Rebar Binding Machine Wire Feed Control to Prevent Slippage
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Solution Overview
Problem
Existing reinforcing bar binding machines face issues with wire feeding speed control, leading to slippage and inadequate wire feeding due to increased load and rotational speed, which affects binding efficiency.
Innovation Solution
A binding machine with a controller that adjusts the rotational speed of the drive unit based on the wire's state in the magazine, switching between two rotational speeds to maintain optimal wire feeding speed and prevent slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the rotational speed of the feeding motor is increased to increase wire feeding speed, then productivity is improved, but slippage occurs between the feeding gear and the wire causing feeding failure
Solution Approach 1:
The patent applies dynamics by making the rotational speed of the feeding motor variable rather than constant. The controller dynamically adjusts the rotational speed based on the detected wire state (coiled vs. straight), allowing the system to adapt to different wire conditions and prevent slippage while maintaining high productivity when appropriate.
Solution Approach 2:
The patent changes the operational parameter (rotational speed) of the feeding motor based on the wire state. When the wire is in a coiled state, the rotational speed is reduced to prevent slippage; when the wire is straight, the rotational speed can be increased for higher productivity. This parameter adjustment resolves the contradiction between speed and reliability.
2Loss of time
If the rotational speed of the feeding motor is increased to reduce binding time, then duration of action is improved, but the load on the wire increases causing slippage
Solution Approach 1:
The patent implements feedback by using a sensor to detect the wire state (coiled or straight) and using this information to control the feeding motor's rotational speed. This closed-loop control ensures that the motor speed is appropriately adjusted based on actual wire conditions, preventing slippage while optimizing binding time.
Solution Approach 2:
The system dynamically adjusts the motor speed based on real-time wire state detection. When the wire is coiled and prone to slippage, the speed is reduced; when the wire is straight and can handle higher speeds, the motor operates faster, thus reducing overall binding time without causing slippage.
Data Source
AI summary
A binding machine includes a magazine configured to accommodate a wire, a wire feeding unit configured to feed the wire in a forward direction in which the wire is pulled out from the magazine and to the magazine, a drive unit configured to drive the wire feeding unit, a curl forming unit configured to form a path along which the wire fed in the forward direction is to be wound around an object, a binding unit configured to twist the wire fed in the reverse direction and wound on the object by the wire feeding unit, and a controller configured to control the drive unit. The controller is configured to change a feeding speed of the wire by controlling a rotational speed of the drive unit based on a state of the wire in the magazine.