Bead Ring Winding With Segmented Grooves For Wire Alignment
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Solution Overview
Problem
Conventional bead ring winding machines face issues with irregular winding conditions due to high wire stiffness, leading to unstable inner circumferential length and potential collapse of the wire, which affects the quality and functionality of the bead ring.
Innovation Solution
A bead ring winding machine with a rotary body featuring an annular winding unit and ungrooved parts between alignment grooves, allowing smooth pitch feed and alignment of wire turns, preventing irregular winding and ensuring a stable inner circumferential length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If alignment grooves are formed in the bead former to guide wire winding, then wire alignment is improved, but wire collapse and irregular winding occur due to high wire stiffness in the turning region
Solution Approach 1:
The bead former is divided into multiple circumferential grooves and oblique grooves, segmenting the wire path into discrete sections. This segmentation allows the wire to be guided through specific zones (alignment region, turning region, pitch feed region) with optimized characteristics for each zone, preventing collapse while maintaining alignment.
Solution Approach 2:
The oblique groove acts as an intermediary element between the circumferential grooves. It provides a transition path that mediates the wire's movement from one circumferential groove to the next, allowing smooth pitch feed while accommodating wire stiffness through the inclined geometry.
2Productivity
If the wire is wound in a spiral pattern to accommodate pitch feed, then winding continuity is improved, but wire alignment at start and end positions deteriorates causing collapse
Solution Approach 1:
Different regions of the bead former are given different functions: the alignment groove region provides precise wire alignment, the turning region (oblique groove) handles pitch feed transitions, and the ungrooved portion allows free wire placement. This local differentiation ensures high alignment precision at critical positions while maintaining winding continuity overall.
3Speed
If the wire is placed at a tilt in the spiral pattern, then winding speed is improved, but inner circumferential length stability and bead ring function deteriorate
Solution Approach 1:
The alignment grooves are configured to preliminarily position the wire at correct intervals before the wire enters the winding region. This preliminary alignment action ensures that even at high winding speeds, the wire maintains proper spacing and orientation, preventing tilt and ensuring stable inner circumferential length.
Data Source
AI summary
A winding unit is formed in an annular pattern along the outer circumferential surface of a rotary body rotatable about a shaft. The winding unit has multiple alignment grooves in which a wire is wound and turns of the wire are aligned. The winding unit is provided with an ungrooved part formed to straddle the alignment grooves.