Bistable Magnetic Alloy Wire Continuous Twisting
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Solution Overview
Problem
Conventional methods for manufacturing bistable magnetic alloy wires, such as mechanical stretching and twisting, result in low deformation on the surface and non-uniform magnetism, limiting their application in precision apparatus and hindering continuous production.
Innovation Solution
A method and device for continuous mechanical twisting of alloy wires, where the wire is uniformly twisted in forward and reverse directions, allowing for precise control of deformation and magnetic properties through adjustable wheel configurations and speeds, enabling uniform deformation and high processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional mechanical stretching or twisting is used to process alloy wire, then deformation can be applied to create magnetic properties, but the deformation on the surface is relatively small and the magnetism is not very high
Solution Approach 1:
The patent employs dynamic alternating twisting and untwisting operations on the alloy wire through a pair of rotating wheels. The wire is twisted in one direction during one half-cycle and untwisted in the opposite direction during the next half-cycle, creating dynamic deformation that significantly enhances surface deformation and magnetic properties compared to static conventional methods.
Solution Approach 2:
The processing mechanism uses periodic alternating action where the alloy wire undergoes repeated cycles of twisting and untwisting. This periodic deformation applies alternating forces to the wire surface, creating cumulative plastic deformation that increases coercivity and magnetic strength while maintaining uniformity throughout the wire.
2Manufacturing precision
If segmented positioning and twisting is used to increase shell deformation, then the outer circle generates relatively large deformation, but continuous production cannot be achieved and processing efficiency is low
Solution Approach 1:
The patent implements continuous processing by passing the alloy wire through rotating wheels that continuously apply twisting and untwisting forces. The wire moves continuously through the processing zone while the wheels rotate, eliminating the need for segmented positioning and enabling uninterrupted production with high processing efficiency while maintaining precise deformation control.
Solution Approach 2:
The patent replaces the manual or mechanical segmented positioning system with a rotating wheel mechanism that uses rotational motion to apply the required twisting forces. This substitution enables continuous wire feeding and processing, transforming a batch process into a continuous manufacturing operation.
3Manufacturing precision
If different twisting loops are applied in clockwise and counterclockwise directions, then deformation can be controlled, but the magnetization direction changes require large intensity magnetic fields and the process becomes complex
Solution Approach 1:
The patent introduces asymmetry in the twisting process by applying different numbers of loops in clockwise versus counterclockwise directions. This asymmetric deformation creates a net permanent deformation in the wire that controls magnetization characteristics. The asymmetric twisting is simpler to implement than applying large intensity magnetic fields and provides precise control over magnetic properties.
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 achieves continuous production of bistable magnetic alloy wires with uniform magnetic properties, enhancing their applicability in precision devices and reducing production costs.
Implementation Method 1
Heat treatment refers to a process of continuously heating the alloy wire, then cooling down, and repeating the process several times, so as to vary the eddy current of an inner layer of the alloy wire from that of the core, and to form a shell with relatively large thermal deformation
Implementation Method 2
The receiving reel operates via an electromotor, and a rotating speed of an anterior pair of wheels is less than that of a back pair of wheels, and therefore a tensile force is applied to a surface of the alloy wire, which generates much larger permanent deformation of the shell than of the core
Implementation Method 3
the fixtures are twisted around an axis of the alloy wire for multiple loops (e.g. 10 loops) in a clockwise (or counterclockwise) direction, and then in an opposite direction for the same number of loops, so that there is a relatively significant deformation on the shell of the alloy wire, and the core maintains a relatively small deformation from the mechanical stress method
Data Source
AI summary
Taught herein is a method for molding a bistable magnetic alloy wire, comprising: processing an alloy wire by heat treatment; and processing the alloy wire by cold treatment of mechanical twisting, the mechanical twisting being a repeated twisting in a continuous state. Also taught herein is a device for molding a bistable magnetic alloy wire.