High-speed high-precision double-station wire take-up and pay-off machine

Abstract

The utility model discloses a high-speed high-precision double-station wire take-up and pay-off machine, and relates to the technical field of take-up and pay-off equipment for cords, carbon fibers, steel wires and chemical fibers. Comprising a rack, a supporting rod, a tension sensor, a hysteresis brake, a wire wheel, a wire drawing wheel, a rolling diameter sensor, a wire coil, a floating wheel piece, a floating wheel position detection sensor, a clutch, a pneumatic brake, a damping brake and a driving motor. Wherein the rack is used for fixing all parts and providing overall support; the supporting rod is connected with the machine frame and the floating wheel piece, and the movement stability of the machine frame and the floating wheel piece in the vertical direction is guaranteed. The high-speed high-precision double-station wire winding and unwinding machine is driven by a single motor, the winding and unwinding modes are automatically switched based on the position change trend of the floating wheel, the speed is dynamically adjusted in combination with a PID algorithm, and high-precision tension control and intelligent damping adjustment are achieved. The device reliability and operation convenience can be remarkably improved, the maintenance cost is reduced, and the requirement of a high-speed application scene is met.

Description

A high-speed, high-precision dual-station wire take-up and untake-down machine Technical Field

[0001] This utility model relates to the technical field of wire take-up and undo equipment, specifically to a high-speed, high-precision dual-station wire take-up and undo machine. Background Technology

[0002] In modern industrial production, wire winding and unwinding operations are indispensable in many fields, especially in scenarios requiring high-speed and high-precision control. Traditional wire winding and unwinding equipment typically uses two independent mechanisms to perform winding and unwinding functions separately. This design not only increases the complexity and cost of the equipment but also limits its flexibility and adaptability. Specifically, the winding function is generally achieved through a combination of a magnetic powder clutch and a winding motor, while the unwinding function relies on a magnetic powder brake. However, this separate design has significant technical drawbacks. For example, when unwinding stops, the system cannot detect whether the wire has become slack, causing the wire to easily jump off the reel upon restarting, leading to equipment failure and production interruption. Furthermore, traditional equipment requires external commands to switch between winding and unwinding modes, lacking adaptive capabilities and failing to meet the demands of modern production for efficient and intelligent operation.

[0003] While some existing technologies attempt to improve wire tension stability by introducing sensors or control systems, these solutions often fail to fundamentally address the issues of complex equipment structure, high maintenance costs, and slow response speeds. Particularly under high-speed operating conditions, the tension control accuracy and dynamic response capability of traditional equipment struggle to reach ideal levels, impacting overall production efficiency and product quality. Furthermore, the lifespan and reliability of traditional equipment are significantly limited due to the easy wear or failure of friction components and magnetic particles. Therefore, developing a wire take-up and release device that integrates take-up and release functions, possesses adaptive switching capabilities, and maintains high-precision tension control under high-speed operation has become a pressing technical challenge. Summary of the Invention

[0004] This invention addresses the shortcomings of existing wire take-up and unwinding machines, such as functional separation, lack of self-adaptive capability, missing wire slack detection, and high maintenance costs. To address these shortcomings, it provides a high-speed, high-precision dual-station wire take-up and unwinding machine. This machine achieves automatic switching between take-up and unwinding functions via a single motor drive, and, combined with intelligent control methods, significantly improves the reliability and ease of operation of the equipment.

[0005] This utility model provides a high-speed, high-precision dual-station wire take-up and undo machine, including a frame, support rod, tension sensor, hysteresis brake, wire reel, pull reel, winding diameter sensor, wire spool, floating wheel assembly, floating wheel position detection sensor, clutch, pneumatic brake, damping brake, and drive motor. The frame is used to fix the components and provide overall support; the support rod connects the frame and the floating wheel assembly, ensuring stable vertical movement; the tension sensor is installed on the wire path to monitor the wire tension in real time and feed back the signal to the control system; the hysteresis brake is located at the end of the wire spool shaft to provide constant and precise torque output; the wire reel and pull reel are located on both sides of the wire spool to guide the smooth operation of the wire; the winding diameter sensor is installed near the wire spool shaft to detect the wire spool diameter in real time and transmit the data to the control system; the wire spool is connected to the frame via bearings for... The system stores or releases wire; the floating wheel is suspended from the frame by a support rod, and its up-and-down movement reflects the wire tension; the floating wheel position detection sensor is installed on the side of the floating wheel to record the floating wheel's position information in real time; the clutch connects the wire reel shaft and the synchronous pulley to control the power transmission path; the pneumatic brake is located at the end of the wire reel shaft for quickly stopping the reel's rotation in an emergency; the damping brake is installed at the other end of the wire reel shaft to provide appropriate damping torque for the wire reel in the wire feeding mode; the drive motor is connected to the wire reel shaft or pulley via a synchronous belt, serving as a power source to drive the entire system.

[0006] Furthermore, the core of this invention lies in dynamically determining the take-up or let-down mode and automatically switching it based on the changing trend of the floating wheel's position. When the floating wheel is above the preset let-down start position, the control system receives a signal from the floating wheel position detection sensor and instructs the drive motor to rotate forward. Simultaneously, the clutch disengages, causing the spool shaft to disengage from the synchronous pulley, and the spool shaft is controlled by a damping brake. During this process, the control system dynamically adjusts the speed of the drive motor based on the floating wheel's position and changing trend using a PID algorithm, keeping the floating wheel stable within the target range. In particular, the damping value of the damping brake is determined by the spool diameter detected by the spool diameter sensor to prevent overshoot due to excessive inertia of the spool.

[0007] Furthermore, when the floating wheel descends to the preset take-up start position, the control system receives a signal from the floating wheel position detection sensor and instructs the drive motor to reverse. Simultaneously, the clutch engages, connecting the spool shaft to the synchronous pulley, and the drive motor directly acts on the spool shaft to complete the winding of the wire. During this process, the control system dynamically adjusts the speed of the drive motor based on the floating wheel position value until the floating wheel is above the preset take-up stop position, at which point the take-up action stops. Both the pulley and the hysteresis brake are equipped with one-way bearings. When the drive motor reverses, the shafts of both are in a free state relative to the spool, thereby reducing unnecessary frictional losses.

[0008] Specifically, this invention proposes a high-precision tension control scheme. The tension sensor monitors the wire tension in real time and feeds it back to the control system. By adjusting the output torque of the hysteresis brake, the wire tension is kept within a set range of 1~20 kgf, with a tolerance range of ±0.3 kgf. Furthermore, this invention includes upper and lower limit protection positions. When the floating wheel exceeds these ranges, a protection mechanism is triggered to prevent mechanical damage. The pneumatic brake can quickly stop the wire movement in emergencies, ensuring safe operation of the equipment.

[0009] The main technical innovations of this invention are reflected in the following aspects: First, the integrated design of take-up and release functions using a single drive motor significantly simplifies the equipment structure and reduces manufacturing costs. Second, the adaptive control method based on the position and changing trend of the floating wheel automatically determines and switches between take-up and release modes without external commands, improving operational convenience and response speed. Third, high-precision tension control is achieved through the synergistic effect of the hysteresis brake and tension sensor, meeting the needs of high-speed applications. Finally, the intelligent damping adjustment function uses a diameter sensor to detect the spool diameter in real time and dynamically adjusts the output of the damping brake, effectively preventing overshoot due to excessive inertia of the spool.

[0010] The technical advantages of this invention are demonstrated through the following means: S1, the maximum winding and unwinding speed reaches 8 meters per second, meeting the requirements of high-speed applications; S2, the tension control tolerance is ±0.3 kgf, ensuring that the wire tension remains stable at all times; S3, a pure hysteresis brake is used, eliminating the need for magnetic particles or friction components, resulting in a long service life and low maintenance costs; S4, pneumatic brakes and upper and lower limit protection positions are provided to effectively prevent unexpected malfunctions during equipment operation; S5, integrated design and intelligent control reduce equipment complexity and manufacturing costs. In summary, this invention, through integrated design and intelligent control methods, solves many problems existing in the prior art and has broad application prospects and market value. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this utility model. For those skilled in the art, other drawings can be obtained based on these drawings.

[0012] Figure 1 is a schematic diagram of the overall structure provided in an embodiment of the present utility model;

[0013] Figure 2 is a front view structural diagram of Figure 1 provided in an embodiment of this utility model;

[0014] Figure 3 is a schematic diagram of the structure at point A in Figure 2 provided in an embodiment of this utility model;

[0015] Figure 4 is a side view of the structure of Figure 1 provided in the embodiment of this utility model.

[0016] Explanation of reference numerals in the attached figures:

[0017] 1. Frame; 2. Support rod; 3. Tension sensor; 4. Hysteresis brake; 5. Wire reel; 6. Wire puller; 7. Wire diameter sensor; 8. Wire spool; 9. Floating wheel component; 10. Floating wheel position detection sensor; 11. Clutch; 12. Pneumatic brake; 13. Damping brake; 14. Wire release start position; 15. Wire release stop position; 16. Upper limit protection position; 17. Lower limit protection position; 18. Drive motor. Detailed Implementation

[0018] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0019] This utility model provides a high-speed, high-precision dual-station wire take-up and unwinding machine, the structure of which is shown in Figures 1 to 4. The device includes a frame 1, a support rod 2, a tension sensor 3, a hysteresis brake 4, a wire reel 5, a pull reel 6, a winding diameter sensor 7, a wire spool 8, a floating wheel 9, a floating wheel position detection sensor 10, a clutch 11, a pneumatic brake 12, a damping brake 13, and a drive motor 18. These components work together to achieve the automatic take-up and unwinding function of the wire. The technical solution of this utility model will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0020] The frame 1 serves as the basic structure of the entire equipment, used to fix and support all components. The support rod 2 connects the frame 1 to the floating wheel component 9, ensuring that the floating wheel component 9 can move smoothly in the vertical direction. The up-and-down movement of the floating wheel component 9 reflects the tension of the wire, which is a key component for achieving adaptive control. A floating wheel position detection sensor 10 is installed on the side of the floating wheel component 9, recording the floating wheel's position information in real time and transmitting the signal to the control system. The control system determines whether to switch to take-up or let-down mode based on these signals.

[0021] When the floating wheel 9 is above the preset wire-laying start position 14, the control system receives a signal from the floating wheel position detection sensor 10 and instructs the drive motor 18 to rotate forward. At this time, the clutch 11 disengages, causing the wire spool shaft to disengage from the synchronous pulley, and the wire spool shaft is controlled by the damping brake 13. The function of the damping brake 13 is to dynamically adjust the damping value when the wire spool diameter changes, preventing the wire spool from overshooting due to excessive inertia. During the wire-laying process, the drive motor 18 acts on the pulley 6 through the synchronous belt, driving the wire to be released from the wire spool 8. Based on the position and changing trend of the floating wheel 9, the control system dynamically adjusts the speed of the drive motor 18 after calculation using a PID algorithm, keeping the floating wheel 9 stable within the target range. This process ensures the smoothness and accuracy of the wire-laying action.

[0022] When the floating wheel 9 descends to the take-up start position, the control system receives the signal from the floating wheel position detection sensor 10 again and commands the drive motor 18 to reverse. At this time, the clutch 11 engages, connecting the spool shaft to the synchronous pulley, and the drive motor 18 directly acts on the spool shaft to complete the winding of the wire. During this process, the control system dynamically adjusts the speed of the drive motor 18 according to the position value of the floating wheel 9 until the floating wheel 9 is above the preset take-up stop position, at which point the take-up action stops. Both the pulley 6 and the hysteresis brake 4 are equipped with one-way bearings. When the drive motor 18 reverses, the shafts of both are in a free state with the spool 5, thereby reducing unnecessary frictional losses. This design not only improves the efficiency of the equipment but also extends the service life of key components.

[0023] Tension sensor 3 is installed on the wire path to monitor the wire tension in real time and feed the signal back to the control system. The control system adjusts the output torque of hysteresis brake 4 to keep the wire tension within a set range of 1 to 20 kgf, with a tolerance range of ±0.3 kgf. The hysteresis brake 4 is characterized by generating torque through pure hysteresis, without the use of magnetic particles or friction components. This method offers smoother torque output, longer service life, excellent repeatability, and high controllability. Furthermore, the hysteresis brake 4 requires minimal maintenance, reducing equipment downtime and further improving overall operating efficiency.

[0024] A winding diameter sensor 7 is installed near the reel shaft to detect the diameter of the reel 8 in real time and transmit the data to the control system. The control system dynamically adjusts the output of the damping brake 13 based on changes in the reel diameter to prevent overshoot due to excessive inertia. This intelligent damping adjustment significantly improves stability during wire feeding, avoiding wire slack or slippage caused by reel inertia. A pneumatic brake 12 is located at the end of the reel shaft for quickly stopping reel rotation in emergencies, ensuring safe equipment operation. The pneumatic brake 12 has a fast response time, achieving emergency braking of the reel within milliseconds, effectively protecting the equipment and operator safety.

[0025] The movement range of the floating wheel component 9 is limited by the upper limit protection position 16 and the lower limit protection position 17. When the floating wheel component 9 exceeds these ranges, a protection mechanism is triggered to prevent mechanical damage. This protection mechanism effectively prevents equipment failure due to unexpected situations, improving equipment reliability. Furthermore, the upper and lower limit protection functions of the floating wheel component 9 can also remind operators to check the equipment status in a timely manner, avoiding potential problems during prolonged operation.

[0026] The core innovation of this invention lies in the integrated design of take-up and let-down functions using a single drive motor 18. This design significantly simplifies the equipment structure and reduces manufacturing costs. Simultaneously, the adaptive control method based on the position and changing trend of the floating wheel 9 automatically determines and switches between take-up and let-down modes without external commands, improving operational convenience and response speed. Through the synergistic effect of the hysteresis brake 4 and the tension sensor 3, high-precision tension control is achieved, meeting the requirements of high-speed applications. The intelligent damping adjustment function utilizes the coil diameter sensor 7 to detect the coil diameter in real time and dynamically adjusts the output of the damping brake 13, effectively preventing overshoot due to excessive inertia of the coil.

[0027] In practical applications, this high-speed, high-precision dual-station wire take-up and unwinding machine is suitable for various industrial scenarios. For example, in the textile industry, high-speed wire take-up and unwinding are crucial for production efficiency. Traditional take-up and unwinding equipment often requires two independent mechanisms to complete the take-up and unwinding functions separately, which not only occupies a large space but also has high maintenance costs. This invention, however, significantly improves the operating efficiency and reliability of the equipment through a single motor drive and intelligent control. In the electronics manufacturing field, wire tension control directly affects product quality. This invention's high-precision tension control scheme ensures that the wire tension remains stable at all times, meeting the needs of precision manufacturing.

[0028] This invention achieves a maximum winding speed of 8 meters per second, fully meeting the requirements of high-speed applications. The tension control tolerance is ±0.3 kgf, ensuring stable wire tension at all times. It employs a pure hysteresis brake 4, eliminating the need for magnetic particles or friction components, resulting in a long service life and low maintenance costs. A pneumatic brake 12 and upper and lower limit protection positions effectively prevent unexpected malfunctions during operation. Through integrated design and intelligent control, the complexity and manufacturing cost of the equipment are reduced. In summary, this invention, through integrated design and intelligent control methods, solves many problems existing in the prior art, possessing broad application prospects and market value.

[0029] The foregoing description only illustrates certain exemplary embodiments of the present invention. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A high-speed, high-precision dual-station wire take-up and untake-down machine, characterized in that, The system includes a frame (1), a support rod (2), a tension sensor (3), a hysteresis brake (4), a wire reel (5), a wire pulley (6), a wire diameter sensor (7), a wire spool (8), a floating wheel assembly (9), a floating wheel position detection sensor (10), a clutch (11), a pneumatic brake (12), a damping brake (13), and a drive motor (18). The support rod (2) connects the frame (1) to the floating wheel assembly (9). The tension sensor (3) is mounted on the wire path. The hysteresis brake (4)... 4) The wire wheel (5) and the wire pulley (6) are located on both sides of the wire wheel (8), the winding diameter sensor (7) is installed near the wire wheel shaft, the floating wheel position detection sensor (10) is installed on the side of the floating wheel (9), the clutch (11) connects the wire wheel shaft and the synchronous belt pulley, the pneumatic brake (12) is located at the end of the wire wheel shaft, the damping brake (13) is installed at the other end of the wire wheel shaft, and the drive motor (18) is connected to the wire wheel shaft or the wire pulley (6) through the synchronous belt.

2. The high-speed, high-precision dual-station wire take-up and untake-down machine according to claim 1, characterized in that, The floating wheel (9) is suspended on the frame (1) by the support rod (2), and the up and down movement of the floating wheel (9) reflects the tension of the wire.

3. A high-speed, high-precision dual-station wire take-up and untake-down machine according to claim 2, characterized in that, The floating wheel position detection sensor (10) is further limited to record the position information of the floating wheel component (9) in real time and transmit the signal to the control system.

4. The high-speed, high-precision dual-station wire take-up and untake-down machine according to claim 1, characterized in that, The hysteresis brake (4) provides a constant and precise torque output, and its output torque is adjusted by the control system based on the feedback signal from the tension sensor (3).

5. A high-speed, high-precision dual-station wire take-up and untake-down machine according to claim 4, characterized in that, The tension sensor (3) is further limited to monitor the wire tension in real time and feed the signal back to the control system to ensure that the wire tension is kept within the set range.

6. A high-speed, high-precision dual-station wire take-up and untake-down machine according to claim 1, characterized in that, The diameter sensor (7) detects the diameter of the coil (8) in real time and transmits the data to the control system for dynamically adjusting the output of the damping brake (13).

7. A high-speed, high-precision dual-station wire take-up and untake-down machine according to claim 6, characterized in that, The damping brake (13) dynamically adjusts the damping value when the diameter of the coil (8) changes, so as to prevent the coil from overshooting due to excessive inertia.

8. A high-speed, high-precision dual-station wire take-up and untake-down machine according to claim 1, characterized in that, The pneumatic brake (12) is used to quickly stop the rotation of the coil (8) in an emergency, and the range of motion of the floating wheel (9) is limited by the upper limit protection position (16) and the lower limit protection position (17).

Images