Asymmetric Grooved Wire Manufacturing via Odd-Number Roller Configuration
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Solution Overview
Problem
Existing wire manufacturing methods are inefficient in minimizing material usage while maintaining desirable mechanical properties like bending yield strength, particularly in creating wires with grooves that can resist shear loads effectively.
Innovation Solution
A method and device using multiple rollers to produce an odd number of grooves asymmetrically distributed around the circumference of a wire, where each grooved section is directly opposite to a protruding section, reducing material usage and maintaining strength by using two sets of rollers with different groove-forming profiles, one set forming grooves and the other filling gaps between them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If identical rollers are used to create grooves in wire, then the manufacturing process is simple and symmetrical, but the wire cannot effectively resist shear loads because grooved sections are directly opposite to other grooved sections
Solution Approach 1:
The patent applies asymmetry by configuring rollers to create an odd number of grooves (5, 7, or 9) around the wire circumference, ensuring that grooved sections are not directly opposite each other. Instead, each grooved section is positioned opposite a protruding (non-grooved) section, which provides superior shear load resistance. This asymmetric groove distribution resolves the technical contradiction by prioritizing strength over symmetric simplicity.
2Strength
If more material is used to manufacture wire, then the wire has greater strength and durability, but the manufacturing cost increases
Solution Approach 1:
The patent applies local quality by creating grooves with specific depth and width parameters that remove material only where necessary for the desired function. The grooves are engineered to provide adequate strength reduction while minimizing overall material consumption. By optimizing the local geometry of grooved sections rather than uniformly thickening the entire wire, the invention achieves the contradiction resolution of maintaining strength while reducing total material usage.
3Quantity of substance
If grooves are formed in wire to reduce material usage, then manufacturing cost and weight decrease, but flashing increases during the groove formation process
Solution Approach 1:
The patent applies preliminary action by carefully pre-configuring the roller groove-forming surfaces with precise geometry and positioning before the wire drawing process. The rollers are designed with specific radii, groove depths, and spacing that preemptively control material flow during groove formation, minimizing flashing generation. This preliminary optimization of roller parameters prevents excessive flashing rather than addressing it after the fact.
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
This approach reduces material costs and weight without compromising the wire's bending yield strength, allowing the wire to effectively resist shear loads and minimize flashing, while also extending tooling life through the use of durable roller materials.
Implementation Method 1
Longitudinal grooves in an elongated metal substrate are produced by pulling the metal substrate through a plurality of rollers. The rollers have groove-forming protrusions thereon...
Data Source
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AI summary
A plurality of rollers (114,116, 214, 216) for producing longitudinal grooves (120, 122, 220, 222) in an elongated metal substrate (w), the plurality of rollers comprising a first set (114) and a second set (116) of rollers, the plurality of rollers having groove -forming fluted edges thereon. The plurality of rollers are aligned circumferentially around and parallel to a longitudinal axis of the elongated metal substrate, wherein the plurality of rollers are configured to produce an odd number of grooves distributed asymmetrically about a circumference of the elongated metal substrate.