What is the working principle of High-Precision Micro Flat Wire Rolling Mill

      The core principle of High-Precision Micro Flat Wire Rolling Mill is to use multi pass, extremely small roll gap, closed-loop measurement and control cold rolling to gradually press round wire (or square wire) into ultra-thin, ultra narrow, precision rectangular/flat wire with a tolerance of ± 0.001~± 0.005 mm, without mold throughout the process, and directly shaped by the rolling mill.

1、 Core working principle (in one sentence)

Round line → Multi pass precision roller extrusion → Step by step thinning, width control, edge trimming → Online size closed-loop → Tension stable speed → Wire winding, essentially cold rolling plastic deformation, only changing shape, without adding materials or cutting.

2、 Complete process disassembly (from feed to finished product)

1. Wire laying → straightening → constant tension feeding

Active wire release+servo tension control (± 1% fluctuation) to avoid stretching deformation.

Multi roll straightening eliminates internal stress and ensures straightness ≤ 0.5 mm/m.

The incoming wires are mostly round wires with a diameter of 0.5 to 3 mm (copper, aluminum, stainless steel, alloy).

2. Multi pass precision rolling (core deformation zone)

Roll configuration: A pair (or two pairs) of tungsten steel/hard alloy rolls, with a small roll diameter (usually ranging from Φ 20 to Φ 60 mm) and extremely high rigidity.

Roll gap control: servo motor+micrometer level ball screw, adjustable roll gap accuracy of 0.1 μ m, long-term stability after locking.

Multi pass progressive: Generally 4-12 passes, each pass is only thinned by 5% -15% to prevent breakage and ensure tissue uniformity.

Deformation mechanism:

Thickness: Thinning by upper and lower rollers (e.g. 0.5 mm → 0.1 mm).

Width: The metal expands horizontally and is precisely controlled by the roller shape (micro convex/micro concave).

Edge: Roll R-corner trimming, without burrs or sharp edges.

Typical dimensions after rolling: thickness 0.02-1 mm, width 0.1-6 mm, tolerance * * ± 0.001 to ± 0.005 mm * *.

3. Online real-time detection → closed-loop correction (key to high precision)

Laser diameter/thickness measurement: hundreds of samples per second, accuracy * * ± 0.1 μ m * *.

CCD vision: monitors width, edges, and surface defects.

PLC closed-loop: When the thickness/width exceeds the tolerance, it automatically adjusts the roll gap/speed/tension without stopping the machine.

4. Rear tension → finishing → winding

Tension buffering+traction servo ensures stable wire speed (up to 150-600 m/min).

Optional online annealing, cleaning, oil coating, and insulation coating.

Precise winding, neat layer winding, no collapse or stretching.

3、 Core Structure and Function

Main frame: cast iron/steel plate welding, high rigidity, low vibration, ensuring micrometer level stability.

Roller assembly: upper and lower rollers+bearings+adjustment mechanism, tungsten steel roller surface, mirror polished, wear-resistant, non stick material.

Servo control system: driving roller gap, speed, tension, fast response, high repeatability accuracy.

Online detection station: laser+CCD, real-time monitoring, closed-loop correction.

Tension system: synchronized tension throughout the entire line to prevent stretching, breakage, and dimensional fluctuations.

4、 Key technical features (why 'high precision')

Mold free rolling: formed directly by rolling rolls to avoid tolerance drift caused by mold wear.

Minimal deformation/pass: Each pass reduces thickness by ≤ 15%, with uniform grain size, no cracks, and consistent strength.

Micro level roll gap control: servo+ball screw, 0.1 μ m level adjustment.

Full process closed-loop measurement and control: automatic correction of size deviations, good batch consistency.

High rigidity+low vibration: thick frame+precision bearings, stable at high speeds.

5、 Typical application scenarios

New energy motor flat wire: Hairpin flat copper wire, thickness 0.3-1 mm, width 2-6 mm, tolerance ± 0.005 mm.

Precision electronic flat wire: ultra-thin/ultra narrow flat wire (thickness 0.02-0.2mm) for sensors, micro motors, and medical equipment.

Spring/elastic element: spring, contact, spring plate, with a smooth surface and no burrs on the edges.

Heat exchange micro flat tube: Micro B-type tube/flat tube for heater core and radiator, with uniform wall thickness and high pressure resistance.