Multi-Wire Tension Buffer System with Pivoted Reversing Pulleys
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Solution Overview
Problem
Existing multi-wire pay-off systems face challenges in maintaining constant tension across multiple wires due to inaccuracies in electronic control systems and the need for multiple devices, which are not reliable in balancing tension differences between wires.
Innovation Solution
A mechanical tension buffer system utilizing guiding and reversing pulleys, where the reversing pulleys are rotatably mounted on pivoted supports, allowing for torque adjustments to balance tension differences by pivoting the supports and maintaining a symmetric structure to equalize force vectors, thereby balancing tension across multiple wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electronic control systems are used to measure and control wire tension, then tension can be monitored, but time delay and inaccuracy occur leading to unreliable tension maintenance
Solution Approach 1:
The patent replaces electronic control systems with a purely mechanical tension buffer system. The system uses pivoted supports with reversing pulleys that mechanically respond to tension differences between wires in real-time, eliminating electronic sensors, processors, and motors. This mechanical substitution removes time delays and electronic inaccuracies, providing immediate and reliable tension equalization through physical force balance.
2Adaptability or versatility
If multiple individual tensile control devices are used to accommodate multiple wires, then each wire can be controlled, but device complexity increases and tension setting differences occur due to manufacturing variations
Solution Approach 1:
The patent merges multiple individual tensile control devices into a single integrated tension buffer system. Multiple reversing pulleys are mounted on common pivoted supports that share a unified mechanical connection to the pay-off drums. This consolidation reduces the number of separate devices needed while maintaining the ability to accommodate and control multiple wires simultaneously, and eliminates tension setting differences by providing a unified tension reference point for all wires.
Solution Approach 2:
The tension buffer system is designed with universal applicability to multi-wire pay-off systems. The pivoted supports with reversing pulleys can handle multiple wires through a single mechanical structure, and the system can be adapted to different numbers of wires by adjusting the configuration of pulleys and supports. This multi-functional design eliminates the need for wire-specific control devices and their associated manufacturing variations.
3Ease of operation
If individual tensile control devices are used for each wire, then wire-specific tension control is possible, but the devices are not reliable in balancing tension differences between wires
Solution Approach 1:
The patent creates a mechanical equipotential system where all wires are connected through common pivoted supports. The pivoted supports act as a mechanical reference plane that equalizes the potential energy state of all wires. When tension differences exist, the pivoted supports rotate to redistribute forces, automatically bringing all wires to the same tension level. This equipotential approach ensures reliable tension balancing without requiring complex individual control for each wire.
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 system effectively balances tension differences between multiple wires, providing a reliable and accurate mechanical solution that maintains constant tension, improving the quality of steel cords produced by ensuring consistent wire tension during the twisting process.
Implementation Method 1
Two reversing pulleys are rotatably mounted on a first support. The first support is pivoted around first support axis lying between the two reversing pulleys so that pivoting brings one of the two reversing pulleys closer to one of said guiding pulleys while the other of the two reversing pulleys more remote from another of said guiding pulleys.
Implementation Method 2
Each reversing pulley is adapted to guide a wire from a guiding pulley and back to a guiding pulley.
Data Source
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Figure 3
Figure 4~5
AI summary
This invention relates to a tension buffer system for multi-wirepay-off system. The tension buffer system comprises guiding pulleys (4, 4a, 4b) adapted to guide wires (6, 6a, 6b) being paid off, and reversing pulleys (8). Each reversing pulley (8) is adapted to guide a wire (6, 6a, 6b) from the guiding pulley (4, 4a, 4b) and back to the guiding pulley (4, 4a, 4b),two reversing pulleys (8) are rotatably mounted on a first support (10), the first support (10) is pivoted around first support axis (12) lying between the two reversing pulleys (8) so that pivoting brings one of the two reversing pulleys (8) closer to the guiding pulley (4, 4a, 4b) while the other of the two reversing pulleys (8) more remote from said guiding pulley (4, 4a, 4b). This invention provides a mechanical device to balance the tension difference between multiple wires in the pay-off system to produce a steel cord with constant tension and satisfactory quality.