Gas Spraying Tension Control Device for Weak Workpieces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional conveyor devices face challenges in achieving high-precision tension control, especially when handling relatively weak workpieces, as they often apply excessive tension during state changes, leading to potential damage.
Innovation Solution
A tension control device incorporating a pressing member that applies tension via gas spraying, an actuator to adjust the pressing member's position, a pressure sensor to detect air pressure, a gap sensor to measure the floating gap, and a control unit to regulate the actuator based on both pressure and gap sensor data, enabling precise tension control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional conveyor devices apply tension by adjusting floater position based on pressure detection only, then the device structure remains simple, but tension control precision is insufficient
Solution Approach 1:
The patent combines pressure detection and gap detection into a unified control system. The control unit receives signals from both the pressure sensor (detecting workpiece pressure) and the gap sensor (detecting distance between floater and workpiece), merging these two detection mechanisms to achieve comprehensive tension control. This resolution allows the system to overcome the limitations of single-sensor approaches and achieve high-precision tension control during intermittent transfer operations.
Solution Approach 2:
The patent implements a feedback control mechanism where the control unit continuously monitors both pressure sensor output and gap sensor output, then adjusts the floater position accordingly. The gap sensor provides real-time feedback on the distance between the floater and workpiece, while the pressure sensor provides feedback on the actual pressure being applied. This dual feedback loop enables precise tension control by dynamically adjusting the actuator based on combined sensor inputs.
2Productivity
If tension is applied during state changes from stopped to travelling or vice versa, then the workpiece can be conveyed, but excessive tension is likely to damage relatively weak workpieces
Solution Approach 1:
The patent applies preliminary action by using the gap sensor to detect the distance between the floater and workpiece before tension is fully applied. During state changes (stopped to travelling or vice versa), the control unit first checks the gap sensor signal to determine the appropriate floater position, then gradually applies tension based on both gap and pressure feedback. This preliminary detection and gradual application prevents sudden excessive tension that could damage weak workpieces, while still enabling efficient conveyance.
Solution Approach 2:
The patent implements dynamics by making the tension application adaptive and variable based on real-time sensor feedback. The control unit dynamically adjusts the floater position and applied tension based on the combined inputs from the pressure sensor and gap sensor. During intermittent transfer operations, the system can vary the tension level according to the workpiece state and positioning, allowing efficient conveyance while preventing excessive tension damage to relatively weak workpieces.
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 allows for higher precision tension control by accurately adjusting tension based on both air pressure and floating gap measurements, reducing the risk of damage to weak workpieces and ensuring stable tension application.
Implementation Method 1
a pressing member configured to press an object in a noncontact manner by spraying a gas onto the object
Implementation Method 2
a pressure sensor configured to detect pressure of the gas
Implementation Method 3
a gap sensor configured to detect a floating amount of the object from the pressing member
Data Source
AI summary
The present disclosure is a tension control device which includes a pressing member configured to press an object in a noncontact manner by spraying a gas onto the object to which tension is applied, an actuator configured to vary a position of the pressing member, a pressure sensor configured to detect pressure of the gas, a gap sensor configured to detect a floating amount of the object from the pressing member, and a control unit configured to control the actuator based on a detected value of the pressure sensor and a detected value of the gap sensor.