Flat Material Clamping Layout for Variable-Length Insulation Stripping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wire processing machines are inefficient and costly in producing partially stripped busbars and coil elements with varying stripping lengths, requiring high-quality output while being cost-effective and having low operating costs.
Innovation Solution
A wire processing machine with an integrated stripping device featuring a clamping system where one clamping unit is fixed, and the other is movable, allowing for adjustable stripping lengths and precise control, using milling tools for mechanical stripping to ensure high precision and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser radiation is used for stripping flat material, then stripping quality is improved, but device cost and operating cost increase
Solution Approach 1:
The patent replaces expensive laser radiation systems with a mechanically simple knife that has a straight cutting edge. The knife mechanically removes the insulation layer through direct contact and friction as the flat material moves forward, achieving effective stripping without the high costs associated with laser systems.
Solution Approach 2:
The patent uses a simple, inexpensive knife that can be easily replaced rather than investing in expensive, complex laser equipment. The knife is a low-cost consumable that achieves the stripping function effectively without the high operating costs of laser systems.
2Manufacturing precision
If milling tools are used for stripping, then stripping precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts only the essential stripping function from complex milling tool systems, using a simple knife with a straight cutting edge that performs stripping through direct mechanical contact and friction, eliminating the need for complex milling mechanisms.
Solution Approach 2:
Instead of using complex milling tools that rotate cutting edges, the patent inverts the approach by using a stationary knife where the flat material moves forward, creating the stripping action through relative motion and friction rather than rotating cutters.
3Adaptability or versatility
If both clamping units are movable to adjust stripping length, then adaptability is improved, but device complexity and cost increase
Solution Approach 1:
The patent implements dynamic adjustability by making only the second clamping unit movable along the feed direction, while the first clamping unit remains fixed. This allows the distance between clamping units to be adjusted for different stripping lengths without requiring both units to be movable, reducing complexity.
Solution Approach 2:
The clamping system is segmented into two independent units: a fixed first clamping unit and a movable second clamping unit. This segmentation allows the movable unit to be independently positioned to achieve the desired stripping length, providing adaptability without requiring the entire clamping system to be complex.
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 machine achieves high productivity and quality in producing straight or curved molded parts with varying stripping lengths, reducing operational costs and ensuring robust construction, while maintaining precision and preventing damage to the metallic carrier material.
Implementation Method 1
a first milling tool engaged with a first lateral surface of the flat material and a second milling tool engaged with a second lateral surface of the flat material, wherein the milling tools move along the stationary flat material parallel to the feed direction for stripping
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
In a process for manufacturing straight or curved molded parts from insulated flat material comprising an electrically conductive substrate encased in an electrically insulating layer, the insulated flat material is drawn from a material supply by means of a feeding device and processed in a wire processing machine into a straight or curved molded part made of insulated flat material. This part is then cut from the supplied insulated flat material in a cutting operation. Before the molded part is cut from the supplied flat material, a section of the flat material is clamped at a first clamping point on the feed side and at a second clamping point located at a distance from it. In an intermediate area between the clamping points, a portion of the insulating layer is stripped from the electrically conductive substrate over a defined stripping length in a stripping operation.The distance between the clamping points is adjusted to parameters of the stripping operation, whereby one of the clamping points remains fixed to the machine and only the other clamping point is moved to change the distance between the clamping points.