CN114464375B - Manufacturing method for improving limit bending of FLR6Y of automobile wire - Google Patents
Manufacturing method for improving limit bending of FLR6Y of automobile wire Download PDFInfo
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- CN114464375B CN114464375B CN202210080817.9A CN202210080817A CN114464375B CN 114464375 B CN114464375 B CN 114464375B CN 202210080817 A CN202210080817 A CN 202210080817A CN 114464375 B CN114464375 B CN 114464375B
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- 238000005452 bending Methods 0.000 title claims abstract description 24
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 16
- 238000009413 insulation Methods 0.000 claims abstract description 48
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 29
- 238000001125 extrusion Methods 0.000 claims abstract description 25
- 239000004020 conductor Substances 0.000 claims abstract description 22
- 229910052802 copper Inorganic materials 0.000 claims abstract description 16
- 239000010949 copper Substances 0.000 claims abstract description 16
- 239000011265 semifinished product Substances 0.000 claims abstract description 12
- 238000003860 storage Methods 0.000 claims abstract description 10
- 238000007599 discharging Methods 0.000 claims abstract description 4
- 238000003475 lamination Methods 0.000 claims abstract description 4
- 238000004804 winding Methods 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 4
- 239000004809 Teflon Substances 0.000 claims description 3
- 229920006362 Teflon® Polymers 0.000 claims description 3
- 238000005336 cracking Methods 0.000 abstract description 7
- 239000013078 crystal Substances 0.000 description 19
- 238000000034 method Methods 0.000 description 15
- 238000012360 testing method Methods 0.000 description 12
- 238000002425 crystallisation Methods 0.000 description 11
- 230000008025 crystallization Effects 0.000 description 11
- 230000008569 process Effects 0.000 description 11
- 238000009826 distribution Methods 0.000 description 6
- 238000013461 design Methods 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 230000006911 nucleation Effects 0.000 description 3
- 238000010899 nucleation Methods 0.000 description 3
- 230000035882 stress Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 206010063385 Intellectualisation Diseases 0.000 description 1
- 239000012267 brine Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000006353 environmental stress Effects 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 229920002379 silicone rubber Polymers 0.000 description 1
- HPALAKNZSZLMCH-UHFFFAOYSA-M sodium;chloride;hydrate Chemical compound O.[Na+].[Cl-] HPALAKNZSZLMCH-UHFFFAOYSA-M 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000012795 verification Methods 0.000 description 1
Classifications
-
- 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
- H01B13/14—Insulating conductors or cables by extrusion
- H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
-
- 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
-
- 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
- H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
-
- 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
- H01B13/14—Insulating conductors or cables by extrusion
- H01B13/145—Pretreatment or after-treatment
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Wire Processing (AREA)
Abstract
The invention discloses a manufacturing method for improving the limit bending of an automobile lead FLR6Y, which comprises the following steps: paying off the coiled copper stranded wires through a copper wire conductor paying-off frame and a straightener; carrying out preheating treatment on the copper wire; performing primary insulation extrusion molding on the copper wire, wherein the insulation extrusion radius is smaller than that of a finished wire; measuring the semi-finished product after the semi-finished product passes through an air cooler; the semi-finished wire is pulled to a wire storage frame by a tractor; detecting semi-finished wires; detecting the smoothness of the semi-finished product wire, counting by a meter counter, and then taking up the wire by a take-up frame; the coiled semi-finished wire is processed in the step 1 and the step 2; performing secondary insulation extrusion molding on the semi-finished wire through an insulation extruder, and performing insulation lamination on an insulation extruded insulation layer and the semi-finished wire to obtain the radius of the finished wire; and (5) repeating the steps 4-7, and discharging. Can effectively improve the bending degree of the automobile lead FLR6Y, strengthen the toughness and prevent cracking.
Description
Technical Field
The invention relates to the field of automobile wires, in particular to a manufacturing method for improving the limit bending of an automobile wire FLR 6Y.
Background
With the development of the intellectualization of automobiles, the automobile electronic control auxiliary device is popularized, new requirements are put on the design and wiring of the wire harness, due to the arrangement of space and electric appliance parts, the bending or reverse phenomenon inevitably exists in the trend of part of the wire harness branches, the minimum wiring radius of the wiring is considered in the design, but the bending radius is smaller than a specified value due to errors in the processing and assembling processes, and partial cracking is caused due to stress concentration.
The bend radius of the automotive wire FLR6Y is affected by the wire harness routing design and assembly process bias in addition to its own requirements (2 x dmax). If the bending radius exceeds the limit bending radius, bending stress exists, so that the insulating skin is excessively stretched, the insulating skin is broken, the phenomenon of copper exposure exists, great hidden danger is caused, and burn-in is seriously caused. In the production process of FLR6Y, the insulation layer is heated differently in two stages of extrusion and cooling, so that the internal temperature distribution in the insulation layer is uneven (more obvious for the very thin automobile wire with the insulation layer), the temperature in the insulation layer is uneven, the distribution of the final crystal form of FEP is influenced, and the crystal form distribution in the insulation layer is uneven. Since crystallization occurs inside the insulating layer, it is difficult to monitor on-line, and at present only the effect of improving the process on the crystalline morphology of the insulating layer can be qualitatively discussed.
In the production process of the cable, the temperature affects nucleation and growth in the crystallization process because of melting and crystallization, and the different distribution of the temperature affects the crystallization form, so that the crystallization form in the insulating layer is affected by the two aspects, and the influence of the temperature on the crystallization form is dominant.
According to the theory of crystallization kinetics, the crystalline polymer can be crystallized at any temperature between the glass transition temperature and the melting point, the crystallization process of the polymer melt comprises two stages of crystal nucleus formation and crystal material growth, and when the temperature is higher, the molecular thermal motion is more severe, so that the formation of crystal nucleus is not facilitated; the lower temperature reduces the mobility of the segment, which, while favors crystal formation, does not favor crystal growth. During crystallization, on the one hand, crystals that have formed are growing; on the other hand, new nuclei are grown, so that the temperature affects the crystal morphology and the size of spherulites. When the temperature is high, the nucleation speed is low, the number of generated crystal nuclei in unit volume is small, and the spherulites can grow very large; when the temperature is low, the nucleation speed is high, and the number of generated crystal nuclei in unit volume is large, so that crystals can only grow smaller.
The traditional automobile wire is usually produced by one-step molding, the insulating layer is basically not crystallized in the extrusion stage, the crystallization state is different in the cooling different process stages, and the temperature of the insulating surface is lower and is in a low-temperature region during cooling, so that the number of crystal materials generated in unit volume is less, the crystals are small, the size distribution is uneven, and the growth is imperfect. And the large crystal has poor environmental stress cracking resistance, and when the wire is bent, the stress is generated, so that the insulating property is reduced to generate a cracking phenomenon.
In the published document CN200910092123, a method for manufacturing a wire and a cable for an automobile, which is made of a bare copper conductor and is made of silicon rubber, the method is also a method for extruding an insulating layer from bare copper, but a method of extruding once is adopted in the process of extruding, and when the wire and the cable are used, a fracture phenomenon is easily generated in the process of bending.
Disclosure of Invention
In order to solve the problems, the invention discloses a manufacturing method for improving the limit bending of an automobile wire FLR6Y, which can effectively improve the bending degree of the automobile wire FLR6Y, strengthen the toughness of the automobile wire FLR6Y and prevent cracking.
The technical scheme of the invention is as follows: a method of manufacturing an improved flex circuit FLR6Y limit for automotive wire, comprising the steps of:
step 1: paying off the coiled copper stranded wires through a copper wire conductor pay-off rack, and leading the copper stranded wires out of the copper wire conductor pay-off rack to a straightener for paying off;
step 2: the copper wires are led out from the straightener in the step 1 and are subjected to preheating treatment through a conductor preheater;
step 3: after preheating in the step 2, carrying out primary insulation extrusion molding on the copper stranded wire through an insulation extruder, wherein the radius of insulation extrusion is 0.18-0.21mm smaller than that of the finished wire;
step 4: after the semi-finished product subjected to primary insulation extrusion molding passes through an air cooler, measuring the diameter of the semi-finished product by a primary laser diameter measuring instrument;
step 5: the semi-finished wire led out from the primary laser diameter measuring instrument is led to a wire storage frame by a tractor for storing the wire;
step 6: the semi-finished wire is led out from the wire storage frame to a spark machine, the coverage degree of an insulating layer on the semi-finished wire is detected, and then the semi-finished wire is led into a secondary laser calliper;
step 7: the semi-finished product wire is led out from the secondary laser diameter measuring instrument to the concave-convex instrument for detecting the smoothness, and finally is wound up by the winding frame after being counted by the meter counter;
step 8: the coiled semi-finished wire is processed in the step 1 and the step 2;
step 9; performing secondary insulation extrusion molding on the semi-finished wire through an insulation extruder, and performing insulation lamination on an insulation extruded insulation layer and the semi-finished wire to obtain the radius of the finished wire;
step 10: and (5) repeating the steps 4-7, and discharging.
Further, the heating temperature of the conductor preheater is 60-80 ℃.
Further, the copper wire conductor pay-off rack, the straightener, the conductor preheater, the insulating extruder, the primary laser diameter measuring instrument, the tractor, the wire storage rack, the spark machine, the secondary laser diameter measuring instrument, the concave-convex instrument, the meter and the wire collecting rack are sequentially arranged in a straight line.
Further, the insulating layer is teflon.
Further, the wires in step 4 are cooled to normal temperature by an air cooler.
Further, in the step 6, the section of the spark machine to the wire is less than or equal to 0.5mm 2 Is applied with a voltage of 3000V to a conductor with a cross section of > 0.5mm 2 Is applied with a voltage of 5000V.
Further, in step 8, the semi-finished wire is heated by a heater after exiting the straightener and then passed through an insulating extruder.
Further, the receiving temperature of the heater is 340-360 ℃.
The invention has the advantages that: according to the invention, the radius of the finished product is smaller in the first extrusion than that of the finished product in the second extrusion, the radius of the finished product is reached after the second extrusion, after the first extrusion of the lead FLR6Y is finished, the first insulation layer on the surface of the copper wire is thinned relative to the previous insulation layer, the internal crystal nuclei grow uniformly due to space reduction, the quantity is more, the crystal nuclei are smaller in volume, and the insulation layer extruded for the first time is preheated when the second extrusion is carried out, so that the insulation layer extruded for the first time can be completely fused with the insulation layer extruded for the second time in the process from a molten state to a solid state after the extrusion of the insulation layer is finished for the second time, layering is prevented, and the insulation layer extruded for the first time can be uniformly distributed due to the internal crystal nuclei, the quantity of the growth is more, the diameter is smaller, the toughness is better, and strong supporting force can be provided for the insulation layer extruded for the second time.
Drawings
FIG. 1 is a flow chart of a first extrusion semi-finished product of the present invention;
FIG. 2 is a flow chart of a second extrusion of the finished product of the present invention;
FIG. 3 is a winding schematic of the present invention;
FIG. 4 is a schematic view of the winding of the present invention prior to modification;
FIG. 5 is a schematic diagram of the test results before improvement according to the present invention.
Detailed Description
In order to enhance the understanding of the present invention, the following detailed description of the invention will be given by way of example only and is not intended to limit the scope of the invention.
As shown in fig. 1 to 5, the manufacturing method for improving the limit bending of the wire FLR6Y of the automobile comprises the steps of:
step 1: paying off the coiled copper stranded wires through a copper wire conductor pay-off rack, and leading the copper stranded wires out of the copper wire conductor pay-off rack to a straightener for paying off;
step 2: the copper wires are led out from the straightener in the step 1 and are subjected to preheating treatment by a conductor preheater, and the heating temperature of the conductor preheater is 70 ℃;
step 3: after preheating in the step 2, carrying out primary insulation extrusion molding on the copper stranded wire through an insulation extruder, wherein the radius of insulation extrusion is 0.2mm smaller than that of a finished wire, and the insulation layer is teflon;
step 4: the semi-finished product of the first insulating extrusion molding is subjected to diameter measurement by a primary laser diameter measuring instrument after passing through an air cooler to normal temperature;
step 5: the semi-finished wire led out from the primary laser diameter measuring instrument is led to a wire storage frame by a tractor for storing the wire;
step 6: the semi-finished wire is led out from the wire storage frame to a spark machine, the coverage degree of an insulating layer on the semi-finished wire is detected, and then the semi-finished wire is led into a secondary laser calliper;
step 7: the semi-finished product wire is led out from the secondary laser diameter measuring instrument to the concave-convex instrument for detecting the smoothness, and finally is wound up by the winding frame after being counted by the meter counter;
step 8: the coiled semi-finished wire is processed in the step 1 and the step 2, the semi-finished wire is heated by a heater after coming out of the straightener, and then the semi-finished wire is processed by an insulating extruder, wherein the receiving temperature of the heater is 350 ℃;
step 9; performing secondary insulation extrusion molding on the semi-finished wire through an insulation extruder, and performing insulation lamination on an insulation extruded insulation layer and the semi-finished wire to obtain the radius of the finished wire;
step 10: and (5) repeating the steps 4-7, and discharging.
The copper wire conductor pay-off rack, the straightener, the conductor preheater, the insulating extruder, the primary laser diameter measuring instrument, the tractor, the wire storage rack, the spark machine, the secondary laser diameter measuring instrument, the concave-convex instrument, the meter and the wire collecting rack are sequentially arranged in a straight line.
In FLR6Y automotive wire routing, the minimum bend radius is less than or equal to 2 dmax, and for example, the minimum bend radius is 3.2MM, and in certain automotive type headlight harness designs, reverse routing (bend radius in broken harness is only 1.0 MM) exists and heat shrink tube processing (temperature of about 225 ℃) is performed at high temperature. Establishing a simulated limit bending test: the natural state of the wire is processed at 225+5 ℃ and 3H; after cooling for 16H, the 2MM mandrel is wound for more than 6 circles, 225+5 ℃,3H is cooled, and then brine pressure resistance is carried out for 5KV and 1MIN, so that no breakdown occurs. The winding diagram is as in fig. 1:
securing the stripped end (see example in the figures). However, L1 must be > 60 mm, L2 > 10 mm.
Before improvement: feedback problematic FLR6Y0.5 wire simulated bending test: two test pieces of sufficient length (about 2 m) at least 1m apart from each other were extracted. The limit bending test was performed with 6 samples and 1 crack was present. As in fig. 2 and 3:
after improvement (naming +ss): FLR6Y-SS 0.5 wire was also used for the simulated bending test: two test pieces of sufficient length (about 2 m) at least 1m apart from each other were extracted. The test was carried out according to the ultimate bending test, 6 samples were free from cracking phenomenon, and the pressure resistance test was passed.
Repeatability verification no cracking was found for all 12 consecutive batches and the pressure resistance test was passed.
Conclusion: from qualitative testing and customer installation feedback, the crystallization effect of the process to improve insulation is consistent with actually reducing the bend radius of the wire. Therefore, in the actual production process, the temperature distribution in the FEP can be utilized by the selected process parameters, so that the crystal form in the insulating layer is improved, and the ultimate bending radius of the cable is improved.
Claims (5)
1. A method of manufacturing an improved flex circuit FLR6Y limit for automotive wire, comprising the steps of:
step 1: paying off the coiled copper stranded wires through a copper wire conductor pay-off rack, and leading the copper stranded wires out of the copper wire conductor pay-off rack to a straightener for paying off;
step 2: the copper wires are led out from the straightener in the step 1 and are subjected to preheating treatment by a conductor preheater, and the heating temperature of the conductor preheater is 60-80 ℃;
step 3: after preheating in the step 2, carrying out primary insulation extrusion molding on the copper stranded wire through an insulation extruder, wherein the radius of insulation extrusion is 0.18-0.21mm smaller than that of the finished wire;
step 4: after the semi-finished product subjected to primary insulation extrusion molding passes through an air cooler, measuring the diameter of the semi-finished product by a primary laser diameter measuring instrument;
step 5: the semi-finished wire led out from the primary laser diameter measuring instrument is led to a wire storage frame by a tractor for storing the wire;
step 6: the semi-finished wire is led out from the wire storage frame to a spark machine, the coverage degree of an insulating layer on the semi-finished wire is detected, and then the semi-finished wire is led into a secondary laser calliper;
step 7: the semi-finished product wire is led out from the secondary laser diameter measuring instrument to the concave-convex instrument for detecting the smoothness, and finally is wound up by the winding frame after being counted by the meter counter;
step 8: the coiled semi-finished wire is processed in the step 1 and the step 2, the semi-finished wire is heated by a heater after coming out of the straightener, and then the semi-finished wire is processed by an insulating extruder, wherein the heating temperature of the heater is 340-360 ℃;
step 9; performing secondary insulation extrusion molding on the semi-finished wire through an insulation extruder, and performing insulation lamination on an insulation extruded insulation layer and the semi-finished wire to obtain the radius of the finished wire;
step 10: and (5) repeating the steps 4-7, and discharging.
2. The manufacturing method for improving the limit bending of the automobile wire FLR6Y according to claim 1, wherein: the copper wire conductor pay-off rack, the straightener, the conductor preheater, the insulating extruder, the primary laser diameter measuring instrument, the tractor, the wire storage rack, the spark machine, the secondary laser diameter measuring instrument, the concave-convex instrument, the meter and the wire collecting rack are sequentially arranged in a straight line.
3. The manufacturing method for improving the limit bending of the automobile wire FLR6Y according to claim 1, wherein: the insulating layer is teflon.
4. The manufacturing method for improving the limit bending of the automobile wire FLR6Y according to claim 1, wherein: and (3) cooling the lead wires in the step (4) to normal temperature through an air cooler.
5. The manufacturing method for improving the limit bending of the automobile wire FLR6Y according to claim 1, wherein: the section of the spark machine to the wire in the step 6 is less than or equal to 0.5mm 2 Is applied with a voltage of 3000V to a conductor with a cross section of > 0.5mm 2 Is applied with a voltage of 5000V.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210080817.9A CN114464375B (en) | 2022-01-24 | 2022-01-24 | Manufacturing method for improving limit bending of FLR6Y of automobile wire |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210080817.9A CN114464375B (en) | 2022-01-24 | 2022-01-24 | Manufacturing method for improving limit bending of FLR6Y of automobile wire |
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| Publication Number | Publication Date |
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| CN114464375A CN114464375A (en) | 2022-05-10 |
| CN114464375B true CN114464375B (en) | 2024-01-26 |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4247504A (en) * | 1976-10-18 | 1981-01-27 | Oy Nokia Ab | Method of manufacturing plastic covered highvoltage cables |
| CN103730210A (en) * | 2012-10-13 | 2014-04-16 | 富阳优恒电缆有限公司 | Production method for three-layer co-extrusion insulating cable and production system used in production method |
| CN104795178A (en) * | 2014-10-11 | 2015-07-22 | 安徽明星电缆有限公司 | Preparation technology for rail transit vehicle cable |
| CN208722641U (en) * | 2018-10-17 | 2019-04-09 | 上海科辰光电线缆设备有限公司 | A kind of photovoltaic cable making apparatus |
-
2022
- 2022-01-24 CN CN202210080817.9A patent/CN114464375B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4247504A (en) * | 1976-10-18 | 1981-01-27 | Oy Nokia Ab | Method of manufacturing plastic covered highvoltage cables |
| CN103730210A (en) * | 2012-10-13 | 2014-04-16 | 富阳优恒电缆有限公司 | Production method for three-layer co-extrusion insulating cable and production system used in production method |
| CN104795178A (en) * | 2014-10-11 | 2015-07-22 | 安徽明星电缆有限公司 | Preparation technology for rail transit vehicle cable |
| CN208722641U (en) * | 2018-10-17 | 2019-04-09 | 上海科辰光电线缆设备有限公司 | A kind of photovoltaic cable making apparatus |
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| CN114464375A (en) | 2022-05-10 |
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