Integrated Chain Pre-Tensioning and Length Measurement Control
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Solution Overview
Problem
Current chain pre-tensioning and length measurement processes are inefficient, requiring excessive human labor and facilities, and struggle to effectively control chain length precision due to separate equipment and fixed pre-tensioning forces and times.
Innovation Solution
A chain intelligent pre-tensioning and chain length detection device that integrates pre-tensioning and measurement on a single device, using a servo system for pre-tensioning and a stepper motor for measurement, with sensors and a console to adjust and control forces, and a grating ruler for precise length measurement, allowing for automatic data recording and adjustment of pre-tensioning parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chain pre-tensioning and chain length measurement are performed separately on different facilities with fixed pre-tensioning force and time, then the equipment structure is simple, but the manufacturing efficiency is low and chain length precision cannot be effectively controlled
Solution Approach 1:
The patent combines the pre-tensioning facility and chain length measurement facility into a single integrated device. The pre-tensioning power device applies controlled force to the chain while the measurement device simultaneously measures chain length, eliminating the need for separate facilities and improving manufacturing efficiency.
Solution Approach 2:
The patent replaces fixed pre-tensioning force and time with dynamically adjustable parameters. The pre-tensioning power device can vary the pre-tensioning force magnitude and duration based on real-time measurement feedback, allowing optimization for different chain specifications and improving precision control.
2Manufacturing precision
If pre-tensioning force is increased to improve chain quality, then chain length precision improves, but the force required increases significantly
Solution Approach 1:
The patent implements a feedback control system where the measurement device continuously monitors chain length during pre-tensioning. When the chain length reaches the target value, the system automatically stops pre-tensioning, eliminating the need for excessively high forces and enabling precision control through real-time monitoring.
Solution Approach 2:
The patent performs preliminary measurement of the chain's original length before pre-tensioning. This allows the system to calculate the required pre-tensioning duration and force magnitude in advance, optimizing the pre-tensioning process to achieve target precision without applying excessive force.
3Ease of manufacture
If separate facilities are used for pre-tensioning and measurement, then each facility can be optimized independently, but excessive human labor and facilities are required
Solution Approach 1:
The patent designs a universal integrated facility that performs both pre-tensioning and chain length measurement functions. The device can handle different chain specifications through programmable parameters, eliminating the need for multiple specialized facilities and reducing overall system complexity.
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 solution enhances manufacturing efficiency, improves product quality, reduces human labor and facility needs, and ensures precise chain length control, significantly reducing the dissatisfactory yield rate and processing time.
Implementation Method 1
a pre-tensioning force sensor, and the other end is elastically connected to the first fixing block
Implementation Method 2
The length measuring device includes a grating ruler, a straight guide rail and an automatic measuring head
Implementation Method 3
The length measuring device includes a grating ruler, a straight guide rail and an automatic measuring head disposed on one side of the work platform
Data Source
AI summary
The disclosure relates to a chain intelligent pre-tensioning and chain length detection method and device thereof. The device includes a rack, a work platform, a pre-tensioning power device, a measuring power device, a length measuring device and a console. The console receives the information of the length measuring device to adjust and control the pre-tensioning power device. The pre-tensioning and chain length measurement adopts a combination structure of an independently operated screw loading system as well as two sets of unique straight guide rails and four pallets mounted on the guide rail. The pre-tensioning force loading adopts the servo system and works with decelerator and precision grinding screw for loading. The measuring force loading adopts stepper motor and works with precision grinding screw for loading. The pretension and measurement adopt two tensile force sensors, so that chain pre-tensioning force and the chain length measuring force can be controlled accurately.