A wire releasing mechanism based on constant tension hot drawing straightening of tungsten wire

Abstract

The utility model provides a kind of based on tungsten wire constant tension hot straightening wire release mechanism, it is related to tungsten wire wire release technology, specifically discloses wire release frame, the top of wire release frame is equipped with sliding table structure, and the sliding end of sliding table structure is equipped with support frame;One side of support frame is equipped with raw material reel, and the side wall of support frame is equipped with first drive mechanism, and first drive mechanism is drivingly connected with raw material reel;One side of support frame is equipped with fixed frame, and the fixed frame is equipped with tungsten wire line speed detection structure for calculating the real-time winding diameter of raw material reel;The side wall of fixed frame is equipped with Load Cell sensor for measuring tungsten wire traction, for real-time feedback control the rotating speed of raw material reel;Waist drum is equipped on the side wall of fixed frame and raw material reel in same side, for compensating the length change caused by the change of tungsten wire release path from "inclined pull" to "positive pull", significantly reduce the fluctuation range of tungsten wire tension caused thereby.

Description

Technical Field

[0001] This utility model relates to the field of tungsten wire feeding technology, and more specifically, to a wire feeding mechanism based on constant tension thermal straightening of tungsten wire. Background Technology

[0002] During the tungsten wire drawing process, maintaining stable wire tension is crucial to ensure the consistency of the tungsten wire diameter, mechanical properties, and surface quality. To improve production efficiency, modern wire drawing machines require linear speeds of 2 meters per second or higher. At this high speed, disturbances such as eccentricity of the raw material reel, irregular wire distribution, and intermittent wire drawing by the traction mechanism are amplified dramatically, making tungsten wire tension control even more challenging.

[0003] When using open-loop speed control for unwinding, if the unwinding speed remains constant, the diameter of the raw material reel continuously decreases as it goes from full to empty, causing the tungsten wire release linear speed to slow down. The tension will increase as the reel diameter decreases (the tension is low when the reel is full and high when the reel is empty).

[0004] Traditional tungsten wire drawing machines often use frictional resistance (such as leather brakes) or reverse damping (such as magnetic powder brakes) to passively unwind the wire. This results in a decrease in tungsten wire tension as the weight of the material on the reel decreases (high tension when fully wound and low tension when empty). Moreover, the tension fluctuates too much during unwinding. When the tension is too high, it can cause the tungsten wire to break during the drawing process, resulting in insufficient wire length and scrap.

[0005] Some manufacturers have improved the wire feeding mechanism based on traditional tungsten wire drawing machines by using angular displacement sensors (such as angle encoders) or linear displacement sensors (such as linear potentiometers) to indirectly detect the tungsten wire tension and then feed back to control the wire feeding speed of the raw material reel. However, these sensors can only respond when the detected object has a large displacement (millimeter level), resulting in low sensitivity (response time > 50ms) and poor anti-interference ability. They cannot suppress millisecond-level tension changes, causing instantaneous fluctuations in wire feeding tension > ±0.5N during high-speed operation, which affects the surface quality of the tungsten wire. Utility Model Content

[0006] The purpose of this invention is to provide a wire feeding mechanism based on constant tension thermal straightening of tungsten wire, which addresses the shortcomings of existing technologies and solves the problems mentioned in the background.

[0007] The technical solution of this utility model is implemented as follows: The utility model provides a wire feeding mechanism based on constant tension thermal straightening of tungsten wire, including a wire feeding frame, a slide structure on the top of the wire feeding frame, and a support frame installed on the sliding end of the slide structure; A raw material reel is installed on one side of the support frame, and a first drive mechanism is installed on the side wall of the support frame. The first drive mechanism is connected to the raw material reel in a transmission manner. A fixed frame is installed on one side of the support frame. The fixed frame and the raw material reel are located on the same side wall and are equipped with a waist drum wheel. The fixed frame is equipped with a tungsten wire linear speed detection structure for calculating the real-time winding diameter of the unwinding reel. A Load Cell sensor for measuring the tungsten wire traction force is cantilevered on the fixed frame. A first guide wheel is installed on the free end of the Load Cell sensor. A second guide wheel is installed between the first guide wheel and the tungsten wire linear speed detection structure.

[0008] In some technical solutions of this utility model, the tungsten wire linear velocity detection structure includes a mounting frame, which is set on the top of the fixed frame. An encoder is installed on the top of the mounting frame, and an encoder wheel is installed at the output end of the encoder. An annular groove is formed on the surface of the encoder wheel.

[0009] In some technical solutions of this utility model, the coding wheel is located directly above the raw material reel, and together with the waist drum wheel, the three are arranged in a triangular shape.

[0010] In some technical solutions of this utility model, the inner tangents of the first guide wheel and the second guide wheel are parallel to the force measurement direction of the LoadCell sensor.

[0011] In some technical solutions of this utility model, a bracket is installed on the side wall of the support frame, and a third guide wheel is rotatably provided on the bracket. The internal tangent of the third guide wheel and the first guide wheel is parallel to the force measurement direction of the Load Cell sensor.

[0012] In some technical solutions of this utility model, the first driving mechanism includes a wire feeding servo motor mounted on a support frame, and the wire feeding servo motor and the raw material reel are driven by a reducer.

[0013] In some technical solutions of this utility model, the diameter of the middle area of ​​the waist drum wheel is larger than the diameter of both ends of the waist drum wheel.

[0014] In some technical solutions of this utility model, the inner width of the waist drum wheel is equal to the inner width of the raw material reel, and the three together with the coding wheel are axially symmetrical on the same plane.

[0015] In some technical solutions of this utility model, one end of the Load Cell sensor is cantilevered and fixed to the side wall of the fixture, while the other end is a free end to allow for nanoscale deformation, with a gap between it and the side wall of the fixture.

[0016] Compared with the prior art, this utility model has at least the following advantages or beneficial effects: the slide structure can drive the support frame and the raw material reel to move axially, allowing the tungsten wire led out by the third guide wheel to align with the positions of multiple die holes on the drawing machine, thereby selecting the placement position of the first die on the die frame and adapting to different drawing die numbers; the wire feeding servo motor drives the raw material reel to actively rotate and feed the wire through a reducer; a high-sensitivity digital Load Cell sensor is mounted on the fixed frame for directly measuring the actual tension of the tungsten wire; the first guide wheel is mounted on the Load Cell sensor, and the second guide wheel and the encoder wheel ensure that the tungsten wire entering and exiting the first guide wheel is parallel to the force measurement direction of the sensor, ensuring the accuracy of tension measurement; the encoder, in conjunction with the encoder wheel, accurately measures the linear velocity and cumulative length of the released tungsten wire for calculating the real-time reel diameter; based on the tension feedback signal of the Load Cell sensor, the control system performs high-speed PID control. The system calculates and dynamically adjusts the speed of the unwinding servo motor in real time. The curved rubber wheel of the waist drum, with a large diameter in the middle and small diameters at both ends, has a high coefficient of friction, forcing the tungsten wire to be released perpendicular to the axis of the raw material reel, preventing slippage, wire collapse, and tension spikes caused by the tungsten wire being pulled at an angle. The waist drum also allows the contact arc length of the tungsten wire on it to change with the unwinding position (from the end of the reel to the middle), automatically compensating for the length change caused by the change in the tungsten wire release path from "oblique pull" to "straight pull," significantly reducing the resulting tension fluctuation. These measures ensure that when the unwinding tension is set within the range of 0.5~5N, the tension fluctuation value is ≤±0.1N. Attached Figure Description

[0017] Figure 1 This is a first-view structural diagram of the wire feeding structure in this utility model.

[0018] Figure 2 This is a second-view structural diagram of the wire feeding structure in this utility model.

[0019] Figure 3 This is a schematic diagram of the installation structure of the Load Cell sensor in this utility model.

[0020] Figure 4 This is a comparative structural diagram of the present invention with and without a waist drum wheel.

[0021] Reference numerals in the attached diagram: 1. Feeding frame; 2. Third guide roller; 3. Raw material reel; 4. Waist drum roller; 5. Encoding roller; 6. Mounting frame; 7. Load Cell sensor; 8. Fixing frame; 9. First guide roller; 10. Second guide roller; 11. Feeding servo motor; 12. Reducer; 13. Support frame; 14. Slide table structure; 15. Bracket; 16. Encoder. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0023] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without inventive effort are within the scope of protection of this invention.

[0024] Example This utility model provides a wire feeding mechanism based on constant tension thermal straightening of tungsten wire, such as... Figures 1-4 As shown, the device includes a wire feeding frame 1. A slide structure 14 is bolted to the top of the wire feeding frame 1. A support frame 13 is installed at the sliding end of the slide structure 14. The support frame 13 is a square frame structure and is bolted to the slider of the slide structure 14. The slide structure 14 is a manual slide with a self-locking function. This is a conventional technique. Adjusting the front and rear position of the slide within the slide structure 14 allows the operator to select the position of the first die of the wire drawing machine, enabling the operator to choose how many wire drawing dies to use to reduce the diameter of the tungsten wire based on its diameter.

[0025] A raw material reel 3 is mounted on one side of the support frame 13. A first drive mechanism is mounted on the side wall of the support frame 13 and is connected to the raw material reel 3. The first drive mechanism includes a wire feeding servo motor 11 mounted on the support frame 13, and a reducer 12 is provided between the wire feeding servo motor 11 and the raw material reel 15. The wire feeding servo motor 11 drives the raw material reel 3 to rotate and feed the wire through the reducer 12, dynamically adjusting the tungsten wire release speed to ensure that the tungsten wire maintains minimal tension fluctuation during the release process.

[0026] A fixed frame 8 is installed on one side of the support frame 13. The fixed frame 8 and the raw material reel 3 are located on the same side wall and are rotatably equipped with a waist drum wheel 4. The fixed frame 8 is equipped with a tungsten wire linear velocity detection structure for calculating the real-time winding diameter of the raw material reel. A Load Cell sensor 7 for measuring the tungsten wire traction force is cantilevered on the side wall of the fixed frame 8. A first guide wheel 9 is installed at the free end of the Load Cell sensor 7. A second guide wheel 10 is installed between the first guide wheel 9 and the tungsten wire linear velocity detection structure. The first guide wheel 9 is mounted on the free end sidewall of the Load Cell sensor 7. The second guide wheel 10 and the third guide wheel 2 ensure that the tungsten wire entering and exiting the first guide wheel 9 is parallel to the force measurement direction of the Load Cell sensor 7, transmitting the tension of the tungsten wire to the Load Cell sensor 7. The Load Cell sensor 7 converts the tension into a high-speed communication digital signal and feeds it back to the control system. The control system performs PID calculations based on the feedback signal to control the real-time speed of the wire feeding servo motor 11: when the wire feeding tension detected by the Load Cell sensor 7 is equal to the set value, the servo motor runs at the reference speed; when the wire feeding tension detected by the Load Cell sensor 7 is greater than the set value, the real-time speed of the servo motor is higher than the reference speed, accelerating the wire feeding speed and thus reducing the tension; when the wire feeding tension detected by the Load Cell sensor 7 is smaller than the set value, the real-time speed of the servo motor is lower than the reference speed, slowing down the wire feeding speed and thus increasing the tension. The entire servo wire feeding mechanism maintains a basically stable wire feeding tension through such continuous dynamic adjustments.

[0027] Because the Load Cell sensor 7 only requires nanometer-level deformation to respond, this tension detection method has much higher sensitivity and response speed than sensors that detect angular or linear displacement. Despite factors such as irregular tungsten wire feeding, reasonable bouncing of the raw material reel 3, and intermittent wire drawing by the traction wheel mechanism, the tension control can still be precisely controlled to ≤0.1N when the tungsten wire travels at a high speed of 2 meters per second. Furthermore, tension adjustment is very convenient; the wire feeding tension setting value can be input as needed through the HMI (Human Machine Interface) window, and the control system can quickly and automatically apply the set tension to the tungsten wire.

[0028] In some technical solutions of this utility model, the tungsten wire linear speed detection structure includes a mounting frame 6, which is set on top of a fixed frame 8. An encoder 16 is mounted on the top of the mounting frame 6, and an encoder wheel 5 is mounted on the shaft end of the encoder 16. An annular groove is formed on the surface of the encoder wheel 5. As the wire is unwound, the diameter of the raw material reel 3 gradually decreases from full to empty. When the tungsten wire passes through the encoder wheel 5, it drives the encoder 16 to generate a pulse signal. The control system can calculate the length and speed of the tungsten wire passing through the encoder wheel 5 per unit time based on the pulse signal, thereby calculating the real-time diameter of the raw material reel 3. The control system can calculate the required reference speed of the unwound servo motor 11 based on the real-time diameter of the raw material reel 3, the feed rate Vf before unwound (determined by the drawing speed and drawing compression ratio), and the reduction ratio of the reducer 12. The unwound servo motor 11, connected to the reducer 12, drives the raw material reel 3 to rotate and unwound the wire, dynamically adjusting the tungsten wire release speed in real time to ensure that the tungsten wire maintains minimal tension fluctuation.

[0029] In some technical solutions of this utility model, the coding wheel 5 is located directly above the raw material reel 3, and together with the waist drum wheel 4, the three are arranged in a triangular shape, and the three are axially symmetrical on the same plane.

[0030] In some technical solutions of this utility model, the internal tangents of the first guide wheel 9, the second guide wheel 10, and the third guide wheel 2 are parallel to the force measurement direction of the Load Cell sensor. By using the second guide wheel 10 and the third guide wheel 2 in the above-mentioned configuration, the tungsten wire entering and exiting the first guide wheel 9 is parallel to the force measurement direction of the Load Cell sensor 7, thereby improving the measurement accuracy of the Load Cell sensor 7.

[0031] In some technical solutions of this utility model, a bracket 15 is installed on the side wall of the support frame 13, and a third guide wheel 2 is provided on the bracket 15. The third guide wheel 2 is used to guide the tungsten wire into the next process in a horizontal direction to prevent the tungsten wire from shifting or loosening.

[0032] Preferably, to ensure tension control accuracy, a LoadCell sensor 7 with a data transmission rate of 20KHz and a resolution of 0.0006N is used to detect tension. During installation, the force measurement direction of the LoadCell sensor 7 is perpendicular to the vibration direction generated by the mounting surface to reduce the interference of external vibration on the highly sensitive LoadCell sensor 7. At the same time, the signal collected by the LoadCell sensor 7 is low-pass filtered in the control program to remove interference noise.

[0033] Preferably, in order to prevent the tungsten wire from loosening and falling off during the wire threading and operation, the program is designed so that each servo motor only responds when the tension detected by the Load Cell sensor 7 is greater than 0.5N, so that the tungsten wire is always under tension and in a taut state.

[0034] Preferably, in order to achieve high-speed and high-precision multi-axis motion control of the wire drawing machine, the control system adopts a high-performance motion controller, EtherCAT high-speed communication, supports at least 6-axis motion control, and has a minimum synchronization time of ≤1 ms.

[0035] Preferably, to ensure that the motion mechanism has a sufficiently fast transient response speed, the servo motor model is selected with an inertia ratio of less than 3, and the servo driver is set to a high rigidity; all guide wheel moving parts adopt a low rotational inertia design, are made of lightweight aluminum alloy, and are designed as thin-walled rotating parts with a maximum diameter ≤60mm.

[0036] In some technical solutions of this utility model, the diameter of the middle region of the waist drum wheel 4 is larger than the diameter of both ends of the waist drum wheel 4, and the inner width of the waist drum wheel 4 is equal to the inner width of the raw material reel 3. This design of the waist drum wheel 4 serves two purposes: First, the waist drum wheel 4 is positioned in the middle of the encoder wheel 5 and the raw material reel 3, arranged in a triangular pattern. This avoids the following problems that occur when the tungsten wire is directly output from the raw material reel 3 to the encoder wheel 5: as it rolls out sequentially from the middle of the raw material reel 3 to any end, the tungsten wire being fed from the raw material reel 3 to the encoder wheel 5 will gradually change from a straight pull to an oblique pull, and the low friction between the smooth tungsten wires on the surface of the raw material reel 3 can cause the tungsten wire to sag or loosen due to the oblique pull. Sag or loosening caused by the oblique pull can cause a step change in the wire release tension, resulting in the PID control system failing to adjust in time and leading to loss of control. Therefore, by adding the waist drum wheel 4 between the encoder wheel 5 and the raw material reel 3, the high coefficient of friction of the rubber surface of the waist drum wheel 4 prevents the tungsten wire from slipping on the surface of the waist drum wheel 4 due to the oblique pull. This ensures that the tungsten wire remains perpendicular to the reel axis when it rolls off the raw material reel 3, and the oblique pull only occurs between the waist drum wheel 4 and the encoder wheel 5.

[0037] Secondly, after the tungsten wire is tensioned by the waist drum wheel 4 between the encoder wheel 5 and the raw material reel 3, as the tungsten wire rolls out sequentially from any end to the middle of the raw material reel 3, the tungsten wire between the encoder wheel 5 and the waist drum wheel 4 gradually changes from being pulled at an angle to being pulled straight. The length of this section of tungsten wire gradually shortens. Excessive changes in the length of the tungsten wire cause significant fluctuations in the tension during wire release, reducing the control accuracy of the control system due to the large adjustment range. To adjust the tension fluctuation trend caused by the length change of this section of tungsten wire, the designers designed the waist drum wheel 4 as a curved surface structure with a gradually increasing diameter from both ends to the middle. This allows the length of the tungsten wire that contacts the curved surface of the waist drum wheel 4 to gradually increase from both ends to the middle. This increase in length during the change process precisely compensates for the decrease in length of the tungsten wire from being pulled at an angle to being pulled straight, keeping the tungsten wire length essentially constant. This ensures that the tension of the tungsten wire is stable and controllable during release.

[0038] Preferably, the surface of the waist drum wheel 4 is made of a material with a high coefficient of friction and wear resistance, such as rubber.

[0039] In some technical solutions of this utility model, one end of the Load Cell sensor 7 is cantilevered and fixed to the side wall of the fixing frame 8. A gap is left between the free end of the Load Cell sensor 7 and the side wall of the fixing frame 8, which allows the Load Cell sensor 7 to have room for deformation after being subjected to pressure, and avoids the Load Cell sensor 7 from being affected by contact with the fixing frame 8. At the same time, a step is provided on the side wall of the fixing frame 8 to ensure that the gap is only 0.4 mm. When the overload deformation of the Load Cell sensor 7 exceeds 0.4 mm, it can play an unloading protection role, preventing the Load Cell sensor 7 from being irreversibly damaged due to excessive deformation.

[0040] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A wire feeding mechanism based on constant tension thermal straightening of tungsten wire, characterized in that, Includes a wire feeding frame (1), the top of which is provided with a slide structure (14), and the sliding end of the slide structure (14) is equipped with a support frame (13). A raw material reel (3) is installed on one side of the support frame (13), and a first drive mechanism is installed on the side wall of the support frame (13). The first drive mechanism is connected to the raw material reel (3) in a transmission manner. A fixed frame (8) is installed on one side of the support frame (13). The fixed frame (8) and the raw material reel (3) are rotatably mounted on the side wall of the fixed frame (8). A tungsten wire linear velocity detection structure for calculating the real-time diameter of the raw material reel is provided on the fixed frame (8). A Load Cell sensor (7) for measuring the tungsten wire traction force is cantilevered on the fixed frame (8). A first guide wheel (9) is installed on the free end of the Load Cell sensor (7). A second guide wheel (10) is installed between the first guide wheel (9) and the tungsten wire linear velocity detection structure.

2. The wire feeding mechanism based on constant tension thermal straightening of tungsten wire according to claim 1, characterized in that, The tungsten wire linear velocity detection structure includes a mounting frame (6), which is located on the top of the fixed frame (8). An encoder (16) is mounted on the top of the mounting frame (6), and an encoder wheel (5) is mounted at the output end of the encoder (16). The encoder wheel (5) has an annular groove on its surface.

3. The wire feeding mechanism based on constant tension thermal straightening of tungsten wire according to claim 2, characterized in that, The coding wheel (5) is located directly above the raw material reel (3), and together with the waist drum wheel (4), the three are arranged in a triangular shape.

4. The wire feeding mechanism based on constant tension thermal straightening of tungsten wire according to claim 3, characterized in that, The inner tangents of the first guide wheel (9) and the second guide wheel (10) are parallel to the force measurement direction of the Load Cell sensor (7).

5. A wire feeding mechanism based on constant tension thermal straightening of tungsten wire according to any one of claims 1-4, characterized in that, A bracket (15) is installed on the side wall of the support frame (13), and a third guide wheel (2) is rotatably provided on the side wall of the bracket (15). The inner tangent of the third guide wheel (2) and the first guide wheel (9) is parallel to the force measurement direction of the Load Cell sensor (7).

6. The wire feeding mechanism based on constant tension thermal straightening of tungsten wire according to claim 5, characterized in that, The first driving mechanism includes a wire feeding servo motor (11) mounted on the support frame (13), and a speed reducer is provided between the wire feeding servo motor (11) and the raw material reel (3).

7. The wire feeding mechanism based on constant tension thermal straightening of tungsten wire according to claim 1, characterized in that, The diameter of the middle area of ​​the waist drum wheel (4) is greater than the diameter of the two ends of the waist drum wheel (4).

8. A wire feeding mechanism based on constant tension thermal straightening of tungsten wire according to claim 1 or 7, characterized in that, The inner width of the waist drum wheel (4) is equal to the inner width of the raw material reel (3), and together with the coding wheel (5), the three are axially symmetrical on the same plane.

9. The wire feeding mechanism based on constant tension thermal straightening of tungsten wire according to claim 1, characterized in that, One end of the Load Cell sensor (7) is cantilevered and fixed to the side wall of the fixture (8), while the other end of the Load Cell sensor (7) is a free end to allow for nanoscale deformation, with a gap between it and the side wall of the fixture (8).

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