A tension adjustment component and a winding machine
By combining the lever mechanism and pneumatic damper in synergy with a closed-loop feedback system, the problem of unstable tension adjustment in the winding machine is solved, enabling precise control of different wires and stability of the winding process, thereby improving production efficiency and product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHANGZHOU SHENYING CARBON FIBER COMPOSITES CO LTD
- Filing Date
- 2025-05-07
- Publication Date
- 2026-05-26
AI Technical Summary
Existing winding machines have unstable tension adjustment, making it difficult to adapt to different wire characteristics, resulting in wire breakage and uneven winding. They also lack real-time monitoring and feedback control, and traditional buffer mechanisms are prone to fatigue failure.
The system employs a lever mechanism in conjunction with a pneumatic damper, a rotating shaft, and a controller. It balances the tension changes of the pulley system through the lever principle, absorbs tension shocks using the pneumatic damper, and achieves precise adjustment with a closed-loop feedback system.
It achieves precise tension control for different wires, reduces wire breakage, ensures stability during the winding process, avoids the shortcomings of traditional mechanical adjustment, and improves production efficiency and product quality.
Smart Images
Figure CN224279325U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of winding machines, and in particular to a tension adjustment component and a winding machine. Background Technology
[0002] A winding machine is a specialized piece of equipment used to wind linear materials (such as enameled copper wire, textile wire, solder wire, etc.) onto a specific workpiece. It is widely used in industries such as electronics, electrical appliances, electric heating appliances, and textiles. During the winding process, controlling the wire tension is crucial, directly affecting the quality, performance, and appearance of the finished coil.
[0003] However, existing tension adjustment technologies for winding machines still have many problems, especially the unstable tension adjustment of the sheave system, which often leads to wire breakage, uneven winding, and equipment damage. The main shortcomings of existing technologies are as follows:
[0004] Traditional winding machine tension adjustment mechanisms mostly employ mechanical manual adjustment, such as adjusting the position of guide wheels or sliders via screws, cranks, or other structures to change the wire tension. However, due to the significant differences in toughness and tensile strength among different wires (such as enameled copper wire, aluminum wire, and textile thread), manual adjustment is difficult to achieve precise control, easily leading to excessively tight or loose tension. Excessive tension may cause the wire to break due to overstretching; insufficient tension will result in loose coils and uneven winding, affecting product performance. Furthermore, while some existing technologies incorporate servo motors for adjustment, sudden tension changes can still occur during adjustment, lacking an effective buffering mechanism, potentially causing wire breakage.
[0005] Most existing winding machines rely on operator experience for tension adjustment, lacking a real-time monitoring and feedback control system. While some improved solutions incorporate tension sensors, they still suffer from the following problems: Traditional tension control systems typically employ single-loop control, meaning they first detect tension changes and then adjust the motor speed. This approach suffers from adjustment lag and cannot quickly respond to sudden tension changes, resulting in significant tension fluctuations during winding.
[0006] During the winding process, the wire tension may change instantaneously due to factors such as the inertia of the pay-off reel and the acceleration and deceleration of the motor. In existing technology, some winding machines use a spring buffer mechanism to absorb tension shocks, but the performance of the springs will decay over time, resulting in a decrease in the buffering effect, requiring frequent adjustments and compensation.
[0007] As the amount of wire wound on the winding reel increases, the reel's moment of inertia also increases. When the reel accelerates or decelerates, this greater inertia causes instantaneous changes in wire tension. At the beginning of winding, the reel is lighter and has less inertia, making tension relatively easy to control. However, as the wire continues to wind, the reel's inertia increases, and the wire is prone to sudden tension changes during acceleration or deceleration, leading to increased tension. When the tension is too high, the wire may break due to excessive tensile force. This is especially true for thinner or more fragile wires (such as enameled copper wire and aluminum wire), where excessive tension can easily cause breakage, wasting raw materials, interrupting production, and reducing efficiency. Excessive tension will cause the wire to wind too tightly, resulting in localized compression; insufficient tension will cause the wire to wind loosely, resulting in unclear coil layers. This not only affects the appearance quality of the coil but may also lead to a decline in the coil's electrical performance, such as unstable inductance and capacitance parameters, affecting product performance and reliability. Summary of the Invention
[0008] To address the shortcomings of existing technologies, this utility model provides a tension adjustment component and a winding machine. Through the synergistic effect of the lever mechanism and the adjustment mechanism, it can balance the tension changes in the reel system and adapt to different wire materials. This overcomes the shortcomings of traditional mechanical manual adjustment, which is difficult to adapt to the characteristics of different wire materials (such as the toughness differences of enameled copper wire and aluminum wire).
[0009] This utility model achieves the above-mentioned technical objectives through the following technical means.
[0010] A tension adjusting assembly includes an adjusting reel, a lever mechanism, a rotating shaft, and an adjusting mechanism;
[0011] The fulcrum of the lever mechanism is connected to the rotating shaft, which is supported on the bracket of the sheave train. The adjusting sheave is used to apply preload to the sheave train. The adjusting sheave is located at one end of the lever mechanism. The rotating shaft is connected to the adjusting mechanism, and by applying an external force to the rotating shaft, it is used to balance the tension changes in the sheave train.
[0012] Furthermore, the lever mechanism includes a balance block and a connecting rod; one end of the connecting rod is fitted with an adjusting wheel via a rotary joint, and the other end of the balance block is fitted with a balance block; a fulcrum is provided on the connecting rod near the balance block, and the fulcrum is connected to one end of the rotating shaft.
[0013] Furthermore, the adjustment mechanism includes a rotating arm and a pneumatic damper; one end of the rotating arm is mounted on a rotating shaft, and the other end of the rotating arm is connected to the output end of the pneumatic damper; the other end of the pneumatic damper is mounted on the bracket of the sheave train; the pressure chamber inside the pneumatic damper is filled with gas at a set pressure, and when the tension of the sheave train changes, the output end of the pneumatic damper extends and retracts within the set pressure range to balance the tension changes of the sheave train.
[0014] Furthermore, the working chamber of the pneumatic damper is connected to the pressure unit via a solenoid valve to change the set pressure of the gas filling the pressure chamber.
[0015] Furthermore, it also includes a controller, which acquires the winding diameter on the winding wheel in the spool system, and controls the solenoid valve to increase the set pressure of the pressure unit in the pressure chamber according to the increase in winding diameter.
[0016] Furthermore, an angle sensor is provided at the other end of the rotating shaft to detect the angle of rotation of the rotating shaft.
[0017] Furthermore, it also includes a controller, which acquires the angle of rotation of the rotating shaft, compares the angle of rotation of the rotating shaft with a set value, and changes the rotational speed of the gear train when the angle exceeds the set value.
[0018] A winding machine includes a spool system, in which the tension adjustment component is provided to balance tension changes in the spool system.
[0019] The beneficial effects of this utility model are as follows:
[0020] 1. The tension adjustment component described in this utility model can balance the tension changes in the reel system through the synergistic effect of the lever mechanism and the adjustment mechanism, and can adapt to different wire materials, overcoming the shortcomings of traditional mechanical manual adjustment that is difficult to adapt to the characteristics of different wire materials (such as the toughness differences of enameled copper wire, aluminum wire, etc.).
[0021] 2. The tension adjustment component described in this utility model, through a pneumatic damper in conjunction with a rotating shaft, can dynamically apply external force according to the tension changes of the sheave system, thereby achieving precise balance of tension fluctuations.
[0022] 3. The tension adjustment component described in this utility model is equipped with an angle sensor at the end of the rotating shaft, which, together with the controller, forms a closed-loop feedback system that can instantly capture sudden changes in tension. When the torsion angle exceeds the set value, the controller can quickly adjust the speed of the thread wheel to ensure that the tension changes are constant throughout the winding process.
[0023] 4. The tension adjustment component described in this utility model employs a pneumatic damper, whose internal pressure chamber can maintain a stable working pressure range. Even under frequent tension impact conditions, it can continuously absorb tension fluctuations, avoiding the decrease in buffering performance caused by fatigue failure of traditional springs. Moreover, the pneumatic damper can be applied to wires of different sizes and types.
[0024] 5. In the tension adjustment component of this utility model, the working chamber of the pneumatic damper is connected to the pressure unit through a solenoid valve. The controller obtains the diameter of the winding on the winding wheel in the reel system. Based on the increase in the winding diameter, the controller controls the solenoid valve to increase the set pressure of the pressure unit in the pressure chamber. In this way, the increase in the amount of wire wound on the winding wheel and the resulting increase in tension can be compensated by the output end of the pneumatic damper, which can more effectively balance the tension of the reel system. Attached Figure Description
[0025] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. The drawings described below are some embodiments of this utility model. For those skilled in the art, it is obvious that other drawings can be obtained from these drawings without creative effort.
[0026] Figure 1 This is a three-dimensional view of the tension adjustment component described in this utility model.
[0027] Figure 2 This is a front view of the tension adjustment component described in this utility model.
[0028] Figure 3 This is a schematic diagram of the installation of the pneumatic damper described in this utility model, showing the view behind the bracket.
[0029] In the picture:
[0030] 1-Adjusting reel; 2-Connecting rod; 3-Balance block; 4-Shaft sleeve; 5-Support seat; 6-Pneumatic damper; 7-Rotating arm; 8-Angle sensor; 9-Rotating shaft; 10-Bracket; 11-Seat-mounted spherical bearing; 12-Stationary wheel. Detailed Implementation
[0031] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.
[0032] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "transverse," "length," "width," "thickness," "upper," "lower," "axial," "radial," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.
[0033] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.
[0034] like Figure 1 and Figure 2 As shown, the tension adjusting assembly of this utility model includes an adjusting wheel 1, a lever mechanism, a rotating shaft 9, and an adjusting mechanism. The rotating shaft 9 is supported at both ends by support seats 5 on a bracket 10 of the wheel system. The wheel system is a mechanism for winding the thread, including several fixed rotating wheels and winding wheels. The fixed rotating wheels and winding wheels form a wheel system with thread, similar to a belt drive system. The winding wheels are connected to a motor to drive the wheel system for winding. The wheel system is a conventional structure. The fulcrum of the lever mechanism is connected to the rotating shaft 9. The adjusting wheel 1 is located at one end of the lever mechanism. Utilizing the lever principle, the adjusting wheel 1 can contact the thread in the wheel system to apply preload to the thread. Applying preload can create tension in the thread during winding. The rotating shaft 9 is connected to the adjusting mechanism. By applying external force to the rotating shaft 9, the tension changes in the wheel system are balanced.
[0035] like Figure 1 and Figure 2As shown, the lever mechanism includes a balance block 3 and a connecting rod 2. One end of the connecting rod 2 is fitted with an adjusting wheel 1 via a revolute joint, allowing the adjusting wheel 1 to rotate freely. The other end of the balance block 3 is fitted with a balance block 3. A fulcrum is provided on the connecting rod 2 near the balance block 3, and this fulcrum is connected to one end of a rotating shaft 9. The counterweight can be added or removed from the balance block 3, thereby changing the preload applied by the adjusting wheel 1, which is also a means of handling wires of different materials. To facilitate disassembly of the lever mechanism, a bushing 4 is fitted onto one end of the rotating shaft 9, and the bushing 4 is connected to the fulcrum.
[0036] like Figure 3 As shown, the adjustment mechanism includes a rotating arm 7 and a pneumatic damper 6; one end of the rotating arm 7 is mounted on a rotating shaft 9, and the other end of the rotating arm 7 is connected to the tension rod of the pneumatic damper 6; the other end of the pneumatic damper 6 is mounted on a bracket 10 of a gear train; a seated spherical bearing 11 is mounted on the tension rod of the pneumatic damper 6, and the seated spherical bearing 11 is supported on the rotating arm 7. The seated spherical bearing 11 allows the two ends of the pneumatic damper 6 to be deflected at a certain angle for installation, which facilitates the installation of the pneumatic damper 6.
[0037] The pneumatic damper 6 has a pneumatic chamber filled with gas at a set pressure. When the tension on the adjusting reel 1 changes, the output end of the pneumatic damper 6 expands and contracts within the set pressure range, thereby balancing the tension changes in the reel system. In this case, the pneumatic damper 6 can be considered a buffer device. When the tension increases, causing the adjusting reel 1 to move away from the wire, the output end of the pneumatic damper 6 needs to be compressed. At this time, a buffering force is generated in the pneumatic chamber of the pneumatic damper 6 to prevent the rapid movement of the adjusting reel 1, thus balancing the increase in tension. When the winding reel begins to wind, the reel is relatively light and has little inertia. At this time, the gas at the set pressure in the pneumatic damper 6's pneumatic chamber can effectively balance the small changes in tension. However, as the wire continues to wind, the inertia of the winding reel gradually increases, and the peak value of the tension fluctuation also increases. In this case, the gas at the initial set pressure in the pneumatic damper 6's pneumatic chamber alone is no longer sufficient to compensate for the increased tension. Therefore, the pneumatic damper 6 of this invention has its air pressure chamber connected to the pressure unit via a solenoid valve. As the mass of the winding wheel increases, the system can increase the pressure into the air pressure chamber as needed via the solenoid valve, thereby more effectively balancing the tension changes of the winding wheel system and ensuring the stability of the winding process.
[0038] The tension adjustment system also includes a controller and a diameter measuring sensor. The diameter measuring sensor is installed near the winding reel to measure the winding diameter on the reel in real time. Based on the increase in winding diameter, the controller controls a solenoid valve to increase the set pressure in the pressure chamber of the pressure unit. Specifically, a standard diameter increase Δ is set. When the winding diameter on the reel increases by Δ, the controller triggers the solenoid valve, connecting the pressure unit to the pressure chamber, and the pressure unit increases the set pressure value into the pressure chamber. The pressure unit is typically an air compressor, with a pressure regulating valve installed at the compressor outlet. This valve allows for precise setting of the required pressure increase. Alternatively, a weight sensor can be installed on the winding reel to measure the mass increment. When the mass increase reaches a preset value, the controller similarly controls the solenoid valve to connect the pressure unit to the pressure chamber to supplement the pressure. The controller can employ a PLC (Programmable Logic Controller), commonly used in existing technologies, to implement the above control functions. The PLC can receive sensor signals, perform logical judgments and signal processing, and output control signals to drive the solenoid valve. In addition, other types of controllers can also be used, such as microcontrollers and embedded control systems. These controllers typically consist of a microprocessor, memory, input / output interfaces, etc., and are capable of implementing more complex control algorithms and functions. Electronic hardware components such as shifters, adders, comparators, and logic gates can be used as internal components of the controller to implement specific signal processing and logic control functions, but using these components alone cannot constitute a complete controller system.
[0039] An angle sensor 8 is provided at the other end of the rotating shaft 9 to detect the angle of twist of the rotating shaft 9. The controller obtains the angle of twist of the rotating shaft 9 and compares the angle of twist of the rotating shaft 9 with a set value. When the angle exceeds the set value, the controller reduces the rotational speed of the sheave train.
[0040] A winding machine includes a spool system, in which a plurality of fixed rotating wheels 12 are mounted on a support 10. A tension adjustment component is installed on the support 10, and adjusting the spools 1 can balance the tension fluctuations of the spool system.
[0041] It should be understood that although this specification is described according to various embodiments, not every embodiment contains only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.
[0042] The detailed descriptions listed above are merely specific descriptions of feasible embodiments of the present utility model, and are not intended to limit the scope of protection of the present utility model. All equivalent embodiments or modifications made without departing from the spirit of the present utility model should be included within the scope of protection of the present utility model.
Claims
1. A tension adjustment component, characterized in that, It includes an adjusting wheel (1), a lever mechanism, a rotating shaft (9), and an adjusting mechanism; The fulcrum of the lever mechanism is connected to the rotating shaft (9), which is supported on the bracket (10) of the sheave system. The adjusting sheave (1) is used to apply preload to the sheave system. The adjusting sheave (1) is located at one end of the lever mechanism. The rotating shaft (9) is connected to the adjusting mechanism. By applying external force to the rotating shaft (9), the tension changes in the sheave system are balanced.
2. The tension adjusting assembly according to claim 1, characterized in that, The lever mechanism includes a balance block (3) and a connecting rod (2); one end of the connecting rod (2) is fitted with an adjusting wheel (1) via a rotary joint, and the other end of the balance block (3) is fitted with a balance block (3); a fulcrum is provided on the connecting rod (2) near the balance block (3), and the fulcrum is connected to one end of the rotating shaft (9).
3. The tension adjusting assembly according to claim 1, characterized in that, The adjustment mechanism includes a rotating arm (7) and a pneumatic damper (6); one end of the rotating arm (7) is mounted on a rotating shaft (9), and the other end of the rotating arm (7) is connected to the output end of the pneumatic damper (6); the other end of the pneumatic damper (6) is mounted on a bracket (10) of the gear train; the pressure chamber inside the pneumatic damper (6) is filled with gas at a set pressure. When the tension of the adjusting gear (1) changes, the output end of the pneumatic damper (6) extends and retracts within the set pressure range to balance the tension change of the gear train.
4. The tension adjusting assembly according to claim 3, characterized in that, The working chamber of the pneumatic damper (6) is connected to the pressure unit through a solenoid valve to change the set pressure of the gas filling the pressure chamber.
5. The tension adjusting assembly according to claim 4, characterized in that, It also includes a controller, which acquires the diameter of the winding on the winding wheel in the spool system, and controls the solenoid valve to increase the set pressure of the pressure chamber of the pressure unit according to the increase in the winding diameter.
6. The tension adjusting assembly according to claim 1, characterized in that, An angle sensor (8) is provided at the other end of the rotating shaft (9) to detect the angle of the rotation of the rotating shaft (9).
7. The tension adjusting assembly according to claim 6, characterized in that, It also includes a controller, which acquires the angle of rotation of the rotating shaft (9), compares the angle of rotation of the rotating shaft (9) with a set value, and changes the rotational speed of the gear train when the angle exceeds the set value.
8. A winding machine, characterized in that, The device includes a reel system, wherein the reel system is provided with a tension adjustment component as described in any one of claims 1-7, for balancing tension variations in the reel system.