Insulated Wire Conductor Rolling with Driven Rolls
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Solution Overview
Problem
Conventional methods for manufacturing insulated electric wires struggle to produce conductors with desired wider cross-sectional widths and stable dimensions due to high back tension and width instability, leading to breakage and quality issues during the rolling process.
Innovation Solution
A method and apparatus where conductors are rolled using a pair of rotating rolls with a drive mechanism, allowing for variable control of roll distance and speed to manage conductor width variations, reducing back tension and enabling the production of conductors with larger cross-sectional widths and stable dimensions, and the entire process is conducted in a tandem arrangement to maintain consistent tension and prevent disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If free rolls rotating freely without a drive mechanism are used for rolling the conductor, then the rolling process is simple, but the conductor width becomes unstable and the reduction rate cannot be controlled, leading to breakage when high reduction is needed
Solution Approach 1:
The patent applies the dynamics principle by transitioning from static free-rotating rolls to dynamic driven rolls with variable speed control. The driven rolls can adjust their rotational speed according to the required reduction rate, enabling controlled deformation of the conductor while maintaining stability. This dynamic control allows the system to adapt to different manufacturing requirements without sacrificing simplicity.
Solution Approach 2:
The patent implements parameter changes by controlling the rotational speed of the driven rolls as a key parameter. By varying the speed of the driven rolls relative to each other and to the feed rate, the system can precisely control the reduction rate and final conductor width. This parameter control resolves the contradiction by enabling both simplicity and precision through speed adjustment rather than mechanical complexity.
2Productivity
If the reduction rate by free rolls is increased to achieve wider conductor cross-section, then the rolling efficiency improves, but the back tension increases excessively causing conductor breakage
Solution Approach 1:
The patent applies feedback control by monitoring the tension in the conductor during rolling and adjusting the driven roll speeds accordingly. When high reduction rates are applied to improve productivity, the feedback system detects the resulting back tension and adjusts the roll speeds to keep tension within safe limits, preventing conductor breakage while maintaining high rolling efficiency.
Solution Approach 2:
The dynamic speed control of driven rolls allows the system to optimize the reduction rate in real-time. By controlling the rotational speed differential between driven rolls, the system can achieve high reduction rates for productivity while dynamically adjusting to prevent excessive back tension, thus protecting the conductor from breaking.
3Speed
If driving rolls with predetermined speed are used, then the rolling speed is controlled, but it becomes difficult to stably manufacture conductors with desired width due to facility-associated factors
Solution Approach 1:
The patent overcomes the limitation of predetermined speed by implementing variable speed control of the driven rolls. Instead of fixed speeds, the system can change rotational speed parameters in response to actual manufacturing conditions, allowing precise control of reduction rate and final conductor width while maintaining stable production.
Solution Approach 2:
The feedback mechanism monitors conductor width and tension during rolling, and adjusts the driven roll speeds to compensate for facility-associated variations. This closed-loop control ensures that despite predetermined base speeds, the actual conductor width remains stable by dynamically adjusting operational parameters.
4Productivity
If the entire process from rolling to enamel varnish-coating and baking is arranged in tandem to improve product quality and extend wire length, then the production continuity improves, but the process becomes difficult to conduct due to width instability of the conductor
Solution Approach 1:
The dynamic control of driven rolls provides the width stability needed for continuous tandem processing. By actively controlling the reduction rate and final dimensions through variable speed operation, the system ensures consistent conductor width that can reliably proceed through subsequent coating and baking processes without interruption, enabling production continuity.
Solution Approach 2:
The feedback control system maintains precise width specifications throughout the rolling process, ensuring that conductors meet dimensional requirements before entering the tandem arrangement of coating and baking processes. This width stability, achieved through real-time monitoring and adjustment, enables the entire process to run continuously without interruptions for rework or quality issues.
Data Source
AI summary
The present invention relates to a method of manufacturing an insulated electric wire and an apparatus for manufacturing an insulated electric wire that can stably manufacture a conductor having a larger sectional width according to desired dimensions as compared to the rolling where the conductor is rolled by a pair of rolling rolls free-rotated, and that can conduct the entire process in a tandem arrangement.