate 10 is adjustable by means of the adjusting screw 15. The further the adjusting screw 15 engages in the base plate 10, the closer the second wedge 30 comes to the base plate 10. If the adjusting screw 15 is unscrewed from the base plate 10, the second wedge 30 is pushed away from the base plate 10 in this exemplary embodiment by means of a return spring 31, thereby increasing the distance of the second wedge 30 to the base plate 10.

[0071] The first wedge 29 and the second wedge 30 each have a first wedge surface 29A and a second wedge surface 30A. In its intended state, the first wedge surface 29A is parallel to the second wedge surface 30A. A cross-section of the first wedge 29 and a cross-section of the second wedge 30 each have an acute angle that is identical. The first wedge 29 can be moved along the wedge surface 29A relative to the second wedge 30. By means of the first wedge 29 and the interacting second wedge 30, a normal force exerted by the adjusting screw 15 is deflected by 90°, so that the paint bench 11 is moved horizontally.

[0072] A guide element 32 is provided to guide the second wedge 30; in this exemplary embodiment, the guide element 32 is vertically oriented. The guide element 32 is immovably connected to the base plate 10 and has a guide rail 33 into which (in the intended state) a corresponding counter-element of the second wedge 30 engages.

[0073] The first wedge 29 also has a guide rail 34, which interacts with a corresponding counter element of the second wedge 30. In total, the paint bench 11 can be moved parallel to the support roller axis 9 by means of the sliding device 14. The paint bench 11 is secured against horizontal displacement perpendicular to the support roller axis 9 by the guide rails 33 and 34 of the guide element 32 and the first wedge 29, respectively, and the corresponding counter elements of the second wedge 30.

[0074] Fig. 9 schematically shows a view of the section of the coating device 2. Fig. 8 in a composite state. Fig. 10 schematically shows the sliding device 14 from Fig. 9 In detail. The vertical position of the second wedge 30 can be adjusted using the adjusting screw 15, which in turn determines the horizontal position of the first wedge 29 and thus of the associated collecting basin 13 on the base plate 10 and parallel to the support roller axis 9. Consequently, the paint bench 11 can be moved parallel to the support roller axis 9 (perpendicular to the wire feed direction 5) using the adjusting screw 15.

[0075] Fig. 11 schematically shows a larger section of the coating device. Fig. 9 . At one of the in the Figuren 8 , 9 und 10 At the opposite end of the collection basin 13 to the sliding device 14 shown (here on the right), a further sliding device 14a is arranged in a mirror image, which is likewise designed to move the paint bench 11 parallel to the support roller axis 9 along the base plate 10.

[0076] The paint bench 11 can be moved with particular precision parallel to the support roller axis 9 by means of the two sliding devices 14 and 14a, and thus also fixed in a particularly stable position. In this embodiment, the paint bench 11 can be moved by means of the adjusting screw 15 and a further adjusting screw 15a of the additional sliding device 14a.

[0077] Fig. 12 schematically shows a front view of the section from Fig. 8 In this view, the collection basin 13 can be moved to the left and right, i.e. parallel to the support roller axis 8, by means of a sliding device 14 (see Fig. 1 ) will be postponed.

Claims

1. Coating device (2) for applying at least one layer of a coating material to a wire (3), comprising: - a base body (7); - a support roller (8) for supporting and conveying the wire (3) in a wire conveying direction (5), wherein the support roller (8) is rotatably mounted about a support roller axis (9), the support roller axis (9) being connected to the base body (7); - a base plate (10) arranged downstream of the support roller (8) in the wire conveying direction (5), wherein the base plate (10) is arranged on the base body (7); - at least one coating bank (11) arranged on the base plate (10) comprising: - at least one application unit (6) for applying coating material to the wire (3) and for removing excess coating material from the wire (3), wherein the application unit (6) has at least one application opening (12) for the wire (3);- at least one collection basin (13) for collecting excess coating material that has been stripped off, wherein the application unit (6) is arranged on or in the collection basin (13); wherein the wire (3) rests on the support roller (8) in its intended state and is passed through the at least one application feedthrough (12); ; characterized by :- at least one sliding device (14) arranged on the base plate (10) with an adjusting screw (15) for moving the paint bench (11) parallel to the support roller axis (9) along the base plate (10); and / or - a leveling device (16) for leveling the base plate (10) normal to the wire feed direction (5) and normal to the support roller axis (9), wherein the base plate (10) has at least one threaded bore (17) with an internal thread, wherein the leveling device (16) has at least one leveling screw (18), wherein an external thread of the leveling screw (18) interacts with the internal thread of the threaded bore (17), and wherein the leveling screw (18) is detachably connected to the base body (7).

2. Coating device (2) according to claim 1, characterized by the fact thatthe leveling screw (18) has a main axis, wherein the leveling screw (18) has a through-hole (26), wherein the main axis of the leveling screw (18) coincides with a main axis of the through-hole (26), wherein the leveling screw (18) is detachably connected to the base body (7) by means of a fixing screw (27), wherein the fixing screw (27) passes through the through-hole (26).

3. Coating device (2) according to claim 2, characterized by the fact that the fixing screw (27) has a first stop element (40), wherein the leveling screw (18) has a second stop element (41), wherein the first stop element (40) is force-fit and detachably connected to the second stop element (41).

4. Coating device (2) according to one of the preceding claims, characterized bya washer (39) arranged between the leveling screw (18) and the base plate (10), wherein the washer (39) has a convex curvature.

5. Coating device (2) according to one of the preceding claims, characterized by the fact that the sliding device (14) has a first wedge (29) and a second wedge (30) cooperating with the first wedge (29), wherein the first wedge (29) is connected to the paint bench (11) and the second wedge (30) is movably connected to the base plate (10), wherein a distance of the second wedge (30) to the base plate (10) is adjustable, wherein the first wedge (29) cooperates with the second wedge (30) in such a way that the distance of the second wedge (30) to the base plate (10) determines a position of the first wedge (29) parallel to the support roller axis (9).

6. Coating device (2) according to claim 5, characterized by the fact thatThe distance of the second wedge (30) to the base plate (10) can be adjusted using the adjusting screw (15).

7. Coating device according to one of the preceding claims, characterized by a tilt sensor configured to detect an inclination angle of the base plate (10) in the wire conveying direction (5) and / or normal to the wire conveying direction (5).

8. Coating device (2) according to one of the preceding claims, characterized by a distance sensor (21) which is configured to detect a position of the paint bench (11) along a straight line parallel to the support roller axis (9).

9. Coating device (2) according to claim 8, characterized by the fact that the distance sensor (21) is attached to the base body (7) and is designed to detect a distance to the paint bank (11).

10. Coating device (2) according to claim 9, characterized by the fact thatAn extension element (22) is arranged at the collection basin (13), wherein the distance sensor (21) is configured to detect a distance to the extension element (22).

11. Device (1) for producing coated wires comprising a coating device (2) according to one of the preceding claims for applying at least one layer of a coating material and an oven (4) for solidifying the applied layer, wherein the oven (4) is arranged in the wire conveying direction (5) after the at least one application unit (6).

12. Method for producing coated wires with a device (1) according to claim 11 comprising the steps of: - conveying the wire (3) with the support roller (8) in the wire conveying direction (5) towards the application unit (6); - applying a layer of the coating material to the wire (3) by means of the application unit (6); - drying and / or curing the coating material in the oven (4).

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