Self-adaptive tension pay-off system for wire twisting, cabling or extrusion process
By using an adaptive tension pay-off system, the jerking sensation is eliminated through a purely mechanical linkage structure, achieving smooth and stepless adjustment of the tension adjustment process. This reduces system cost and failure rate, adapts to load changes, and solves the problems of strong jerking sensation and uneven adjustment in existing mechanical solutions.
Patent Information
- Application Number
- CN202511273979.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-08
- Publication Date
- 2025-11-04
AI Technical Summary
Existing mechanical tensioning devices suffer from problems such as strong jerking and uneven adjustment, which affect the quality of the wire. Furthermore, while purely mechanical solutions are low in cost, they are easily affected by environmental interference.
The system employs an adaptive tension pay-off system, which includes a pay-off reel, torque transmission shaft, force feedback torque control unit, lever arm, swing arm, cable guide wheel, and tension feedback transmission system. Through a purely mechanical linkage structure, tension adjustment is achieved, eliminating jerking sensations and realizing smooth, stepless adjustment.
It achieves zero-step, shock-free tension adjustment, reduces system cost and failure rate, and adapts to load changes through fully mechanical feedback closed-loop control, maintaining real-time matching between tension and load.
Smart Images
Figure CN120887286A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application belongs to the field of cable tension control. BACKGROUND
[0002] In the production of cable stranding, cabling or extrusion process, stable pay-off tension is crucial to ensure product quality. The existing tension pay-off scheme mainly has two problems:
[0003] Electrical control scheme (sensor + controller): Although the adjustment is smooth, it relies on sensors, controllers and other electronic devices, resulting in complex system, high cost and easy to be disturbed by environment, difficult to maintain.
[0004] Pure mechanical scheme: simple structure, low cost, high reliability. However, its adjustment action usually shows mutation, step or obvious hysteresis, resulting in violent tension fluctuation and "jerky feeling"; such tension mutation will be directly transmitted to the wire, and the tension adjustment process has significant jerky feeling, and the response is lagging or sudden when the speed or reel diameter changes, which is easy to cause wire shaking and damage, affecting product quality.
[0005] Therefore, there is an urgent need for a self-adaptive tension pay-off device that can maintain the advantages of low cost and high reliability of pure mechanical structure, and overcome the disadvantages of strong jerky feeling and uneven adjustment of existing mechanical scheme. SUMMARY
[0006] The purpose of the present application is to overcome the shortcomings of the prior art, and to provide a self-adaptive tension pay-off system for stranding, cabling or extrusion process, which overcomes the problems of strong jerky feeling and uneven adjustment of existing mechanical scheme.
[0007] Technical scheme: In order to achieve the above purpose, the self-adaptive tension pay-off system for stranding, cabling or extrusion process of the present application comprises a pay-off reel, a torque transmission shaft, a force feedback type torque control unit, a lever arm, a swing arm, a line cable guide wheel a, a line cable guide wheel b, a line cable guide wheel c and a tension feedback transmission system.
[0008] The pay-off reel is connected to one end of the torque transmission shaft in the transverse direction, and the force feedback type torque control unit is connected to the other end of the torque transmission shaft and cooperates with the force transmission; the lever arm is above the torque transmission shaft, and the middle segment of the lever arm is rotatably installed on the lever support through the lever shaft.
[0009] The a line cable guide wheel and the b line cable guide wheel are respectively at both ends of the lever arm; the swing arm is above the lever arm, the c line cable guide wheel is rotatably installed at the upper end of the swing arm, and the lower end of the swing arm is connected to the force feedback type torque control unit through the tension feedback transmission system; the swing action of the swing arm is transmitted to the force feedback type torque control unit through the tension feedback transmission system, so as to change the torque transmitted by the force feedback type torque control unit to the torque transmission shaft.
[0010] Further, the cable from the pay-off reel passes over the upper side of the a cable guide, the lower side of the b cable guide and the upper side of the c cable guide in sequence; the section of the cable between the pay-off reel and the a cable guide is referred to as the first cable lead-out section, the section of the cable between the a cable guide and the b cable guide is referred to as the second cable lead-out section, the section of the cable between the b cable guide and the c cable guide is referred to as the third cable lead-out section, and the section of the cable finally led out from the c cable guide is referred to as the final cable lead-out section.
[0011] Further, the tension feedback transmission system comprises a follow-up gear, a special-shaped drive gear, a rack, a tension spring, a linkage wire and a rack guide structure.
[0012] The follow-up gear is rotatably mounted on a section of the lever arm between the lever shaft and the b cable guide by a gear shaft, the rack is obliquely engaged with the side of the follow-up gear close to the lever shaft, and the rack can only displace along its own axis direction under the guidance of the rack guide structure; the tension spring pulls the upper end of the rack along the length direction, and the other end of the tension spring is connected to the tension spring seat.
[0013] The special-shaped drive gear is rotatably mounted on the fixed shaft by a bearing; the lower end of the swing arm is fixedly connected to the upper end of the outer periphery of the special-shaped drive gear; the outer periphery of the special-shaped drive gear has a profiled curved surface gradually away from the axis of the fixed shaft in the clockwise direction, the profiled curved surface has a plurality of transmission teeth bodies equidistantly arrayed along the curved surface path, the transmission teeth body at the lower end of the special-shaped drive gear is engaged with the follow-up gear; the upper end of the vertically extending linkage wire is fixedly connected to the connecting seat at the end of the lever arm close to the b cable guide, and the lower end of the linkage wire is linked to the force feedback type torque control unit.
[0014] Further, the two sides of the swing direction of the swing arm are respectively provided with a first limiting column and a second limiting column; the first limiting column and the second limiting column are both fixed parts; when the tension of the final cable lead-out section is zero, the swing arm is limited to abut against the first limiting column.
[0015] Furthermore, the force feedback torque control unit includes a friction wheel, an arc-shaped friction plate, a friction plate support, a floating bar, and a fixed arm. The friction wheel is coaxially fixed to the end of the torque transmission shaft. The friction plate support is located on the upper side of the friction wheel. The inner arc surface of the arc-shaped friction plate slides and frictionally engages with the lower end of the friction wheel surface. Both ends of the upper part of the arc-shaped friction plate are fixedly connected to the friction plate support. The floating bar is located between the friction plate support and the fixed arm. The fixed arm is a fixed component. A pair of upwardly extending guide rods are fixedly connected to the upper side of the friction plate support. The floating bar has guide holes at both ends for the guide rods to move through. A pair of ball bearing guide cylinders are fixedly installed on the fixed arm. The upper end of the guide rods moves through the two ball bearing guide cylinders. Spring A is sleeved on the guide rod between the floating bar and the friction plate support, and spring B is sleeved on the guide rod between the fixed arm and the floating bar. The fixed arm has a hole through which the linkage wire passes. The lower end of the linkage wire passes downward through the linkage wire hole and is fixedly connected to the floating bar. In the initial state, the linkage wire is taut and exerts an upward pulling force on the floating bar. The upper end of spring A is fixedly connected to the floating bar, and the lower end of spring A exerts an upward pulling force on the friction plate support, which is ultimately transmitted as pressure between the inner arc surface of the arc-shaped friction plate and the lower end of the friction wheel. The lower end of spring B exerts a downward pushing force on the floating bar. The floating bar remains in balance under the combined action of spring A, spring B, and the linkage wire.
[0016] Furthermore, when the equipment is running at a constant speed under normal tension, the swing arm is subjected to a resultant force F6 from the tension of the third cable lead-out section and the tension of the final lead-out section of the wire harness. Under the action of force F6, the swing arm swings downward around the fixed axis until it separates from the first limit post. Under the action of force F6, the irregular drive gear rotates counterclockwise, and then drives the follower gear to rotate clockwise under the action of meshing. The clockwise rotation of the follower gear drives the rack to move downward along the length direction under the action of meshing, thereby making the tension spring longer and the tension force F2 of the tension spring larger. When the tension force F2 of the tension spring increases to a certain extent, the tension of the tension spring is transmitted in the opposite direction to the irregular drive gear in the form of clockwise torque through the rack and the follower gear, which just completely resists the counterclockwise torque applied to the irregular drive gear by force F6, so that the swing arm returns to a stable state.
[0017] Furthermore, the tension F2 of the tension spring causes the lever arm 36 to tend to rotate clockwise around the lever axis;
[0018] The combined force F formed by the tension of the second cable lead-out section and the tension of the third cable lead-out section causes the lever arm to tend to rotate clockwise around the lever axis.
[0019] The combined force F5 formed by the tension of the first cable lead-out section and the tension of the second cable lead-out section causes the lever arm to tend to rotate clockwise around the lever axis.
[0020] The tension F4 exerted by the linkage on the lever arm causes the lever arm to tend to rotate counterclockwise around the lever axis;
[0021] The radial force F1 exerted by the irregularly shaped drive gear on the follower gear causes the lever arm to tend to rotate counterclockwise around the lever axis;
[0022] The lever arm remains balanced under the combined action of F1, F2, F3, F4, and F5.
[0023] Furthermore, the reaction force of the tension F4 of the linkage line is transmitted to the floating bar, so that the floating bar remains in balance under the combined action of spring a, spring b and linkage line. The lower end of spring a forms an upward tension on the friction plate support, which is then ultimately transmitted as the pressure F7 between the inner arc surface of the arc-shaped friction plate and the lower end wheel surface of the friction wheel.
[0024] Beneficial effects: This invention achieves smooth stepless tension adjustment. Through the cam-type transmission structure of the irregularly shaped drive gear, the input force F6 is converted into a smooth radial thrust F1, which drives the follower gear and lever arm to swing continuously, eliminating the jerking feeling of traditional mechanical devices and achieving zero step and no impact in the tension adjustment process.
[0025] Precision Damping Adaptive Control
[0026] The floating displacement of the lever arm → the extension and contraction of springs a and b are adjusted in conjunction with the lever arm → the clamping force F7 of the arc-shaped friction plate and the friction wheel is directly controlled → so that the sliding friction damping of the unwinding coil and the input force F6 are strictly maintained in a smooth transmission relationship, and the tension and load changes are matched in real time.
[0027] Fully mechanical feedback closed loop
[0028] Without the need for sensors or electronic control systems, the closed-loop control of "increased input force → smooth decrease in damping → smooth reduction in output tension" is achieved solely through a purely mechanical linkage structure, significantly reducing system cost and failure rate. Attached Figure Description
[0029] Figure 1 This is a schematic diagram of the overall structure of this solution;
[0030] Figure 2 This is the front view of this plan;
[0031] Figure 3 for Figure 2 An enlarged view of the mark at 80;
[0032] Figure 4 This is a schematic diagram of a force feedback torque control unit. Detailed Implementation
[0033] The invention will now be further described with reference to the accompanying drawings.
[0034] As attached Figures 1 to 4The adaptive tension pay-off system for stranding, cabling, or extrusion processes includes a pay-off reel 35, a torque transmission shaft 7, a force feedback torque control unit 34, a lever arm 36, a swing arm 31, a cable guide roller 37, b cable guide roller 33, c cable guide roller 52, and a tension feedback transmission system 80. The pay-off reel 35 is coaxially connected to one end of the transverse torque transmission shaft 7, which is rotatably mounted on several bearing seats 8 via bearings. The force feedback torque control unit 34 is located at the other end of the torque transmission shaft 7 and is engaged with it for force transmission. The lever arm 36 is located above the torque transmission shaft 7, and its middle section is rotatably mounted on a lever support via a lever shaft 24. On seat 23; cable guide rollers a and b are rotatably mounted at both ends of lever arm 36, with cable guide rollers a and b directly above wire reel 35 and force feedback torque control unit 34, respectively; swing arm 31 is on the upper side of lever arm 36, and cable guide roller c is rotatably mounted on the upper end of swing arm 31. The lower end of swing arm 31 is linked with force feedback torque control unit 34 through tension feedback transmission system 80. The swinging motion of swing arm 31 is transmitted to force feedback torque control unit 34 through tension feedback transmission system 80, thereby changing the magnitude of torque transmitted by force feedback torque control unit 34 to torque transmission shaft 7.
[0035] The cable leading from the cable reel 35 passes sequentially over the upper side of cable guide roller 37 (a), the lower side of cable guide roller 33 (b), and the upper side of cable guide roller 52 (c). The section of cable bundle between the cable reel 35 and cable guide roller 37 (a) is designated as the first cable lead-out section 40a; the section of cable bundle between cable guide roller 37 (a) and cable guide roller 33 (b) is designated as the second cable lead-out section 40b; the section of cable bundle between cable guide roller 33 (b) and cable guide roller 52 (c) is designated as the third cable lead-out section 40c; and the final section of cable bundle leading from cable guide roller 52 (c) is designated as the final cable lead-out section 40d.
[0036] The tension feedback transmission system 80 includes a follower gear 18, a non-circular drive gear 17, a rack 21, a tension spring 26, a linkage line 14, and a rack guide structure. The follower gear 18 is rotatably mounted on a section of lever arm 36 between lever shaft 24 and cable guide wheel 33 via gear shaft 28. The oblique rack 21 meshes with the side of the follower gear 18 near lever shaft 24, and the rack 21 can only move along its own axis under the guidance of the rack guide structure. The tension spring 26 pulls the upper end of the rack 21 along its length, and the other end of the tension spring 26 is connected to the tension spring seat 27. The non-circular drive gear 17 is rotatably mounted on a fixed shaft 29 via bearings, and the fixed shaft 29 is fixed on a fixed arm 30. The lower end of the swing arm 31 is fixedly connected to the upper end of the outer circumference of the non-circular drive gear 17.
[0037] The outer peripheral surface of the irregular drive gear 17 has a contour surface 90 that gradually moves away from the axis of the fixed shaft 29 in a clockwise direction. The contour surface 90 has several transmission teeth 32 arranged equidistantly along the surface path. The transmission teeth 32 at the lower end of the irregular drive gear 17 mesh with the follower gear 18.
[0038] The upper end of the vertically extending linkage line 14 is fixedly connected to the connecting seat 50 of the lever arm 36 near the b cable guide wheel 33, and the lower end of the linkage line 14 is linked to the force feedback torque control unit 34; the swing arm 31 is provided with a first limiting post 39 and a second limiting post 38 on both sides of the swing direction; the first limiting post 39 and the second limiting post 38 are both fixed parts; when the tension of the final lead-out section 40d of the wire harness is zero, the swing arm 31 is limited to abutting against the first limiting post 39.
[0039] The rack guide structure includes a support arm 22 parallel to the rack 21. One end of the support arm 22 is fixed to the lever arm 36. At least two guide wheels 20 are rotatably mounted on the support arm 22. The back of the rack 21 has guide wheel grooves along the length direction. The two guide wheels 20 are engaged with the guide wheel grooves along the length direction on the back of the rack 21 to guide the rack 21.
[0040] like Figure 4 As shown, the force feedback torque control unit 34 includes a friction wheel 10, an arc-shaped friction plate 9, a friction plate support 4, a floating bar 12, and a fixed arm 13.
[0041] Friction wheel 10 is coaxially fixed to the end of torque transmission shaft 7. Friction plate support 4 is located on the upper side of friction wheel 10. The inner arc surface of arc-shaped friction plate 9 slides and rubs against the lower end of the friction wheel 10. Both ends of the upper part of arc-shaped friction plate 9 are fixedly connected to friction plate support 4. Floating bar 12 is located between friction plate support 4 and fixed arm 13, which is a fixed component. A pair of upwardly extending guide rods 1 are fixedly connected to the upper side of friction plate support 4. Both ends of floating bar 12 have guide holes 3 for the guide rods 1 to move through. A pair of ball guide cylinders 16 are fixedly installed on fixed arm 13. The upper end of the guide rod 1 moves through the two ball guide cylinders 16. A spring 5 is sleeved on the guide rod 1 between floating bar 12 and friction plate support 4. A guide rod 1 between the fixed arm 13 and the floating bar 12 is fitted with a spring 2 (b). The fixed arm 13 has a perforated hole 15 for the linkage line. The lower end of the linkage line 14 passes downward through the linkage line perforation hole 15 and is fixedly connected to the floating bar 12. In the initial state, the linkage line 14 is taut and exerts an upward pulling force on the floating bar 12. The upper end of the spring 5 (a) is fixedly connected to the floating bar 12, and the lower end of the spring 5 exerts an upward pulling force on the friction plate support 4, which is ultimately transmitted as pressure between the inner arc surface of the arc-shaped friction plate 9 and the lower end of the friction wheel 10. The lower end of the spring 2 (b) exerts a downward pushing force on the floating bar 12. The floating bar 12 remains in balance under the combined action of the spring 5 (a), the spring 2 (b), and the linkage line 14.
[0042] Under normal operating conditions, the tension F2 of the tension spring 26 causes the lever arm 36 to tend to rotate clockwise around the lever axis 24.
[0043] The combined force F3 formed by the tension of the second cable lead-out section 40b and the tension of the third cable lead-out section 40c causes the lever arm 36 to tend to rotate clockwise around the lever axis 24.
[0044] The combined force F5 formed by the tension of the first cable lead-out section 40a and the tension of the second cable lead-out section 40b causes the lever arm 36 to tend to rotate clockwise around the lever axis 24.
[0045] The tension F4 exerted by the linkage line 14 on the lever arm 36 causes the lever arm 36 to tend to rotate counterclockwise around the lever axis 24.
[0046] The radial force F1 of the irregular drive gear 17 on the follower gear 18 causes the lever arm 36 to tend to rotate counterclockwise around the lever axis 24.
[0047] Working principle:
[0048] When the equipment is not running: the tension of the final lead-out section 40d of the wire harness is approximately zero, thus making F3 / F5 / F6 all zero. The pulling force of the tension spring 26 on the rack 21 is transmitted to the irregular drive gear 17 through the follower gear 18, causing the irregular drive gear 17 to rotate clockwise. When F6 is zero, the swing arm 31 swings upward around the fixed shaft 29 until the swing arm 31 is limited to contact the first limit post 39, thus entering a stable state. At this time, the lever arm 36 remains balanced under the combined action of F1, F2, and F4.
[0049] When the equipment operates at a constant speed under normal tension, tension is generated in the first cable lead-out section 40a, the second cable lead-out section 40b, the third cable lead-out section 40c, and the final cable harness lead-out section 40d. Under this tension, the unwinding reel 35 rotates to unwind the cable. The force situation at this time is as follows: Figure 2 and 3 As shown.
[0050] The combined force F6 of the tension in the third cable lead-out section 40c and the final lead-out section 40d of the wire harness causes the swing arm 31 to swing downwards around the fixed axis 29 until it separates from the first limiting post 39. Figure 1 and 2As shown, the irregularly shaped drive gear 17 rotates counterclockwise under the action of force F6, and then drives the follower gear 18 to rotate clockwise under the action of meshing. The clockwise rotation of the follower gear 18 drives the rack 21 to move downward along its length under the action of meshing, thereby making the tension spring 26 longer and the tension force F2 of the tension spring 26 larger. When the tension force F2 of the tension spring 26 increases to a certain extent, the tension force of the tension spring 26 is transmitted to the irregularly shaped drive gear 17 in the form of clockwise torque through the rack 21 and the follower gear 18, and then just completely resists the counterclockwise torque applied to the irregularly shaped drive gear 17 by force F6, so that the rocker arm 31 returns to a stable state. Figure 1 , 2 As shown in Figure 3.
[0051] The tension F2 of the tension spring 26 causes the lever arm 36 to tend to rotate clockwise around the lever axis 24;
[0052] The combined force F3 formed by the tension of the second cable lead-out section 40b and the tension of the third cable lead-out section 40c causes the lever arm 36 to tend to rotate clockwise around the lever axis 24.
[0053] The combined force F5 formed by the tension of the first cable lead-out section 40a and the tension of the second cable lead-out section 40b causes the lever arm 36 to tend to rotate clockwise around the lever axis 24.
[0054] The tension F4 of the linkage line 14 on the lever arm 36 causes the lever arm 36 to tend to rotate counterclockwise around the lever axis 24;
[0055] The radial force F1 of the irregular drive gear 17 on the follower gear 18 causes the lever arm 36 to tend to rotate counterclockwise around the lever axis 24.
[0056] At this point, lever arm 36 remains balanced under the combined action of F1, F2, F3, F4, and F5;
[0057] At the same time, the reaction force of the tension F4 of the linkage line 14 is transmitted to the floating bar 12, so that the floating bar 12 is kept in balance under the combined action of spring a 5, spring b 2 and linkage line 14. The lower end of spring a 5 forms an upward tension on the friction plate support 4, which is then ultimately transmitted as the pressure F7 between the inner arc surface of the arc-shaped friction plate 9 and the lower end wheel surface of the friction wheel 10. At this time, the arc-shaped friction plate 9 and the friction wheel 10 slide friction under the action of pressure F7. The resulting sliding friction force is transmitted as the rotational reverse torque of the unwinding reel 35, so that the unwinding reel 35 forms stable damping during the unwinding process, thereby maintaining the tension of the first cable lead-out section 40a, the second cable lead-out section 40b, the third cable lead-out section 40c and the final lead-out section 40d of the wire harness.
[0058] When the tensions of the first cable lead-out section 40a, the second cable lead-out section 40b, the third cable lead-out section 40c, and the final cable harness lead-out section 40d suddenly increase due to the accelerated operation of the stranding, cabling, or extrusion equipment, the resultant force F6 of the tensions of the third cable lead-out section 40c and the final cable harness lead-out section 40d increases significantly. Under the action of the significantly increased force F6, the irregularly shaped drive gear 17 rotates counterclockwise, and then, under the action of meshing, drives the follower gear 18 to rotate clockwise. The clockwise rotation of the follower gear 18... The rotation of the needle drives the rack 21 to move downward along its length under the action of meshing, thereby lengthening the tension spring 26 and increasing the tension force F2 of the tension spring 26. When the tension force F2 of the tension spring 26 increases to a certain extent, the tension force of the tension spring 26 is transmitted in the form of clockwise torque to the irregular drive gear 17 through the rack 21 and the follower gear 18, which in turn completely resists the increased force F6 applied to the irregular drive gear 17 in the counterclockwise direction, so that the rocker arm 31 returns to a stable state.
[0059] As the contour surface 90 of the irregular drive gear 17 gradually moves away from the axis of the fixed shaft 29 in a clockwise direction, during the counterclockwise rotation of the irregular drive gear 17 under the action of the significantly increased force F6, the irregular drive gear 17 will smoothly push the follower gear 18 downward in a cam-like manner with the radial force F1, causing the lever arm 36 to rigidly swing counterclockwise a short distance around the lever shaft 24. This causes the connecting seat 50 at one end of the lever arm 36 to float downward a certain distance. The downward floating of the lever arm 36 reduces the tension F4, and the floating bar 12 is affected by the tension of spring a5 and the elastic force b5. The spring 2 floats downward a certain distance under its thrust, thus shortening spring 5 and reducing its tension. This, in turn, reduces the pressure F7 transmitted between the inner arc surface of the arc-shaped friction plate 9 and the lower end wheel surface of the friction wheel 10, thereby reducing the sliding friction between the arc-shaped friction plate 9 and the friction wheel 10. This reduces the damping of the unwinding reel 35. The degree of reduction in the damping of the unwinding reel 35 is positively correlated with the degree of increase in F6, thus smoothly reducing the tension of the first cable lead-out section 40a, the second cable lead-out section 40b, the third cable lead-out section 40c, and the final cable harness lead-out section 40d.
[0060] After the tension of the first cable lead-out section 40a, the second cable lead-out section 40b, the third cable lead-out section 40c, and the final cable harness lead-out section 40d decreases to the normal range, the device returns to its normal operating state, thereby achieving the purpose of adaptive tension adjustment.
[0061] The above technical principle realizes smooth stepless tension adjustment. Through the cam-type transmission structure of the irregular drive gear 17, the input force F6 is converted into a smooth radial thrust F1, which drives the follower gear 18 and lever arm 36 to swing continuously, eliminating the jerking feeling of traditional mechanical devices and realizing zero step and no impact in the tension adjustment process.
[0062] Precision Damping Adaptive Control
[0063] The floating displacement of lever arm 36 → linkage adjustment of the extension and contraction of spring a 5 and spring b 2 → direct control of the clamping force F7 of arc-shaped friction plate 9 and friction wheel 10 → ensures that the sliding friction damping of the unwinding coil 35 and the input force F6 maintain a strict and smooth transmission relationship, realizing real-time matching of tension and load changes.
[0064] Fully mechanical feedback closed loop
[0065] Without the need for sensors or electronic control systems, the closed-loop control of "increased input force → smooth decrease in damping → smooth reduction in output tension" is achieved solely through a purely mechanical linkage structure, significantly reducing system cost and failure rate.
[0066] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.
Claims
1. An adaptive tension pay-off system for stranding, cabling, or extrusion processes, characterized in that: Includes a wire reel (35), a torque transmission shaft (7), a force feedback torque control unit (34), a lever arm (36), a swing arm (31), a cable guide wheel (37), a cable guide wheel (33), a cable guide wheel (52), and a tension feedback transmission system (80). The unwinding coil (35) is located at one end of the transverse torque transmission shaft (7), and the force feedback torque control unit (34) is located at the other end of the torque transmission shaft (7) and is engaged in force transmission; the lever arm (36) is located above the torque transmission shaft (7), and the middle section of the lever arm (36) is rotatably mounted on the lever support (23) via the lever shaft (24); a. Cable guide wheel (37) and b. Cable guide wheel (33) are located at both ends of the lever arm (36); the swing arm (31) is located on the upper side of the lever arm (36), and c. Cable guide wheel (52) is rotatably mounted on the upper end of the swing arm (31). The lower end of the swing arm (31) is linked with the force feedback torque control unit (34) through the tension feedback transmission system (80). The swinging motion of the swing arm (31) is transmitted to the force feedback torque control unit (34) through the tension feedback transmission system (80), thereby changing the magnitude of the torque transmitted by the force feedback torque control unit (34) to the torque transmission shaft (7).
2. The adaptive tension pay-off system for stranding, cabling, or extrusion processes according to claim 1, characterized in that: The cable drawn from the cable reel (35) passes sequentially over the upper side of cable guide wheel (37), the lower side of cable guide wheel (33), and the upper side of cable guide wheel (52); the section of cable bundle between the cable reel (35) and cable guide wheel (37) is designated as the first cable lead-out section (40a), the section of cable bundle between cable guide wheel (37) and cable guide wheel (33) is designated as the second cable lead-out section (40b), the section of cable bundle between cable guide wheel (33) and cable guide wheel (52) is designated as the third cable lead-out section (40c), and the section of cable bundle finally drawn from cable guide wheel (52) is designated as the final cable lead-out section (40d).
3. The adaptive tension pay-off system for stranding, cabling, or extrusion processes according to claim 2, characterized in that: The tension feedback transmission system (80) includes a follower gear (18), a non-circular drive gear (17), a rack (21), a tension spring (26), a linkage line (14), and a rack guide structure; The follower gear (18) is rotatably mounted on a lever arm (36) between the lever shaft (24) and the b cable guide wheel (33) via the gear shaft (28). The inclined rack (21) meshes with the side of the follower gear (18) near the lever shaft (24), and the rack (21) can only move along its own axis under the guidance of the rack guide structure. The tension spring (26) pulls the upper end of the rack (21) along the length direction, and the other end of the tension spring (26) is connected to the tension spring seat (27). The irregular drive gear (17) is rotatably mounted on the fixed shaft (29) via a bearing; the lower end of the swing arm (31) is fixedly connected to the upper end of the outer peripheral surface of the irregular drive gear (17); the outer peripheral surface of the irregular drive gear (17) has a contour surface (90) that gradually moves away from the axis of the fixed shaft (29) in a clockwise direction, and the contour surface (90) has several transmission teeth (32) arranged equidistantly along the surface path, and the transmission teeth (32) at the lower end of the irregular drive gear (17) meshes with the follower gear (18); the upper end of the vertically extending linkage line (14) is fixedly connected to the connecting seat (50) of the lever arm (36) near the end of the b cable guide wheel (33), and the lower end of the linkage line (14) is linked to the force feedback torque control unit (34).
4. The adaptive tension pay-off system for stranding, cabling, or extrusion processes according to claim 3, characterized in that: The swing arm (31) is provided with a first limiting post (39) and a second limiting post (38) on both sides of the swing direction; the first limiting post (39) and the second limiting post (38) are both fixed parts; when the tension of the final lead-out section (40d) of the wire harness is zero, the swing arm (31) is limited to abutting against the first limiting post (39).
5. The adaptive tension pay-off system for stranding, cabling, or extrusion processes according to claim 4, characterized in that: The force feedback torque control unit (34) includes a friction wheel (10), an arc-shaped friction plate (9), a friction plate support (4), a floating bar (12), and a fixed arm (13). The friction wheel (10) is coaxially fixed at the end of the torque transmission shaft (7). The friction plate support (4) is on the upper side of the friction wheel (10). The inner arc surface of the arc-shaped friction plate (9) slides and rubs against the lower end of the friction wheel (10). Both ends of the upper part of the arc-shaped friction plate (9) are fixedly connected to the friction plate support (4). The floating bar (12) is between the friction plate support (4) and the fixed arm (13). The fixed arm (13) is a fixed part. A pair of upwardly extending guide rods (1) are fixedly connected to the upper side of the friction plate support (4). The floating bar (12) has guide holes (3) at both ends for the guide rods (1) to move through. A pair of ball guide cylinders (16) are fixedly installed on the fixed arm (13). The upper end of the guide rod (1) moves through the two ball guide cylinders (16). The guide rod (1) between the floating bar (12) and the friction plate support (4) is covered with a spring (5). The guide rod (1) between the fixed arm (13) and the floating bar (12) is covered with a b spring (2). The fixed arm (13) has a hole (15) through which the linkage line passes. The lower end of the linkage line (14) passes through the linkage line hole (15) downward and is fixedly connected to the floating bar (12). In the initial state, the linkage line (14) is taut and exerts an upward pulling force on the floating bar (12). The upper end of the a spring (5) is fixedly connected to the floating bar (12), and the lower end of the a spring (5) exerts an upward pulling force on the friction plate support (4), which is then ultimately transmitted as the pressure between the inner arc surface of the arc-shaped friction plate (9) and the lower end of the friction wheel (10). The lower end of the b spring (2) exerts a downward pushing force on the floating bar (12). The floating bar (12) remains in balance under the combined action of the a spring (5), the b spring (2), and the linkage line (14).
6. The adaptive tension pay-off system for stranding, cabling, or extrusion processes according to claim 5, characterized in that: When the equipment is running at a constant speed under normal tension, the swing arm (31) is subjected to a resultant force F6 by the tension of the third cable lead-out section (40c) and the tension of the final lead-out section (40d) of the wire harness. Under the action of force F6, the swing arm (31) swings downward around the fixed shaft (29) until it separates from the first limit post (39). The irregular drive gear (17) rotates counterclockwise under the action of force F6, and then drives the follower gear (18) to rotate clockwise under the action of meshing. The clockwise rotation of the follower gear (18) drives the follower gear (18) to rotate clockwise under the action of meshing. The moving rack (21) moves downward along the length direction, thereby lengthening the tension spring (26) and increasing the tension force F2 of the tension spring (26). When the tension force F2 of the tension spring (26) increases to a certain extent, the tension force of the tension spring (26) is transmitted in the reverse direction to the irregular drive gear (17) in the form of clockwise torque through the rack (21) and the follower gear (18), which then just completely resists the torque applied by the force F6 to the irregular drive gear (17) in the counterclockwise direction, so that the swing arm (31) re-enters a stable state.
7. The adaptive tension pay-off system for stranding, cabling, or extrusion processes according to claim 6, characterized in that: The tension F2 of the tension spring (26) causes the lever arm (36) to rotate clockwise around the lever axis (24); The combined force F3 formed by the tension of the second cable lead-out section (40b) and the tension of the third cable lead-out section (40c) causes the lever arm (36) to tend to rotate clockwise around the lever axis (24). The combined force F5 formed by the tension of the first cable lead-out section (40a) and the tension of the second cable lead-out section (40b) causes the lever arm (36) to tend to rotate clockwise around the lever axis (24). The tension F4 of the linkage line (14) on the lever arm (36) causes the lever arm (36) to rotate counterclockwise around the lever axis (24); The radial force F1 of the irregular drive gear (17) on the follower gear (18) causes the lever arm (36) to rotate counterclockwise around the lever axis (24); The lever arm (36) remains in balance under the combined action of F1, F2, F3, F4, and F5.
8. The adaptive tension pay-off system for stranding, cabling, or extrusion processes according to claim 7, characterized in that: The reaction force of the tension F4 of the linkage line (14) is transmitted to the floating bar (12), so that the floating bar (12) is kept in balance under the combined action of spring a (5), spring b (2) and linkage line (14). The lower end of spring a (5) forms an upward tension on the friction plate support (4), which is then ultimately transmitted as the pressure F7 between the inner arc surface of the arc-shaped friction plate (9) and the lower end wheel surface of the friction wheel (10).
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