Double-twist Bunching Machine Speed and Bobbin Volume Trade-off
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Double-lay stranding machines face limitations in processing speed and storage capacity due to the size of rotating hoops and strand diameters, leading to reduced productivity and increased downtime for coil changes.
Innovation Solution
The design features a deflection device with at least two rotatably mounted deflection rollers, allowing the strand material to loop around and be guided out of the rotating bracket's rotation area, enabling independent coil size and strand cross-section processing, with a guide roller for direction change and trough-shaped depressions for support, reducing power consumption and wear costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the rotating bracket is made large to increase storage volume of bobbins, then the storage capacity increases, but the rotation speed decreases due to increased inertia
Solution Approach 1:
The patent divides the stranding process into two separate stages: a first twisting rotor that performs initial twisting at high speed, and a second twisting rotor that performs final twisting at lower speed. This segmentation allows each rotor to be optimized independently - the first rotor remains small and fast for high-speed processing, while the second rotor handles the final stranding with larger bobbins without compromising overall productivity
Solution Approach 2:
The patent employs different rotational speeds for the two twisting rotors, with the first rotor operating at high speed and the second rotor operating at lower speed. This dynamic speed differentiation allows the system to maintain high processing speed in the first stage while accommodating larger bobbin sizes in the second stage, resolving the contradiction between speed and storage volume
2Speed
If the rotating bracket is made small to increase rotation speed, then the processing speed increases, but the storage volume of coils is reduced
Solution Approach 1:
The patent segments the stranding function into two separate twisting rotors, allowing the first rotor to be small and fast for high processing speed, while the second rotor can be larger to accommodate greater storage volume. This eliminates the need for a single large rotating bracket that would compromise speed
Solution Approach 2:
The patent arranges the two twisting rotors in sequence along the stranding path, utilizing the longitudinal dimension of the machine rather than relying on a single large rotating bracket. This dimensional transition allows high-speed processing in the first rotor while providing storage capacity in the second rotor downstream
3Volume of stationary object
If very large rotating hoops are used with small strand diameters to achieve high storage capacity, then the storage capacity increases, but the number of strokes and operating speed are reduced
Solution Approach 1:
The patent divides the stranding operation into two separate twisting rotors, allowing the first rotor to operate at high speed for small-diameter strands while the second rotor handles the final stranding with larger bobbins. This segmentation prevents the operating speed from being limited by the size of the largest bobbin
Solution Approach 2:
The patent employs different rotational speeds for the two twisting rotors, with the first rotor operating at high speed optimized for small strand diameters and the second rotor operating at lower speed. This dynamic speed differentiation maintains high productivity while achieving high storage capacity in the second rotor
4Adaptability or versatility
If the stranding machine uses a complex gear arrangement to achieve different rotational speeds, then the processing capability increases, but the structural complexity and space requirements increase
Solution Approach 1:
The patent segments the speed control function into two independent twisting rotors, each with its own drive system. This allows each rotor to operate at its optimal speed without requiring complex gear arrangements to coordinate speeds between components, simplifying the overall structure while maintaining versatility
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 configuration enhances processing speed, reduces power consumption, and allows for flexible bobbin sizes and faster coil changes, maintaining strand integrity and increasing output while minimizing structural complexity and space requirements.
Implementation Method 1
The guide roller is provided laterally offset to the axis of rotation of the bracket and feeds the extruded material to the eccentric feed point of the deflection device
Implementation Method 2
A deflection device is provided in the second deflection point, which comprises at least one second deflection roller, which is mounted so as to rotate about its longitudinal axis in order to enable high processing speeds
Implementation Method 3
trough-shaped depressions for support
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a double-twist bunching machine for producing bunched strand material (14), in particular wires, with an inlet (17) for individual strands (12) which can be supplied to a first deflection point (18) which has a first deflection roller (19), wherein the first deflection roller (19) is arranged in a manner such that it can rotate about an axis of rotation (21) in order to form a first twist, with a hoop (24) which rotates about the axis of rotation (21) and connects the first deflection point (18) to a second deflection point (26), wherein the second deflection point (26) has at least one second deflection roller (32) which is rotatable about the axis of rotation (21) in order to form a second twist, and with a reel (36) onto which the bunched strand material (14) is wound and which is arranged outside the region of rotation of the hoop (24), wherein the second deflection roller (32) and at least one further deflection roller (55) which is assigned to the second deflection roller (32) form a deflection device (31), said deflection device (31) being mounted in pairs in a manner such that they can rotate about the axis of rotation (21), and wherein a supply point (33) for the strand material (14) is provided on the further deflection roller (55), said supply point lying between the second and at least one further deflection roller (32, 55) and having a take-off point of the strand material (14) on the second deflection roller (32), said take-off point lying in the second deflection point on the axis of rotation (21).