Adaptive Stripping of Flat Metallic Wires
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Solution Overview
Problem
Existing methods for stripping insulating layers from flat metallic wires often result in uneven removal, leading to cross-sectional reductions of the wire, which affects the wire's quality and lifespan, especially in applications requiring precise thickness adjustments, such as electric motors.
Innovation Solution
A device with coordinated linear actuators and vertebral current sensors is used to precisely measure and remove the insulating layer without affecting the metallic wire's diameter, ensuring accurate stripping and maintaining the wire's original cross-sectional profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical devices are set to remove the thickest insulating layer reliably, then complete insulation removal is ensured, but part of the metallic wire is inevitably removed causing cross-sectional reduction
Solution Approach 1:
The device dynamically adjusts the blade penetration depth based on real-time insulation thickness measurements. The control unit processes signals from thickness sensors and automatically positions the blade at the optimal depth, transforming a static fixed-depth mechanism into a dynamic adaptive system that responds to actual insulation variations.
Solution Approach 2:
The system implements closed-loop feedback by continuously measuring insulation thickness with sensors, comparing the measurement against target values, and adjusting the blade penetration depth accordingly. This feedback mechanism ensures that the blade removes exactly the required insulation thickness without penetrating into the metallic wire.
2Productivity
If fixed mechanical devices are used for stripping, then the stripping process is simple and quick, but uneven insulation thickness leads to wire cross-sectional reduction
Solution Approach 1:
The device performs preliminary measurement of the insulation thickness before the stripping operation. By capturing the actual insulation thickness in advance and using this information to set the blade penetration depth, the system prepares the optimal stripping parameters before contact is made, enabling precise and efficient removal.
Solution Approach 2:
The system changes the penetration depth parameter of the stripping blade based on measured insulation thickness. Instead of using a fixed mechanical setting, the blade depth is adjusted as a variable parameter determined by actual insulation measurements, allowing the system to adapt to variations while maintaining high productivity.
3Manufacturing precision
If laser beam is used for insulation removal, then independent of insulation thickness is achieved, but large proportion of pollution due to burned residues is created
Solution Approach 1:
The invention replaces the thermal laser process with a mechanical blade-based stripping system. Instead of using high-energy laser beams that burn and vaporize insulation creating residues, a mechanically controlled blade physically removes the insulation through controlled penetration and scraping action, eliminating the pollution problem while maintaining precision through sensor feedback.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables precise and efficient removal of the insulating layer, preventing cross-sectional reductions and ensuring consistent wire quality and extended device lifespan by decoupling graduation depth and stripping movement, allowing for precise parameter setting during the stripping process.
Implementation Method 1
a vertebrae sensor to capture a thickness of the insulation, wherein the vertebrae sensor is set up in such a way that suitable means induce a vertebral current in the metallic wire below its insulating layer is, the properties of which in turn can be read out by a suitable reception
Data Source
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Figure 3a~3c
Figure 4
AI summary
The present invention relates to a device (10) for adaptively stripping insulated flat metallic wires (D), comprising at least one device for detecting the total thickness (14) of a supplied insulated wire (D), at least one device for detecting a thickness of the insulation (16) of the supplied wire (D) at at least one position, at least one adjustable device (20) for mechanically stripping the supplied wire (D) on at least one of its flat sides, wherein the device for mechanically stripping (20) is adjustable with respect to its stripping depth and comprises a mechanical stripping means (24);and a control unit (18) which is operationally coupled to the at least one device for detecting the total thickness (14) and the at least one device for detecting the thickness of the insulation (16) and is configured to adjust the stripping depth of the mechanical stripping device (20) based on the detected thicknesses. Furthermore, the invention relates to a method for stripping insulated flat metallic wires.