Segmented Wire Scraper for Lubricant Debris Removal
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Solution Overview
Problem
The presence of debris adhering to metal wires due to lubricants used in the wire drawing process poses challenges, particularly in sensitive manufacturing processes like vehicle manufacturing, as it can negatively affect the quality of the final product.
Innovation Solution
A multi-segment device with leading edges and a resilient member that applies force to contact the metal wire, allowing for debris removal without requiring the wire to be threaded through the device, ensuring efficient stripping without damaging protective coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wire threading device is used to strip debris, then debris removal effectiveness is improved, but device complexity and ease of operation worsen due to threading requirements
Solution Approach 1:
Instead of threading the wire through a closed device, the device segments are opened and the wire is simply placed into the passage, inverting the traditional threading approach. This resolves the contradiction by maintaining debris removal effectiveness while eliminating threading complexity.
Solution Approach 2:
The device is divided into multiple separable segments that can be opened and closed. This segmentation allows the wire to be easily inserted without threading while still providing the enclosed passage needed for effective debris stripping, thus resolving both complexity and operational ease issues.
2Reliability
If force is applied to strip debris, then debris removal effectiveness is improved, but risk of damaging protective coating increases
Solution Approach 1:
The leading edges of the segments are specifically designed with conformation to the wire outer diameter, creating localized contact only at the leading edges rather than along the entire wire surface. This allows force to be applied effectively for debris removal while minimizing contact area and reducing risk of coating damage.
Solution Approach 2:
The force application parameters are controlled by the resilient member, which provides sufficient force for debris stripping while limiting excessive force that could damage the coating. The leading edge geometry parameters are optimized to conform to the wire diameter, balancing stripping effectiveness with coating protection.
3Adaptability or versatility
If multiple segments are used to form the passage, then adaptability and ease of operation are improved, but device complexity increases
Solution Approach 1:
The multiple segments collectively form a universal passage structure that can accommodate different wire sizes through the resilient member's adjustment capability. Each segment performs multiple functions: forming the passage wall, providing the leading edge for stripping, and allowing for assembly/disassembly, thus reducing overall device complexity despite having multiple components.
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 device effectively removes debris from metal wires, maintaining the integrity of the wire and preventing debris from affecting downstream processes, while being simple and cost-effective to implement.
Implementation Method 1
a resilient member positioned around and applying a force to the at least two segments sufficient to cause contact between the leading edges and the metal wire passing through the passage
Data Source
AI summary
A device and related method for removing debris from a metal wire formed by a process utilizing a lubricant is provided. The device includes at least two segments forming a passage through which the wire passes, each having a leading edge for stripping debris from the wire, and a resilient member positioned around the at least two segments and applying a force to the segments sufficient to cause contact between the leading edges and at least the debris on the metal wire passing through the passage. The method broadly includes the steps of moving the metal wire through a passage formed by a plurality of segments, contacting the wire moving through the passage using a leading edge of each of the at least two segments, and applying a force to the at least two segments to cause contact between the leading edge of each of the at least two segments and at least the debris on the wire passing through the passage.