CA2081593C - Method and installation for manufacturing rectangular enamelled magnet wire with in-line rolling and enamelling - Google Patents
Method and installation for manufacturing rectangular enamelled magnet wire with in-line rolling and enamellingInfo
- Publication number
- CA2081593C CA2081593C CA 2081593 CA2081593A CA2081593C CA 2081593 C CA2081593 C CA 2081593C CA 2081593 CA2081593 CA 2081593 CA 2081593 A CA2081593 A CA 2081593A CA 2081593 C CA2081593 C CA 2081593C
- Authority
- CA
- Canada
- Prior art keywords
- enamelling
- rolling
- wire
- magnet wire
- rectangular
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 238000005096 rolling process Methods 0.000 title claims abstract description 58
- 238000000034 method Methods 0.000 title claims abstract description 24
- 238000009434 installation Methods 0.000 title claims abstract description 22
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 210000003298 dental enamel Anatomy 0.000 claims description 23
- 238000001816 cooling Methods 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 230000015556 catabolic process Effects 0.000 claims description 5
- 238000009413 insulation Methods 0.000 claims description 5
- 238000005461 lubrication Methods 0.000 claims description 5
- 230000001131 transforming effect Effects 0.000 claims description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 3
- 239000010949 copper Substances 0.000 claims description 3
- 238000000137 annealing Methods 0.000 claims description 2
- 239000002344 surface layer Substances 0.000 claims description 2
- 239000002699 waste material Substances 0.000 abstract 1
- 230000008569 process Effects 0.000 description 9
- 238000012360 testing method Methods 0.000 description 5
- 239000004020 conductor Substances 0.000 description 3
- 230000003749 cleanliness Effects 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000005219 brazing Methods 0.000 description 1
- 230000002844 continuous effect Effects 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B45/00—Devices for surface or other treatment of work, specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
- B21B1/16—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling wire rods, bars, merchant bars, rounds wire or material of like small cross-section
- B21B1/166—Rolling wire into sections or flat ribbons
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
- B21C37/042—Manufacture of coated wire or bars
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21F—WORKING OR PROCESSING OF METAL WIRE
- B21F19/00—Metallic coating of wire
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/065—Insulating conductors with lacquers or enamels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
- B21B1/16—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling wire rods, bars, merchant bars, rounds wire or material of like small cross-section
- B21B1/18—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling wire rods, bars, merchant bars, rounds wire or material of like small cross-section in a continuous process
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B15/00—Arrangements for performing additional metal-working operations specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
- B21B15/0085—Joining ends of material to continuous strip, bar or sheet
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
- B21B1/38—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling sheets of limited length, e.g. folded sheets, superimposed sheets, pack rolling
- B21B2001/383—Cladded or coated products
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
- B21B2003/005—Copper or its alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21B—ROLLING OF METAL
- B21B15/00—Arrangements for performing additional metal-working operations specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
- B21B2015/0028—Drawing the rolled product
Abstract
A novel method and installation are proposed for manufacturing rectangular enamelled magnet wire using an in-line rolling and enamelling system. The in-line rolling and enamelling of the magnet wire in a single, continuous operation provides many advantages and eliminates quality programs, inefficiencies and waste which are inherent in the manufacture of shaped magnet wire using separate rolling and enamelling operations. It is particularly suitable for use with the so called "mini" rolling mills which are small and flexible and modular in design.
Description
M~T~D AND INS~ATTATION FOR MANUFACTURING R~CTANGULAR
EN~ .T~n MAGNET WIRB WITH IN-LINE ROLLING AND D~TTTNG
This invention relates to a method and an installation for manufacturing rectangular enamelled magnet wire. More particularly, it relates to an improved method and installation wherein the rolling and enamelling operations are combined into an in-line rolling and enamelling system.
The conventional method for manufacturing rectangular enamelled magnet wire has remained unchanged for many years and it is fraught with many problems mostly connected with the input of the rectangular bare conductor into the enamelling machine. Essentially the conventional method involves four separate operations, namely: (a) shaving;
(b) drawing; (c) rolling; and (d) enamelling.
Thus, the conventional installation for manufacturing enamelled magnet wire comprises four separate machines which operate independently of one another. These are:
(a) a rod shaving machine into which continuous cast and rolled rod is fed from 4500 kg coils and wherein the surface of the rod is shaved off to present a bright, clear surface suitable for subsequent enamelling, and whereafter the shaved rod is wound onto stems for subsequent drawing;
(b) a breakdown machine where the shaved stems are drawn to predetermined size of round bare wire which is then wound onto 76 cm (30") reels for subsequent rolling;
(c) a rolling mill where the round bare wire is rolled at high speed to form rectangular bare wire of desired size which is then wound onto 76 cm (30") reels and stored for enamelling; and (d) and enamelling machine into which the rectangular bare wire is fed and which comprises an annealer, a cooling zone and an enamel oven where the enamel coats are applied in a continuou~ manner until a predetermined thickness of insulation is achieved.
The quality of the rolled or rectangular conductor which is entering the enamelling operation is of paramount importance and it is this factor that offers most opportunities for significant problems in the conventional installation.
The major problems are:
(a) Scrap In the current system, a scrap allowance is introduced at the rolling stage and because of the variety of sizes produced, this allowance becomes scrap irrespective of whether the enamelling process uses it or not.
(b) Continuity of production At present, due to the batch processing methods required when utilizing a high speed rolling mill, large quantities of the entering round wire for the rolling mill and of shaped wire for the enamelling machine are required to achieve continuity of production.
(c) Remakes Shaped remakes, especially in small quantities, have the effect of making the conventional rolling mills very inefficient because of high set-up time required.
(d) Brazes Currently all spools of shaped (rectangular) bare wire are brazed together to facilitate the continuous operation of the enamelling machine. This is not a totally satisfactory solution, since the braze is weaker than the parent metal and also the wire on the bottom of the spool and the action of the brazing process often scratches the wire and leads to test failures.
(e) Surface Ouality Due to its capital cost, a conventional ~olling mill is not normally used exclusively for producing wire for enamelling purposes and consequently a compromise has to be made to achieve a surface finish on the wire to satisfy several purposes. This, although the most practical procedure under the circll~stances, is not an ideal situation for the best possible enamelling operation.
(f) Wire Cleanliness In the conventional process, a residue of rolling lubricant is inevitably left on the wire surface. When the wire is then stored on the reels for at least several hours, this lubricant dries on the wire and is very difficult to clean off. If the enamelling is delayed further, the rolled wire is subjected to a combination of dust, dirt and metal oxidation, which often lead to test failures in the enamelling process.
(g) Wire Damage In the conventional rolling operation, the rolled wire is spooled onto a steel reel. Even with perfect winding, damage to the wire is inevitable at the points where the wire contacts the sides of the reel and where the windings cross over. Also, during subsequent moving of the reels or wire by lift truck and/or by hand, damage to the wire occasionally occurs due to mishandling.
(h) Tension Conventionally, a controlled, consistent tension on the enamelling machine is difficult to achieve, especially on smaller sizes. The changing weight of the spool and the changing effective braking torque combine to give inconsistent results which can produce test failures.
(i) Size Variations A conventional rolling mill holds the wire size, with minimum variation, when it reaches operating speed and hence equilibrium. During the starting and stopping operations, more variation in the wire size is introduced and this can lead to inconsistencies in the enamelling operation.
(j) Productivity Because of the continual problems associated with the current process, as mentioned above, the opportunity to obtain productivity improvements in the conventional system per se are very limited.
It is an object of the present invention to provide a method and an installation for manufacturing rectangular enamelled magnet wire, which will obviate the above disadvantages of the conventional system.
Another object of the invention is to provide an _ -5-improved method and installation wherein the rolling and enamelling operations are combined into one and are operated in-line as a single system or operation.
Other objects and advantages of the invention will become apparent from the following description.
Thus, the method of the present invention for the manufacturing of rectangular enamelled magnet wire, comprises feeding a rod made of suitable metal, such as copper, into a shaving machine and shaving the surface layer of the rod to produce a bright, clean surface suitable for subsequent enamelling, then coiling the shaved rod onto stems for drawing, then drawing the shaved stems to predetermined size of round, bare magnet wire and coiling the same onto stems and finally rolling the round bare magnet wire to form a rectangular bare magnet wire of predetermined size and enamelling said rectangular magnet wire by annealing the same, cooling and then passing through and enamel oven where the enamel coats are applied until a predetermined thickness of insulation is achieved, the novel method being characterized in that the rolling and enamelling are carried out in-line as a single, continuous operation.
The speed of the overall in-line operation is controlled by the speed of enamelling and the rolling speed is adjusted accordingly. The rolling-enamelling operation also includes a self-contained lubrication of the wire as it is being rolled.
The installation in accordance with the present 2o8l593 invention comprises: a shaving machine for shaving the surface of the rod fed into said machine to produce a bright, clean surface; a rod breakdown machine for drawing the shaved rod to a predetermined round, bare magnet wire;
and an in-line rolling and enamelling system for transforming the round, bare magnet wire into a magnet wire of predetermined rectangular shape and enamelling the same in a single continuous operation. The rolling section and the enamelling section of the system operate in tandem with one another.
The enamelling section comprises an annealer, followed by a cooling zone and followed by an enamel oven and an enamel capstan pulling the wire through the system. Also, a dancer arrangement is provided within the rolling section for controlling the speed of the rolling section relative to the speed of the enamelling section which is controlled by the enamel capstan which also provides a constant and controlled tension. The rolling section further comprises a self-contained lubrication unit to lubricate the wire.
Moreover, the rolling secti-on comprises a set of mill rolls for achieving a particular surface finish, designed to produce predetermined shaped wire for enamel application.
Thus, in accordance with this invention, in an installation for manufacturing rectangular enamelled magnet wire, there is provided an in-line rolling and enamelling system for transforming round bare magnet wire supplied thereto into a magnet wire of predetermined rectangular shape in the rolling section of the system, and enamelling said rectangular wire in a single continuous operation within the enamelling section of the system positioned in tandem to the rolling section.
The novel method and installation of the present invention essentially obviates most if not all of the disadvantages of the conventional system, thus:
(a) Scrap The novel method and installation will eliminate the need for scrap allowance and subsequent scrap by producing the exact amount of shaped conductor required by the enamelling operation.
(b) Continuity of Production The novel system will require only a few stems of entering round wire to function.
(c) Remakes The invention will eliminate the need for rolling mill remakes since the in-line operation will match the requirements of the enamelling machine.
(d) Brazes The in-line system utilizes a simple cold pressure weld on the entering round wire. A cold weld is as strong as the parent metal and any scratches on the wire will be rolled out, thereby eliminating test failures.
(e) Surface Ouality The in-line mill can be provided with a set of mill rolls having a surface finish which is designed to produce the desired shaped wire for enamel application.
__ -8-(f) Wire Cleanliness The new in-line rolling-enamelling system, being continuous, supplies a clean, dirt and dust free rectangular bare wire into the enamelling section of the machine, eliminating test failures for these reasons.
(g) Wire Damage The in-line mill eliminates wire damage by eliminating the need to spool the rolled wire.
(h) Tension The in-line mill, through a dancer arrangement, delivers a smooth, consistent, controlled tension onto the enamelling machine, produced by the enamel capstan pulling the wire through the system.
(i) Size Variations The in-line mill will not have periods of inconsistency producing size variations, because it reaches equilibrium in a few seconds.
(j) Productivity Productivity is increased because of elimination of a separate stage in the overall process, with consequent reduction in labour requirements.
The invention will now be described with reference to the accompanying drawings, in which:
Fig. 1 is a schematic representation, in perspective, of the conventional enamelled magnet wire manufacturing practice and is labelled "PRIOR ART"; and Fig. 2 is a schematic representation, in perspective, of the preferred embodiment of an installation in accordance with the present invention.
~ - 9 -Referring to Fig. 1, the PRIOR ART or conventional system for manufacturing rectangular magnet core comprises a rod shaving machine 10 into which continuous cast and rolled rod 11 is fed from 4500 kg coils 12. The shaving 5 operation produces a bright, clean surface rod 13 which is wound onto stems 14 for subsequent drawing. The drawing of the shaved rod 13 is carried out on a rod breakdown machine 15 where the shaved rod is drawn to a bare round wire 16 of desired size, which is wound on reels 17 for subsequent rolling.
The round wire 16 is then transferred to the rolling station and fed from reels 17 into a rolling mill 18 in which it is rolled to a wire 19 of predetermined rectangular size. The rolling operation is controlled by the control panel 20 and once the bare rectangular wire 19 of desired size is produced, it is wound onto reels 21 and stored for enamelling. The reels 21 are then transferred to the enamelling station 22 wherein the rectangular wire 19 is first fed into an annealer 23, then goes through a cooling zone 24 and then through the enamel oven 25 where the enamel coats are applied in a continuous process until the desired thickness of insulation is achieved. The produced enamelled magnet wire 26 is drawn by a capstan 27 and wound onto reels 28 which are shipped to the customer.
As is obvious from the above description, the conventional system comprises four distinct and separate operations, namely: (a) shaving; (b) drawing; (c) rolling;
and (d) enamelling.
B
The installation in accordance which the present invention is illustrated in Fig. 2 in which the rod shaving machine 30 is fed with rod 31 from coil 32 where it is shaved in a similar manner as in the conventional operation to form a shaved rod 33 with a bright, clean surface, which is wound onto stems 34 for subsequent drawing. The shaved rod is then drawn on a rod breakdown machine 35 to a bare round wire 36 of desired size and then, unlike the conventional process where 30" reels are used, the wire is coiled onto stems 37 for the in-line rolling and enamelling process. From stems 37 the round wire 36 is fed into the in-line rolling-enamelling system 38 comprising, in tandem, a rolling section 39 and an enamelling section 40. In the rolling section 39 the round wire 36 is rolled into a rectangular wire 41 which then passes through the annealer 42 where it is annealed prior to enamelling. Then the annealed wire is cooled in the cooling zone 43 and then passes through the enamel oven 44 where the enamel coats are applied until the desired thickness of insulation is achieved. Then the enamelled wire, which is drawn by enamel capstan 45, is wound on reels 46 which are shipped to the customer. The enamel capstan 45 controls the tension and the speed of the wire in the rolling - enamelling system 38 and a dancer arrangement is provided in the rolling section 39 for maint~i ni ng the required speed in said rolling section 39 relative to the speed of the enamelling section 40. Also there is provided a self-contained lubrication unit within the rolling section 39 to lubricate the wire being rolled.
This novel arrangement is particularly suitable for use with a "mini" rolling mill which has been designed for continuous operation periods of 12 months between maintenance services or roll changes. Such unit is modular and consists of two high powered mill stands 39a and 39b with a powered edger unit 47 between the mill stands. It is controlled by control panels 48. The drive of the mill is usually specifically sized for small reductions and is accurately co-ordinated, through a dancer arrangement, with the enamel machine capstan 45.
The method and installation in accordance with the present invention operate approximately 50% faster than conventional systems and eliminate approximately 20% of the manufacturing cost. As already discussed, losses caused by set-up, run to length and bare wire related quality problems are significantly reduced. However, the novel system may not produce very satisfactory results with wires of large width and/or thickness for which the conventional system may still be the best process.
It should be understood that this invention is not limited by the preferred embodiment described and illustrated herein and that obvious modifications or adaptations may readily be carried out by a person skilled in the art. The scope of the invention should, therefore, only be construed by reference to the appended claims.
'n -
EN~ .T~n MAGNET WIRB WITH IN-LINE ROLLING AND D~TTTNG
This invention relates to a method and an installation for manufacturing rectangular enamelled magnet wire. More particularly, it relates to an improved method and installation wherein the rolling and enamelling operations are combined into an in-line rolling and enamelling system.
The conventional method for manufacturing rectangular enamelled magnet wire has remained unchanged for many years and it is fraught with many problems mostly connected with the input of the rectangular bare conductor into the enamelling machine. Essentially the conventional method involves four separate operations, namely: (a) shaving;
(b) drawing; (c) rolling; and (d) enamelling.
Thus, the conventional installation for manufacturing enamelled magnet wire comprises four separate machines which operate independently of one another. These are:
(a) a rod shaving machine into which continuous cast and rolled rod is fed from 4500 kg coils and wherein the surface of the rod is shaved off to present a bright, clear surface suitable for subsequent enamelling, and whereafter the shaved rod is wound onto stems for subsequent drawing;
(b) a breakdown machine where the shaved stems are drawn to predetermined size of round bare wire which is then wound onto 76 cm (30") reels for subsequent rolling;
(c) a rolling mill where the round bare wire is rolled at high speed to form rectangular bare wire of desired size which is then wound onto 76 cm (30") reels and stored for enamelling; and (d) and enamelling machine into which the rectangular bare wire is fed and which comprises an annealer, a cooling zone and an enamel oven where the enamel coats are applied in a continuou~ manner until a predetermined thickness of insulation is achieved.
The quality of the rolled or rectangular conductor which is entering the enamelling operation is of paramount importance and it is this factor that offers most opportunities for significant problems in the conventional installation.
The major problems are:
(a) Scrap In the current system, a scrap allowance is introduced at the rolling stage and because of the variety of sizes produced, this allowance becomes scrap irrespective of whether the enamelling process uses it or not.
(b) Continuity of production At present, due to the batch processing methods required when utilizing a high speed rolling mill, large quantities of the entering round wire for the rolling mill and of shaped wire for the enamelling machine are required to achieve continuity of production.
(c) Remakes Shaped remakes, especially in small quantities, have the effect of making the conventional rolling mills very inefficient because of high set-up time required.
(d) Brazes Currently all spools of shaped (rectangular) bare wire are brazed together to facilitate the continuous operation of the enamelling machine. This is not a totally satisfactory solution, since the braze is weaker than the parent metal and also the wire on the bottom of the spool and the action of the brazing process often scratches the wire and leads to test failures.
(e) Surface Ouality Due to its capital cost, a conventional ~olling mill is not normally used exclusively for producing wire for enamelling purposes and consequently a compromise has to be made to achieve a surface finish on the wire to satisfy several purposes. This, although the most practical procedure under the circll~stances, is not an ideal situation for the best possible enamelling operation.
(f) Wire Cleanliness In the conventional process, a residue of rolling lubricant is inevitably left on the wire surface. When the wire is then stored on the reels for at least several hours, this lubricant dries on the wire and is very difficult to clean off. If the enamelling is delayed further, the rolled wire is subjected to a combination of dust, dirt and metal oxidation, which often lead to test failures in the enamelling process.
(g) Wire Damage In the conventional rolling operation, the rolled wire is spooled onto a steel reel. Even with perfect winding, damage to the wire is inevitable at the points where the wire contacts the sides of the reel and where the windings cross over. Also, during subsequent moving of the reels or wire by lift truck and/or by hand, damage to the wire occasionally occurs due to mishandling.
(h) Tension Conventionally, a controlled, consistent tension on the enamelling machine is difficult to achieve, especially on smaller sizes. The changing weight of the spool and the changing effective braking torque combine to give inconsistent results which can produce test failures.
(i) Size Variations A conventional rolling mill holds the wire size, with minimum variation, when it reaches operating speed and hence equilibrium. During the starting and stopping operations, more variation in the wire size is introduced and this can lead to inconsistencies in the enamelling operation.
(j) Productivity Because of the continual problems associated with the current process, as mentioned above, the opportunity to obtain productivity improvements in the conventional system per se are very limited.
It is an object of the present invention to provide a method and an installation for manufacturing rectangular enamelled magnet wire, which will obviate the above disadvantages of the conventional system.
Another object of the invention is to provide an _ -5-improved method and installation wherein the rolling and enamelling operations are combined into one and are operated in-line as a single system or operation.
Other objects and advantages of the invention will become apparent from the following description.
Thus, the method of the present invention for the manufacturing of rectangular enamelled magnet wire, comprises feeding a rod made of suitable metal, such as copper, into a shaving machine and shaving the surface layer of the rod to produce a bright, clean surface suitable for subsequent enamelling, then coiling the shaved rod onto stems for drawing, then drawing the shaved stems to predetermined size of round, bare magnet wire and coiling the same onto stems and finally rolling the round bare magnet wire to form a rectangular bare magnet wire of predetermined size and enamelling said rectangular magnet wire by annealing the same, cooling and then passing through and enamel oven where the enamel coats are applied until a predetermined thickness of insulation is achieved, the novel method being characterized in that the rolling and enamelling are carried out in-line as a single, continuous operation.
The speed of the overall in-line operation is controlled by the speed of enamelling and the rolling speed is adjusted accordingly. The rolling-enamelling operation also includes a self-contained lubrication of the wire as it is being rolled.
The installation in accordance with the present 2o8l593 invention comprises: a shaving machine for shaving the surface of the rod fed into said machine to produce a bright, clean surface; a rod breakdown machine for drawing the shaved rod to a predetermined round, bare magnet wire;
and an in-line rolling and enamelling system for transforming the round, bare magnet wire into a magnet wire of predetermined rectangular shape and enamelling the same in a single continuous operation. The rolling section and the enamelling section of the system operate in tandem with one another.
The enamelling section comprises an annealer, followed by a cooling zone and followed by an enamel oven and an enamel capstan pulling the wire through the system. Also, a dancer arrangement is provided within the rolling section for controlling the speed of the rolling section relative to the speed of the enamelling section which is controlled by the enamel capstan which also provides a constant and controlled tension. The rolling section further comprises a self-contained lubrication unit to lubricate the wire.
Moreover, the rolling secti-on comprises a set of mill rolls for achieving a particular surface finish, designed to produce predetermined shaped wire for enamel application.
Thus, in accordance with this invention, in an installation for manufacturing rectangular enamelled magnet wire, there is provided an in-line rolling and enamelling system for transforming round bare magnet wire supplied thereto into a magnet wire of predetermined rectangular shape in the rolling section of the system, and enamelling said rectangular wire in a single continuous operation within the enamelling section of the system positioned in tandem to the rolling section.
The novel method and installation of the present invention essentially obviates most if not all of the disadvantages of the conventional system, thus:
(a) Scrap The novel method and installation will eliminate the need for scrap allowance and subsequent scrap by producing the exact amount of shaped conductor required by the enamelling operation.
(b) Continuity of Production The novel system will require only a few stems of entering round wire to function.
(c) Remakes The invention will eliminate the need for rolling mill remakes since the in-line operation will match the requirements of the enamelling machine.
(d) Brazes The in-line system utilizes a simple cold pressure weld on the entering round wire. A cold weld is as strong as the parent metal and any scratches on the wire will be rolled out, thereby eliminating test failures.
(e) Surface Ouality The in-line mill can be provided with a set of mill rolls having a surface finish which is designed to produce the desired shaped wire for enamel application.
__ -8-(f) Wire Cleanliness The new in-line rolling-enamelling system, being continuous, supplies a clean, dirt and dust free rectangular bare wire into the enamelling section of the machine, eliminating test failures for these reasons.
(g) Wire Damage The in-line mill eliminates wire damage by eliminating the need to spool the rolled wire.
(h) Tension The in-line mill, through a dancer arrangement, delivers a smooth, consistent, controlled tension onto the enamelling machine, produced by the enamel capstan pulling the wire through the system.
(i) Size Variations The in-line mill will not have periods of inconsistency producing size variations, because it reaches equilibrium in a few seconds.
(j) Productivity Productivity is increased because of elimination of a separate stage in the overall process, with consequent reduction in labour requirements.
The invention will now be described with reference to the accompanying drawings, in which:
Fig. 1 is a schematic representation, in perspective, of the conventional enamelled magnet wire manufacturing practice and is labelled "PRIOR ART"; and Fig. 2 is a schematic representation, in perspective, of the preferred embodiment of an installation in accordance with the present invention.
~ - 9 -Referring to Fig. 1, the PRIOR ART or conventional system for manufacturing rectangular magnet core comprises a rod shaving machine 10 into which continuous cast and rolled rod 11 is fed from 4500 kg coils 12. The shaving 5 operation produces a bright, clean surface rod 13 which is wound onto stems 14 for subsequent drawing. The drawing of the shaved rod 13 is carried out on a rod breakdown machine 15 where the shaved rod is drawn to a bare round wire 16 of desired size, which is wound on reels 17 for subsequent rolling.
The round wire 16 is then transferred to the rolling station and fed from reels 17 into a rolling mill 18 in which it is rolled to a wire 19 of predetermined rectangular size. The rolling operation is controlled by the control panel 20 and once the bare rectangular wire 19 of desired size is produced, it is wound onto reels 21 and stored for enamelling. The reels 21 are then transferred to the enamelling station 22 wherein the rectangular wire 19 is first fed into an annealer 23, then goes through a cooling zone 24 and then through the enamel oven 25 where the enamel coats are applied in a continuous process until the desired thickness of insulation is achieved. The produced enamelled magnet wire 26 is drawn by a capstan 27 and wound onto reels 28 which are shipped to the customer.
As is obvious from the above description, the conventional system comprises four distinct and separate operations, namely: (a) shaving; (b) drawing; (c) rolling;
and (d) enamelling.
B
The installation in accordance which the present invention is illustrated in Fig. 2 in which the rod shaving machine 30 is fed with rod 31 from coil 32 where it is shaved in a similar manner as in the conventional operation to form a shaved rod 33 with a bright, clean surface, which is wound onto stems 34 for subsequent drawing. The shaved rod is then drawn on a rod breakdown machine 35 to a bare round wire 36 of desired size and then, unlike the conventional process where 30" reels are used, the wire is coiled onto stems 37 for the in-line rolling and enamelling process. From stems 37 the round wire 36 is fed into the in-line rolling-enamelling system 38 comprising, in tandem, a rolling section 39 and an enamelling section 40. In the rolling section 39 the round wire 36 is rolled into a rectangular wire 41 which then passes through the annealer 42 where it is annealed prior to enamelling. Then the annealed wire is cooled in the cooling zone 43 and then passes through the enamel oven 44 where the enamel coats are applied until the desired thickness of insulation is achieved. Then the enamelled wire, which is drawn by enamel capstan 45, is wound on reels 46 which are shipped to the customer. The enamel capstan 45 controls the tension and the speed of the wire in the rolling - enamelling system 38 and a dancer arrangement is provided in the rolling section 39 for maint~i ni ng the required speed in said rolling section 39 relative to the speed of the enamelling section 40. Also there is provided a self-contained lubrication unit within the rolling section 39 to lubricate the wire being rolled.
This novel arrangement is particularly suitable for use with a "mini" rolling mill which has been designed for continuous operation periods of 12 months between maintenance services or roll changes. Such unit is modular and consists of two high powered mill stands 39a and 39b with a powered edger unit 47 between the mill stands. It is controlled by control panels 48. The drive of the mill is usually specifically sized for small reductions and is accurately co-ordinated, through a dancer arrangement, with the enamel machine capstan 45.
The method and installation in accordance with the present invention operate approximately 50% faster than conventional systems and eliminate approximately 20% of the manufacturing cost. As already discussed, losses caused by set-up, run to length and bare wire related quality problems are significantly reduced. However, the novel system may not produce very satisfactory results with wires of large width and/or thickness for which the conventional system may still be the best process.
It should be understood that this invention is not limited by the preferred embodiment described and illustrated herein and that obvious modifications or adaptations may readily be carried out by a person skilled in the art. The scope of the invention should, therefore, only be construed by reference to the appended claims.
'n -
Claims (10)
1. Method of manufacturing rectangular enamelled magnet wire, which comprises feeding a rod made of a suitable metal, such as copper, into a shaving machine and shaving the surface layer of the rod to produce a bright, clean surface suitable for subsequent enamelling; coiling said shaved rod onto stems for drawing; drawing the shaved stems to predetermined size of round, bare magnet wire and coiling the same onto stems; rolling the round, bare magnet wire to form a rectangular bare, magnet wire of predetermined size; and enamelling said rectangular magnet wire by annealing the same, then cooling and then passing through an enamel oven where the enamel coats are applied until a predetermined thickness of insulation is achieved, the method being characterized in that the rolling and enamelling are carried out in-line, as a single, continuous operation.
2. Method according to claim 1, in which the speed of the in-line rolling-enamelling operation is controlled by the speed of enamelling and the rolling speed is adjusted accordingly.
3. Method according the claim 1, in which the in-line rolling-enamelling operation includes a self-contained lubrication of the wire as it is being rolled.
4. Installation for manufacturing rectangular enamelled magnet wire, comprising: a shaving machine for shaving the surface of a rod made of a suitable metal, such as copper, which is fed into said machine to produce a bright, clean surface; a rod breakdown machine for drawing the shaved rod to a predetermined round bare magnet wire; and an in-line rolling and enamelling system for transforming the round, bare magnet wire into a magnet wire of predetermined rectangular shape and enamelling the same in a single continuous operation.
5. Installation according to claim 4, in which the in-line rolling and enamelling system comprises a rolling section and an enamelling section operating in tandem with one another.
6. Installation according to claim 5, in which the enamelling section comprises an annealer, followed by a cooling zone and followed by an enamel oven and an enamel capstan pulling the wire through the system.
7. Installation according to claim 6, in which a dancer arrangement is provided within the rolling section for controlling the speed of the rolling section relative to the speed of the enamelling section which is controlled by the enamel capstan which also provides a constant and controlled tension.
8. Installation according to claim 7, further comprising a self-contained lubrication unit within the rolling section.
9. Installation according to claim 5, wherein the rolling section comprises a set of mill rolls for achieving a particular surface finish, designed to produce predetermined shaped wire for enamel application.
10. In an installation for manufacturing rectangular enamelled magnet wire, an in-line rolling and enamelling system for transforming round, bare magnet wire supplied thereto into a magnet wire of predetermined rectangular shape in a rolling section of the system, and enamelling said rectangular wire in a single, continuous operation within an enamelling section of the system positioned in tandem to the rolling section.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2081593 CA2081593C (en) | 1992-10-28 | 1992-10-28 | Method and installation for manufacturing rectangular enamelled magnet wire with in-line rolling and enamelling |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2081593 CA2081593C (en) | 1992-10-28 | 1992-10-28 | Method and installation for manufacturing rectangular enamelled magnet wire with in-line rolling and enamelling |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2081593A1 CA2081593A1 (en) | 1994-04-29 |
| CA2081593C true CA2081593C (en) | 1998-12-29 |
Family
ID=4150607
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2081593 Expired - Fee Related CA2081593C (en) | 1992-10-28 | 1992-10-28 | Method and installation for manufacturing rectangular enamelled magnet wire with in-line rolling and enamelling |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2081593C (en) |
Families Citing this family (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2824004B1 (en) * | 2001-04-30 | 2003-05-30 | Valeo Equip Electr Moteur | METHOD FOR MANUFACTURING AN ELECTRICALLY CONDUCTIVE WIRE AND DEVICE FOR CARRYING OUT SUCH A METHOD |
| CN101831818B (en) * | 2010-05-25 | 2012-04-04 | 玉溪玉杯金属制品有限公司 | Stress relieving device |
| CN104889293B (en) * | 2015-06-10 | 2017-10-27 | 天津市安博尔金属制品有限公司 | A kind of cleaning ball flat filament forming machine |
| ITUA20162162A1 (en) * | 2016-03-31 | 2017-10-01 | New Tech Srl | METHOD AND PLANT FOR THE ENAMELLING OF METAL CABLES. |
| CN108922695B (en) * | 2018-08-22 | 2024-01-26 | 格力电工（马鞍山）有限公司 | Enameled wire stop lever operating device, working method thereof and enamelling machine |
| CN109102966B (en) * | 2018-08-28 | 2024-04-02 | 无锡巨一同创科技股份有限公司 | Painting device |
| CN110743930A (en) * | 2019-09-24 | 2020-02-04 | 惠州市海韵电子有限公司 | Square wire conductor forming method |
| CN111081430B (en) * | 2019-12-31 | 2021-07-16 | 红旗集团江西铜业有限公司 | Integral type automated control package lacquer equipment |
| CN112620386A (en) * | 2020-11-25 | 2021-04-09 | 浙江三行电气科技有限公司 | Production process of enameled wire |
| CN112872084B (en) * | 2020-12-25 | 2022-01-25 | 松田电工（台山）有限公司 | Enameled wire drawing production method without special flat wire die |
| CN113470894B (en) * | 2021-06-30 | 2023-05-23 | 芜湖铜冠电工有限公司 | Take-up equipment for enameled wire production |
-
1992
- 1992-10-28 CA CA 2081593 patent/CA2081593C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2081593A1 (en) | 1994-04-29 |
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