Cable Straightening Device with Adjustable Roller Force
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Solution Overview
Problem
Existing straightening devices for cables lack reproducibility and flexibility in adjusting settings, leading to suboptimal straightening results due to inadequate adjustment mechanisms and reliance on manual, non-standardized methods, which are sensitive to cable material variations and production tolerances.
Innovation Solution
A straightening device with adjustable roller assemblies that allow precise setting of roller distance and force application in two degrees of freedom, enabling reproducible and optimal straightening across different machines and cable types, utilizing a combination of adjustable roller plates and a pneumatic cylinder for controlled force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional adjustment mechanisms with engraved scales and adjusting screws are used, then the device structure remains simple, but the adjustment precision and reproducibility deteriorate
Solution Approach 1:
The patent replaces traditional mechanical adjustment mechanisms (engraved scales and adjusting screws) with a motor-driven roller bar positioning system. The drive unit (motor) automatically positions the roller bar according to stored setting data, eliminating manual mechanical adjustment and achieving high precision through automated control.
Solution Approach 2:
The patent implements a setting data storage system that stores optimal roller bar positions and roller inclinations for different cable types. These settings can be copied and transferred between different straightening devices, ensuring reproducibility without requiring manual re-adjustment on each device.
2Manufacturing precision
If manual adjustment with rule of thumb is used, then the operation is simple, but the straightening quality and consistency deteriorate
Solution Approach 1:
The system uses stored setting data as a reference standard for optimal straightening parameters. The automated positioning system compares actual positions with target positions from the stored data, ensuring consistent high-quality straightening results across different operations and operators.
Solution Approach 2:
Optimal straightening settings for different cable types are pre-calculated and stored in the setting data storage system. When a cable type is selected, the corresponding pre-optimized settings are automatically retrieved and applied, eliminating the need for operators to manually adjust based on experience.
3Adaptability or versatility
If roller positions are fixed for specific materials, then the device structure remains simple, but the adaptability to different cable types deteriorates
Solution Approach 1:
The straightening device is designed with universal adaptability through its adjustable roller bar positioning system and roller inclination mechanism. By storing setting data for multiple cable types and using automated motor-driven adjustment, a single device can handle various cable types (different materials, diameters, elasticity) without requiring multiple dedicated devices.
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 device ensures consistent and optimal straightening performance by allowing precise adjustment of roller distance and force, reducing the impact of cable material variations and manufacturing tolerances, and enabling easy transfer of settings between machines, resulting in improved reproducibility and reduced deviations in straightening results.
Implementation Method 1
a pneumatic cylinder for controlled force application
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
Straightening device (100) for straightening cables (1) with an input roller arrangement (110) and an output roller arrangement (120), they are arranged such that a cable (1) to be straightened, viewed in the transport direction (X), passes between rollers (111, 112, 113) of the input roller arrangement (110) into the straightening device (100) and, after passing between rollers (121, 122, 123, 124) of the output roller arrangement (120), leaves the straightening device (100), wherein a distance (d) between two rollers (122, 123) of the output roller arrangement (120) is adjustable. Furthermore, a force (F) can be specified which acts on the cable (1) between two rollers (111, 112) of the input-side roller arrangement (110) perpendicular to the transport direction (X).