Square-Wire Conductor Rolling for Fine-Gauge Precision Forming
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Solution Overview
Problem
Existing methods for producing square-wire conductors are inefficient and costly, particularly for specifications below 0.40 mm, as they struggle to meet the smaller size requirements of the electronic industry, leading to difficulties in mass production due to challenges in manufacturing the necessary dies.
Innovation Solution
A method involving sequential calendering and straightening processes using longitudinal and transverse calendering rollers with specifically arranged gaps to transform a circular conductor into a stable and reliable fine square-wire conductor, allowing for the production of square enameled wires with nominal specifications of 0.80 mm and below.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wire drawing forming method is used for square-wire conductor production, then conventional manufacturing processes can be applied, but it becomes difficult to manufacture square-wire-drawing dies for specifications below 0.40 mm
Solution Approach 1:
The forming process is segmented into multiple sequential steps: first forming a circular cross-section, then progressively shaping into square through multiple rolling passes. This divides the difficult single-step die drawing into manageable stages, each with simpler tooling requirements.
Solution Approach 2:
The method performs preliminary shaping actions using calendering rollers to prepare the conductor cross-section before final square formation. The circular conductor is pre-formed with controlled dimensions, making subsequent square-shaping operations more feasible and precise.
2Device complexity
If wire drawing forming method is used, then existing manufacturing equipment can be utilized, but the specification changing process becomes complicated
Solution Approach 1:
The calendering roller gaps are made adjustable to dynamically change the forming dimensions. By modifying the gap between rollers, different square-wire specifications can be produced without changing the fundamental equipment configuration, enabling flexible adaptation to various product requirements.
3Productivity
If conventional forming methods are used, then standard production processes can be maintained, but production costs become high for fine specifications
Solution Approach 1:
The calendering process inherently performs both shaping and sizing functions in integrated passes. The rollers simultaneously form the square cross-section and control the final dimensions, eliminating the need for separate operations and reducing overall manufacturing complexity and cost.
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
This method enables the production of high-quality square-wire conductors with stable and reliable production, facilitating mass production by effectively addressing the limitations of existing methods and achieving precise dimensions.
Implementation Method 1
passing the conductor through a gap of a longitudinal calendering roller to longitudinally calender the conductor up and down to form a conductor with flat upper and lower surfaces
Data Source
AI summary
Disclosed is a method for forming a square-wire conductor, which includes: providing a circular conductor with a diameter d; passing the conductor through a gap of a longitudinal calendering roller to longitudinally calender the conductor up and down to form a conductor with flat upper and lower surfaces, the gap L1 of the longitudinal calendering roller is 0.886 d to 0.911 d; longitudinally and transversely straightening the conductor; passing the conductor through a gap of a transverse calendering roller to transversely calender the conductor left and right to form a conductor with flat left and right surfaces, the gap L2 of the transverse calendering roller is 0.886 d to 0.911 d; and longitudinally and transversely straightening the conductor.