Manufacturing method of enamel wire and manufacturing apparatus of enamel wire

Abstract

To provide a manufacturing method of an enamel wire, and a manufacturing apparatus of an enamel wire, hardly generating abnormality on the surface of a manufactured enamel wire.SOLUTION: A manufacturing method of an enamel wire includes moving a conductor and performing straight angle rolling, straight angle wire drawing and film formation on the moving conductor. Tensile force is added by a dancer pulley to the conductor on which the straight angle rolling is performed but the straight angle wire drawing is not performed. The traveling direction of the conductor passing through the dancer pulley is changed by using a return pulley. The dancer pulley is a hard chromium plating pulley, a monomer-cast nylon pulley or a Bakelite (phenol resin) pulley.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a method and an apparatus for manufacturing an enameled wire. [Background technology]

[0002] Patent Document 1 discloses a method for manufacturing an enameled wire. In this method, a conductor is run. Then, the running conductor is rolled into a rectangular shape, drawn into a rectangular shape, and coated. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2019-122974 A Summary of the Invention [Problem to be solved by the invention]

[0004] If the conductor is made to travel along a straight travel path throughout the entire production line, the length of the production line will become long. Therefore, it is conceivable to change the travel direction of the conductor in the middle of the production line using a return pulley. In this case, abnormalities may occur on the surface of the produced enameled wire. In one aspect of the present disclosure, it is preferable to provide an enameled wire manufacturing method and an enameled wire manufacturing apparatus that are less likely to cause abnormalities on the surface of the produced enameled wire. [Means for solving the problem]

[0005] One aspect of the present disclosure is a method for producing an enameled wire, which comprises running a conductor and performing flat rolling, flat wire drawing, and coating on the running conductor. In the method for producing an enameled wire, tension is applied to the conductor, which has been flat rolled but not flat wire drawn, by a dancer pulley, and the running direction of the conductor that has passed the dancer pulley is changed by a return pulley. The dancer pulley is a hard chrome plated pulley, a monomer cast nylon pulley, or a Bakelite (phenolic resin) pulley.

[0006] According to a method for producing an enameled wire according to one aspect of the present disclosure, it is possible to suppress the occurrence of abnormalities such as grains and bubbles on the surface of the produced enameled wire. Another aspect of the present disclosure is an enameled wire manufacturing apparatus including a conductor running section configured to run a conductor, a processing section configured to perform rectangular rolling, rectangular wire drawing, and coating on the running conductor, a dancer pulley configured to apply tension to the conductor that has been rectangular rolled but not rectangular wire drawn, and a return pulley configured to change the running direction of the conductor that has passed through the dancer pulley. The dancer pulley is a hard chrome plated pulley, a monomer cast nylon pulley, or a Bakelite (phenolic resin) pulley.

[0007] A method for producing an enameled wire according to another aspect of the present disclosure can suppress the occurrence of abnormalities such as grains and bubbles on the surface of the produced enameled wire. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a plan view showing a configuration of an enameled wire manufacturing apparatus. [Diagram 2] FIG. 2 is an explanatory diagram showing the configuration of a flat rolling machine and a tension applying unit. [Diagram 3] FIG. 2 is a plan view showing the arrangement of a first section, a second section, and a third section. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Exemplary embodiments of the present disclosure will now be described with reference to the drawings. First Embodiment 1. Overall configuration of enameled wire manufacturing equipment 1 The configuration of an enameled wire manufacturing apparatus 1 will be described with reference to Fig. 1 to Fig. 3. As shown in Fig. 1, the enameled wire manufacturing apparatus 1 includes a round wire drawing machine 3, a flat rolling machine 5, a tension applying section 6, an annealing furnace 7, a first return pulley 9, a second return pulley 11, a first flat wire drawing machine 13, a second flat wire drawing machine 15, an annealing furnace 17, a paint applicator 19, and a baking furnace 21.

[0010] The conductor running section (not shown) runs a linear conductor 23 along a running path 25. The running path 25 passes through the round wire drawing machine 3, the rectangular rolling mill 5, the tension applying section 6, the annealing furnace 7, the first return pulley 9, the second return pulley 11, the first rectangular wire drawing machine 13, the second rectangular wire drawing machine 15, the annealing furnace 17, the paint applicator 19, and the baking furnace 21 in this order.

[0011] The material of the conductor 23 is, for example, copper or a copper alloy. The cross-sectional shape of the conductor 23 is, for example, a circular shape until the conductor 23 is rolled into a rectangular shape, which will be described later. The round wire drawing machine 3 draws the conductor 23 having a circular cross-sectional shape. The rectangular rolling machine 5 performs rectangular rolling on the traveling conductor 23. The conductor 23 to be subjected to rectangular rolling is the conductor 23 drawn by the round wire drawing machine 3. The rectangular rolling is a process of rolling the conductor 23 having a circular cross-sectional shape into a rectangular shape.

[0012] The rectangular rolling mill 5 rolls the conductor 23 from top to bottom and left to right so that the thickness and width of the conductor 23 become predetermined dimensions, and processes the cross-sectional shape of the conductor 23 into a rectangular shape. As shown in FIG. 2, the rectangular rolling mill 5 performs rolling using two rolling rolls 5A and 5B. The rectangular rolling mill 5 is provided with a pulley 5C downstream of the rolling rolls 5A and 5B. Note that downstream means downstream in terms of the running direction of the conductor 23. Upstream means the opposite direction of downstream. The conductor 23 runs from the upstream side to the downstream side along the running path 25.

[0013] The tension applying portion 6 applies tension to the conductor 23. The conductor 23 to which the tension applying portion 6 applies tension is a conductor 23 that has been subjected to rectangular rolling but has not yet been subjected to rectangular wire drawing. 2, the tension applying unit 6 includes an inlet pulley 6A, a dancer pulley 6B, and an outlet pulley 6C. The dancer pulley 6B is located downstream of the inlet pulley 6A. The outlet pulley 6C is located further downstream of the dancer pulley 6B. The inlet pulley 6A, the dancer pulley 6B, and the outlet pulley 6C each come into contact with the conductor 23 and guide the conductor 23.

[0014] The inlet pulley 6A and the outlet pulley 6C are located in the Z1 direction shown in FIG. 2 from the conductor 23. The Z1 direction is a direction intersecting the running direction of the conductor 23. The dancer pulley 6B is located in the Z2 direction shown in FIG. 2 from the conductor 23. The Z2 direction is the opposite direction to the Z1 direction. The Z1 direction is, for example, a downward direction. The Z2 direction is, for example, an upward direction.

[0015] The positions of the entrance pulley 6A and the exit pulley 6C are fixed. The position of the dancer pulley 6B is movable in the Z1 direction and the Z2 direction. The more the position of the dancer pulley 6B moves in the Z1 direction, the greater the tension that the dancer pulley 6B applies to the conductor 23.

[0016] The inlet pulley 6A, the dancer pulley 6B, and the outlet pulley 6C are each a hard chrome plated pulley, a monomer cast nylon pulley, or a Bakelite pulley. Bakelite is a phenolic resin.

[0017] The inlet pulley 6A, the dancer pulley 6B, and the outlet pulley 6C are, for example, the same type of pulleys. For example, the inlet pulley 6A, the dancer pulley 6B, and the outlet pulley 6C are all hard chrome plated pulleys.

[0018] The inlet pulley 6A, the dancer pulley 6B, and the outlet pulley 6C are, for example, different types of pulleys from each other. For example, the dancer pulley 6B is a hard chrome plated pulley, and the inlet pulley 6A and the outlet pulley 6C are each a monomer cast nylon pulley or a Bakelite (phenolic resin) pulley.

[0019] The hard chrome plated pulley is a pulley having a hard chrome plated layer on the surface of the main body. The material of the main body is, for example, S45C (carbon steel for mechanical construction). The monomer cast nylon pulley is a pulley made of monomer cast nylon. The bakelite (phenolic resin) pulley is a pulley made of bakelite (phenolic resin).

[0020] The annealing furnace 7 anneals the conductor 23. The conductor 23 annealed by the annealing furnace 7 is the conductor 23 that has been subjected to flat rolling by the flat rolling mill 5. The first return pulley 9 and the second return pulley 11 each change the direction of the travel path 25. By changing the direction of the travel path 25, the travel direction of the conductor 23 changes. The travel direction of the conductor 23 is first changed by the first return pulley 9, and then by the second return pulley 11. The conductor 23 whose travel direction is changed by the first return pulley 9 and the second return pulley 11 is a conductor 23 that has already been flat-rolled but has not yet been flat-wiredrawn or coated. The conductor 23 whose travel direction is changed by the first return pulley 9 and the second return pulley 11 is a conductor 23 that has already passed through the dancer pulley 6B.

[0021] 3, a portion of the travel path 25 that is upstream of the first return pulley 9 is defined as a first section 25A. A portion of the travel path 25 between the first return pulley 9 and the second return pulley 11 is defined as a second section 25B. A portion of the travel path 25 that is downstream of the second return pulley 11 is defined as a third section 25C.

[0022] When viewed from above, the first section 25A, the second section 25B, and the third section 25C are arranged in a Z-shape. The angle α between the first section 25A and the second section 25B is an acute angle. The angle β between the second section 25B and the third section 25C is also an acute angle. The axial direction of the first return pulley 9 and the axial direction of the second return pulley 11 are both horizontal.

[0023] When viewed from above, the traveling direction of the conductor 23 immediately before it reaches the first return pulley 9 forms an angle α with the traveling direction of the conductor 23 immediately after it has passed the first return pulley 9. Therefore, when the conductor 23 passes the first return pulley 9, the conductor 23 is shifted in a width direction W1 with respect to the outer circumferential surface of the first return pulley 9. The width direction W1 is a direction that is parallel to the outer circumferential surface of the first return pulley 9 and perpendicular to the circumferential direction of the first return pulley 9.

[0024] When viewed from above, the traveling direction of the conductor 23 immediately before it reaches the second return pulley 11 forms an angle β with the traveling direction of the conductor 23 immediately after it has passed the second return pulley 11. Therefore, when the conductor 23 passes the second return pulley 11, the conductor 23 is shifted in a width direction W2 with respect to the outer circumferential surface of the second return pulley 11. The width direction W2 is a direction that is parallel to the outer circumferential surface of the second return pulley 11 and perpendicular to the circumferential direction of the second return pulley 11.

[0025] The first rectangular wire drawing machine 13 and the second rectangular wire drawing machine 15 perform rectangular wire drawing on the traveling conductor 23. The conductor 23 to be subjected to rectangular wire drawing is the conductor 23 that has already passed through the first return pulley 9 and the second return pulley 11.

[0026] The flat wire drawing is a process of drawing a flat conductor 23. The first flat wire drawing machine 13 and the second flat wire drawing machine 15 process the conductor 23 to a desired dimension. The desired dimension is, for example, a dimension related to the product specifications. The first flat wire drawing machine 13 and the second flat wire drawing machine 15 are equipped with, for example, a wire drawing die.

[0027] The annealing furnace 17 anneals the conductor 23. The conductor 23 annealed by the annealing furnace 17 is the conductor 23 that has been subjected to rectangular wire drawing by the first rectangular wire drawing machine 13 and the second rectangular wire drawing machine 15. The paint applicator 19 applies enamel paint to the conductor 23 to form a coating of enamel paint of a predetermined thickness on the conductor 23. The conductor 23 to which the enamel paint is applied by the paint applicator 19 is the conductor 23 that has been annealed by the annealing furnace 17.

[0028] The baking furnace 21 applies heat to the traveling conductor 23 on which a coating of enamel paint of a predetermined thickness has been formed by the paint applicator 19, thereby forming a coating. The conductor 23 on which the coating is formed by the baking furnace 21 is the conductor 23 on which the enamel paint has been applied by the paint applicator 19. The coating formation is a process of forming a coating on the surface of the conductor 23. As shown in Fig. 1, the application of the enamel paint by the paint applicator 19 and the coating formation by the baking furnace 21 are repeated. As a result, an enameled wire 27 having a predetermined coating thickness is manufactured.

[0029] The method of forming the coating is, for example, as follows. An enamel wire paint is applied to the conductor 23. The enamel wire paint is, for example, a paint containing a resin and a solvent. Next, the solvent in the enamel wire paint applied to the conductor 23 is evaporated, and the resin in the enamel wire paint is hardened. After the solvent has evaporated and the resin has hardened, an enamel wire 27 is formed.

[0030] The round wire drawing machine 3, the rectangular rolling machine 5, the annealing furnace 7, the first rectangular wire drawing machine 13, the second rectangular wire drawing machine 15, the annealing furnace 17, the paint applicator 19, and the baking furnace 21 correspond to a processing unit that processes the traveling conductor 23. The first return pulley 9 and the second return pulley 11 correspond to a traveling direction changing unit.

[0031] 2. Manufacturing method of enameled wire 27 The enameled wire 27 can be manufactured using the enameled wire manufacturing apparatus 1. The method for manufacturing the enameled wire 27 is, for example, as follows. The conductor 23 is made to run along the running path 25. The running conductor 23 is wire-drawn using a round wire drawing machine 3. Next, the running conductor 23 is subjected to flat rolling using a flat rolling machine 5.

[0032] Next, tension is applied to the running conductor 23 using the tension applying unit 6. The conductor 23 to which tension is applied is a conductor 23 that has been subjected to rectangular rolling but has not yet been subjected to rectangular wire drawing. The tension applying unit 6 applies tension to the conductor 23 by the dancer pulley 6B.

[0033] Next, the running conductor 23 is annealed using the annealing furnace 7. Next, the running conductor 23 is subjected to rectangular wire drawing using the first rectangular wire drawing machine 13 and the second rectangular wire drawing machine 15. Next, the running conductor 23 is annealed using the annealing furnace 17. Next, the running conductor 23 is coated with enamel paint using the paint applicator 19. Next, the running conductor 23 is coated with a film using the baking furnace 21. As shown in FIG. 1, the application of enamel paint by the paint applicator 19 and the coating formation by the baking furnace 21 are repeated.

[0034] When the enameled wire 27 is being manufactured, the running direction of the running conductor 23 is changed by the first return pulley 9 and the second return pulley 11. The running direction of the conductor 23 is first changed by the first return pulley 9, and then changed by the second return pulley 11.

[0035] 3. Effects of the enameled wire manufacturing method and the enameled wire manufacturing apparatus 1 (1A) According to the enameled wire manufacturing method and enameled wire manufacturing apparatus 1 of the present disclosure, the occurrence of abnormalities such as grains and bubbles on the surface of the manufactured enameled wire 27 can be suppressed.

[0036] The reason why abnormalities have occurred on the surface of enameled wire 27 in the past is presumed to be as follows. Copper powder gets into the rough parts of the surface of dancer pulley 6B that comes into contact with conductor 23 (hereinafter referred to as conductor contact portion). When the conductor contact portion comes into contact with conductor 23, the copper powder that had been present in the conductor contact portion moves to the surface of conductor 23.

[0037] As described above, when the conductor 23 passes through the first return pulley 9, the conductor 23 is displaced in the width direction W1 with respect to the outer circumferential surface of the first return pulley 9. In addition, when the conductor 23 passes through the second return pulley 11, the conductor 23 is displaced in the width direction W2 with respect to the outer circumferential surface of the second return pulley 11.

[0038] When the conductor 23 with copper powder adhering to its surface is shifted in the width directions W1 and W2 relative to the outer circumferential surfaces of the first return pulley 9 and the second return pulley 11, the copper powder causes scratches on the surface of the conductor 23. When a coating is formed on the conductor 23 with scratches on its surface, abnormalities such as grains and bubbles occur on the surface of the enameled wire 27.

[0039] The reason why the production method and production apparatus 1 for enameled wire according to the present disclosure are able to prevent particles, bubbles, and the like from forming on the surface of the enameled wire 27 can be presumed as follows. The dancer pulley 6B is a hard chrome plated pulley, a monomer cast nylon pulley, or a Bakelite (phenolic resin) pulley. The conductor contact portion of such a dancer pulley 6B has few rough parts, and copper powder is less likely to adhere to the conductor contact portion. Therefore, copper powder is also less likely to adhere to the surface of the conductor 23 that has passed through the dancer pulley 6B. Since copper powder is less likely to adhere to the surface of the conductor 23, scratches caused by copper powder are less likely to occur on the surface of the conductor 23 when the conductor 23 passes through the first return pulley 9 and the second return pulley 11. As a result, abnormalities such as grains and bubbles are less likely to occur on the surface of the enameled wire 27.

[0040] It is preferable that the dancer pulley 6B is a hard chrome plated pulley. A hard chrome plated pulley has high durability. Therefore, when the dancer pulley 6B is a hard chrome plated pulley, the running speed of the conductor 23 can be increased and high tension can be applied to the conductor 23.

[0041] (1B) The inlet pulley 6A and the outlet pulley 6C are also hard chrome plated pulleys, pulleys made of monomer cast nylon, or pulleys made of bakelite (phenolic resin). The conductor contact parts of the inlet pulley 6A and the outlet pulley 6C have few rough parts, and copper powder is less likely to adhere to the conductor contact parts. Therefore, copper powder is less likely to move from the inlet pulley 6A and the outlet pulley 6C to the surface of the conductor 23. As a result, when the conductor 23 passes through the first return pulley 9 and the second return pulley 11, scratches caused by copper powder are less likely to occur on the surface of the conductor 23, and abnormalities such as grains and bubbles are even less likely to occur on the surface of the enameled wire.

[0042] The inlet pulley 6A and the outlet pulley 6C are preferably hard chrome plated pulleys. Hard chrome plated pulleys have high durability. Therefore, when the inlet pulley 6A and the outlet pulley 6C are hard chrome plated pulleys, the running speed of the conductor 23 can be increased and high tension can be applied to the conductor 23.

[0043] (1C) The enameled wire manufacturing apparatus 1 changes the running direction of the conductor 23 at two locations, the first return pulley 9 and the second return pulley 11. Therefore, the line length of the manufacturing apparatus 1 can be reduced.

[0044] (1D) As shown in Fig. 3, the first section 25A, the second section 25B, and the third section 25C are arranged in a Z-shape. Therefore, it is possible to prevent interference between the round wire drawing machine 3, the rectangular rolling mill 5, the tension applying section 6, and the annealing furnace 7 in the first section 25A and the first rectangular wire drawing machine 13, the second rectangular wire drawing machine 15, the annealing furnace 17, the paint applicator 19, and the baking furnace 21 in the third section 25C.

[0045] 4. Examples and Comparative Examples (1) Examples The enameled wire 27 was manufactured using the enameled wire manufacturing apparatus 1. The inlet pulley 6A, the dancer pulley 6B, and the outlet pulley 6C were each a hard chrome plated pulley. The enameled wire 27 was manufactured every day from September 10 to September 20.

[0046] The produced enameled wire 27 was wound around 130 bobbins. The length of the enameled wire 27 wound around each bobbin was 3200 m. For each bobbin, the number of particles that had formed on the enameled wire 27 wound around that bobbin was counted. The measurement results are shown in Table 1. The values ​​shown in Table 1 are the number of particles that had formed on 3,200 m of enameled wire 27. Note that the "Bobbin No." in Table 1 is the serial number given to the bobbin used on each manufacturing date.

[0047] [Table 1]

[0048] The number of particles generated in all the produced enameled wires 27 was 7910. The number of particles per bobbin was 60.8. (2) Comparative Example The enameled wire 27 was manufactured using an apparatus basically similar to the enameled wire manufacturing apparatus 1. However, the inlet pulley 6A, the dancer pulley 6B, and the outlet pulley 6C were ceramic sprayed pulleys. The enameled wire 27 was manufactured every day from June 13 to June 23.

[0049] The produced enameled wire 27 was wound around 75 bobbins. The length of the enameled wire 27 wound around each bobbin was 3200 m. For each bobbin, the number of particles that had formed on the enameled wire 27 wound around that bobbin was counted. The measurement results are shown in Table 2. The values ​​shown in Table 2 are the number of particles that had formed on 3,200 m of enameled wire 27.

[0050] [Table 2]

[0051] The number of particles generated in all the produced enameled wires 27 was 6055. The number of particles per bobbin was 80.7. In the comparative example, the number of particles per bobbin was significantly larger than in the example. <Other embodiments> Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above-described embodiments and can be implemented in various modified forms.

[0052] (1) Either or both of the inlet pulley 6A and the outlet pulley 6C may be any of the following: a hard chrome plated pulley, a monomer cast nylon pulley, and a Bakelite (phenolic resin) pulley.

[0053] (2) The enameled wire manufacturing apparatus 1 may include only one of the first return pulley 9 and the second return pulley 11. In this case, the manufacturing apparatus 1 changes the running direction of the conductor 23 at one location. Even in this case, the line length of the manufacturing apparatus 1 can be reduced compared to when the running direction is not changed.

[0054] (3) The enameled wire manufacturing apparatus 1 may include return pulleys at three or more locations, and the running direction of the conductor 23 may be changed at three or more locations. (4) One or both of the first return pulley 9 and the second return pulley 11 may be located downstream of the second rectangular wire drawing machine 15 and upstream of the baking furnace 21. In this case, the pulley located downstream of the second rectangular wire drawing machine 15 changes the running direction of the conductor 23 that has already been rectangular rolled and rectangular wire drawn but has not yet been coated. In this case, the same effect as in the first embodiment is achieved.

[0055] (5) The function of one component in each of the above embodiments may be shared by multiple components, or the functions of multiple components may be performed by one component. Also, part of the configuration of each of the above embodiments may be omitted. Also, at least part of the configuration of each of the above embodiments may be added to or substituted for the configuration of another of the above embodiments.

[0056] (6) In addition to the enameled wire manufacturing apparatus 1 described above, the present disclosure can be realized in various forms, such as a system including the manufacturing apparatus 1 as a component, a traveling device for the conductor 23, and the like. [Explanation of symbols]

[0057] Reference Signs List 1...Enamelled wire manufacturing equipment, 3...Round wire drawing machine, 5...Rectangular rolling machine, 5A, 5B...Rolling rolls, 5C...Pulley, 6...Tensioning section, 6A...Inlet pulley, 6B...Dancer pulley, 6C...Outlet pulley, 7...Annealing furnace, 9...First return pulley, 11...Second return pulley, 13...First rectangular wire drawing machine, 15...Second rectangular wire drawing machine, 17...Annealing furnace, 19...Paint applicator, 21...Baking furnace, 23...Conductor, 25...Traveling path, 25A...First section, 25B...Second section, 25C...Third section, 27...Enamelled wire

Claims

1. A method for manufacturing an enameled wire, comprising the steps of running a conductor, performing flat rolling, flat wire drawing, and coating on the running conductor, A tension is applied to the conductor that has been rolled but not drawn by a dancer pulley. A return pulley is used to change the running direction of the conductor that has passed through the dancer pulley, The dancer pulley is a hard chrome plated pulley, a monomer cast nylon pulley, or a Bakelite pulley. Manufacturing method of enameled wire.

2. A conductor running portion configured to run a conductor; A processing unit configured to perform flat rolling, flat wire drawing, and coating on the running conductor; A dancer pulley configured to apply tension to the conductor that has been rolled but not drawn; a return pulley configured to change the running direction of the conductor that has passed through the dancer pulley; Equipped with The dancer pulley is a hard chrome plated pulley, a monomer cast nylon pulley, or a Bakelite pulley. Enamelled wire manufacturing equipment.

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