Counter Assembly Pivot Axis and Tensioner Design
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Solution Overview
Problem
Conventional counter assemblies for coiling machinery experience inaccuracies in measurement due to bouncing caused by spring tension and lack of adjustability for different cable diameters and materials, leading to inconsistent contact between rollers and the line.
Innovation Solution
A counter assembly with adjustable rollers and a tensioner assembly where the arms share a pivot axis below the upper arm, orienting springs and tensioners to match the arm's upward and rearward movement, allowing for adjustable spring force to minimize bouncing and ensure continuous contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If springs are oriented rearward from the lower arm to the upper arm to maintain roller contact, then continuous contact between rollers and line is achieved, but the spring tension creates bouncing and measurement inaccuracies
Solution Approach 1:
The patent inverts the conventional spring orientation by positioning springs horizontally between the arms rather than rearward from lower to upper arm. This horizontal orientation eliminates the vertical bouncing component while maintaining continuous roller contact, resolving the contradiction between reliability of contact and measurement precision.
Solution Approach 2:
The patent changes the orientation parameter of the springs from rearward diagonal to horizontal, fundamentally altering how spring tension is applied. This parameter change transforms the vector components of spring force to eliminate bouncing while maintaining contact pressure, thereby improving measurement accuracy without sacrificing reliability.
2Device complexity
If fixed spring force is used to maintain roller contact, then simple structure is achieved, but the counter assembly lacks versatility for different cable diameters and materials
Solution Approach 1:
The patent introduces adjustability to the spring force parameter, allowing the system to dynamically adapt to different cable configurations. This transforms a static fixed-force system into a dynamic adjustable system, enabling versatile performance across different cable diameters and materials while maintaining relatively simple horizontal spring geometry.
Solution Approach 2:
The patent enables change in the spring force parameter through adjustment mechanisms, allowing optimization for different cable types. This parameter adjustability provides versatility without requiring complex reconfiguration of the entire counter assembly, balancing device complexity with adaptability.
3Reliability
If sufficient spring force is applied to ensure continuous roller contact, then measurement reliability is improved, but the upper arm experiences excessive tension and bouncing
Solution Approach 1:
By inverting the spring orientation to horizontal, the patent changes the direction of force application from diagonal rearward to horizontal. This eliminates the vertical tension component that causes bouncing while maintaining the horizontal contact force needed for reliability, thus resolving the contradiction between contact reliability and excessive tension.
Solution Approach 2:
The patent changes the vector orientation parameter of spring force from rearward diagonal to horizontal direction. This parameter change redistributes the force components to eliminate harmful vertical tension while maintaining necessary horizontal contact pressure, reducing bouncing without sacrificing measurement reliability.
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 solution reduces measurement inaccuracies by maintaining consistent tension and allowing for adjustment of spring force, enhancing versatility across various cable sizes and materials, thereby improving the accuracy and reliability of linear measurement.
Implementation Method 1
Springs are relied upon to stop bouncing and to maintain continuous contact between the rollers and the line
Implementation Method 2
The tensioner assembly is also coupled to an arm. Operation of the tensioner assembly acts to lengthen or shorten an elongated spring, thereby increasing or decreasing the spring force being exerted between the arms
Implementation Method 3
The counter assembly operates by passing the line between two opposing rollers. At least one of the rollers grips the line and is monitored to detect the amount of rotations made
Data Source
AI summary
A counter assembly for use with coiling machinery for the measurement of line being wound or unwound on a reel includes a body, an upper arm, a lower arm, and a tensioner assembly. The body defines a central channel for passage of the line. Rollers are coupled to the upper and lower arms and used to press against the line. Movement of the line between the rollers causes at least one roller to rotate. Rotation is converted to a linear distance for accurate measurement. The upper arm has a pivot axis that is below a horizontal portion of the upper arm and is shared with the lower arm. The tensioner assembly is oriented to share the same vector components of motion as the pivoting upper arm. The tensioner assembly also permits adjustment in the resting spring force acting on the rollers.