Die Alignment Mechanism for Enameled Wire Manufacturing
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Solution Overview
Problem
In enameled wire manufacturing, the vibration, twist, and catenary shape of traveling wires make it difficult for them to pass through the center of the die's through-hole in horizontal-type equipment, leading to uneven coating material deposition and alignment issues.
Innovation Solution
A die with an alignment mechanism featuring a through-hole, a bearing member for rotational movement, and a movable member that aligns the central axis of the through-hole with the traveling wire's direction without inhibiting rotational movement, ensuring the wire can pass through the center even when vibrating or twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the traveling wire passes through the die in horizontal-type equipment, then the coating material can be applied around the wire, but the wire vibration, twist, or catenary shape causes misalignment with the through-hole center
Solution Approach 1:
The die is made rotatable about the wire's circumferential direction through a bearing member, allowing the die to dynamically adjust its orientation to follow wire twist or vibration, maintaining alignment between the through-hole center and wire surface
Solution Approach 2:
The alignment mechanism adds a rotational degree of freedom in the circumferential direction, transforming the alignment problem from a fixed 2D plane to a 3D dynamic system that can accommodate wire deviations
2Ease of operation
If the die is fixed in position, then the structure is simple, but the wire cannot pass through the center when it vibrates or twists
Solution Approach 1:
The die is made rotatable about the wire's circumferential direction through a bearing member, allowing the die to dynamically adjust its orientation to follow wire twist or vibration, maintaining alignment between the through-hole center and wire surface
Solution Approach 2:
The die's rotational position parameter is made variable through the bearing member, allowing the die to change its angular position to compensate for wire vibration or twist, ensuring continuous center alignment
3Manufacturing precision
If the die rotates to follow wire movement, then alignment is maintained, but the travel direction changes may interfere with rotational movement
Solution Approach 1:
The alignment function is separated into two independent components: the bearing member handles circumferential rotation while the movable member handles axial positioning, allowing each to operate independently without interfering with the other
Solution Approach 2:
The movable member acts as an intermediary that translates wire axial movements into die position adjustments, while the bearing member independently handles rotational adjustments, mediating between wire motion and die orientation
Data Source
AI summary
A die with alignment mechanism includes a die including a through-hole through which a traveling wire travels, a bearing member for rotationally moving the die in a circumferential direction of the traveling wire, and a movable member that moves the die so that a central axis of the through-hole is aligned with a travel direction of the traveling wire without inhibiting the rotational movement of the die produced by the bearing member when the travel direction changes in a direction orthogonal to the travel direction.