Reel Drive Control for Constant Wire Tension
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Solution Overview
Problem
Existing methods for controlling the drive of a reel with a coil in wire processing machines fail to maintain constant wire tension and adapt to highly dynamic processing machines, leading to uneven wire feed and fluctuating tensile loads, which affect the accuracy and reproducibility of machining tasks.
Innovation Solution
A method where the speed profile of the reel is controlled using a predetermined speed-time profile that is offset by a specified period of time relative to the feed speed profile, allowing the reel to start before the feed rollers, ensuring smooth operation and compensating for rapid changes in wire feed speed, thereby maintaining constant tensile loads and achieving higher processing speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reel is controlled as a reaction to feed movement using known control methods, then the reel can adapt to feed speed changes, but the reaction is not sufficiently rapid for highly dynamic processing machines, causing uneven wire feed and fluctuating tensile loads
Solution Approach 1:
The speed-time profile for the reel is determined in advance based on the feed speed-time profile, allowing the reel to anticipate and prepare for speed changes rather than reacting to them. This preliminary determination enables the reel control to proactively adjust wire delivery speed before feed speed changes occur, eliminating delays and ensuring consistent wire tension during dynamic processing operations
2Adaptability or versatility
If the reel speed is adjusted to follow feed speed changes, then wire feed can adapt to processing requirements, but tensile loads fluctuate and wire can buckle, affecting machining accuracy
Solution Approach 1:
The control system continuously monitors the feed speed and uses this information to dynamically adjust the reel speed through the determined speed-time profile. This feedback mechanism ensures that the reel delivers wire at the precise speed required by the processing machine, maintaining constant tensile loads and preventing wire buckling while adapting to varying processing requirements
3Ease of manufacture
If the reel starts after the feed rollers, then the system follows a simple sequential operation, but pressure peaks occur during start-up and wire tension fluctuates
Solution Approach 1:
The reel is configured to start before the feed rollers based on the predetermined speed-time profile, which calculates the optimal start sequence. This preliminary action allows the reel to begin delivering wire in advance, creating a buffer that prevents tension fluctuations and pressure peaks during feed roller startup, while the automated profile determination keeps the control system relatively simple
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 approach ensures smooth reel operation, maintains constant tensile loads, and allows for higher processing speeds, improving the accuracy and reproducibility of machining tasks while enabling the production of different parts without changing the coiler, with minimal fluctuation in tensile loads.
Implementation Method 1
a tensioning device which is resiliently pretensioned in a direction of deflection and is effective up to a maximum deflection, in order to keep the wire tension approximately constant
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The device has a wire storage that is formed in the form of a coil (9), from which the wire (5) is fed under interposition of a clamping unit (11) for approximated stabilization of the wire tension of a transverse feed unit (4). The drive control of a winch (3) starts the speed-time profile of the reel opposite to the speed-time profile of feed speed around a predetermined time period.