Rectangular Drawing Die Alignment to Reduce Enamel Film Defects
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Solution Overview
Problem
The large entry angle between the conductor and the drawing die during the rectangular drawing process leads to increased friction, resulting in conductor abrasion, generation of copper powder, and formation of microbubbles in the enamel film, causing abnormalities in the external appearance of the enameled wire.
Innovation Solution
An entry angle enlargement inhibiting device that measures and adjusts the pitch, yaw, and roll angles of the conductor relative to the drawing die, reducing friction and copper powder generation by minimizing these angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the entry angle of the conductor with respect to the drawing die is large, then the conductor can pass through the drawing die more easily, but friction between the drawing die and the conductor increases, causing conductor abrasion and copper powder generation
Solution Approach 1:
The patent introduces a guide device positioned upstream of the drawing die that pre-aligns the conductor before it enters the drawing hole. This preliminary alignment action reduces the entry angle, thereby decreasing friction and copper powder generation while still allowing the conductor to pass through efficiently
Solution Approach 2:
The guide device acts as an intermediary component between the conductor and the drawing die. It mediates the interaction by controlling the conductor's approach angle, reducing direct friction between the conductor and drawing die, and preventing harmful abrasion
2Productivity
If friction between the drawing die and conductor is large, then the conductor can be drawn through the die, but the conductor is abraded which increases copper powder generation and adheres to the conductor surface
Solution Approach 1:
The guide device performs preliminary alignment of the conductor before it enters the drawing die, reducing the entry angle and thereby minimizing friction-induced abrasion and copper powder generation during the drawing process
Solution Approach 2:
The patent changes the geometric parameter of the conductor's entry angle by introducing the guide device. By controlling this angle parameter, the system reduces friction and copper powder generation while maintaining drawing throughput
3Ease of manufacture
If copper powder adheres to the conductor surface, then the coating material can be applied, but micro bubbles are easily formed in the coating film causing abnormalities in the enamel film appearance
Solution Approach 1:
The guide device performs a preliminary anti-action by reducing copper powder generation at the source through angle control. This prevents the subsequent problem of micro bubble formation in the coating film, ensuring high appearance quality of the enamel film
Solution Approach 2:
By pre-aligning the conductor and reducing friction before coating application, the system prevents copper powder adhesion. This preliminary action ensures that subsequent coating application produces a defect-free enamel film without micro bubbles
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces conductor abrasion and microbubble formation, thereby improving the external appearance of the enamel film by minimizing copper powder adhesion and film abnormalities.
Implementation Method 1
a measurer configured to measure a pitch angle, a yaw angle, and a roll angle of the rolled conductor or the rectangular conductor with respect to the rectangular drawing die
Implementation Method 2
If an entry angle of the conductor with respect to the drawing die is large, friction between the drawing die and the conductor on their boundary surface becomes large
Data Source
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AI summary
Provided herein are an entry angle enlargement inhibiting device (33) and a method of manufacturing an enameled wire that can reduce abnormalities in an external appearance of an enamel film. The enameled wire manufacturing system (1) includes a mechanism (11) of letting a rolled conductor (23A) or a rectangular conductor (23B) pass through a rectangular drawing die (31). The entry angle enlargement inhibiting device (33) includes a measurer (37) and an adjuster (39). In the enameled wire manufacturing system (1), the measurer (37) measures a pitch angle, a yaw angle, and a roll angle of the rolled conductor (23A) or the rectangular conductor (23B) with respect to the rectangular drawing die (31). The adjuster (39) moves or rotates the rolled conductor (23A) or the rectangular conductor (23B) upstream of the rectangular drawing die (31) in a direction where the pitch angle, the yaw angle, and the roll angle measured by the measurer (37) decrease.