Servo Controlled Wire Pulling for Paper Stitching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wire stitching machines face issues with uneven wire feeding, leading to improper stapling due to unrestrained wire pulling, which results in tangling, kinking, and inconsistent staple lengths, affecting product quality and the lifespan of the stitching head.
Innovation Solution
A servo-controlled stitching apparatus with a programmable servo motor and gearbox system that uses wire pulling rollers with grooves and pressure rollers to pull a predefined length of wire, maintaining uniform tension and avoiding direct pulling from the spool, ensuring consistent wire length and reducing load on the stitching head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the stitching head directly pulls wire from the spool, then the stitching operation can be performed, but the wire feeding becomes uneven and inconsistent staple lengths occur
Solution Approach 1:
A wire pulling mechanism with controlled rollers is introduced as an intermediary between the spool and stitching head. This mechanism includes a pulling roller that engages the wire and a control roller that regulates wire feed, preventing direct pulling by the stitching head and ensuring uniform wire delivery
Solution Approach 2:
The wire feeding parameters are controlled by adjusting the rotation speed and position of the pulling and control rollers. The system changes the wire feed rate dynamically to maintain consistent tension and length, resolving the precision issue while maintaining operational ease
2Productivity
If the stitching head pulls wire directly from the spool, then the stitching process continues, but the wire becomes tangled and kinked
Solution Approach 1:
The wire pulling mechanism with guided rollers acts as a mediator that controls wire extraction from the spool. The rollers guide the wire smoothly and prevent tangling by maintaining proper tension and alignment during the stitching process
Solution Approach 2:
The wire is pre-pulled and positioned by the pulling mechanism before reaching the stitching head. This preliminary action ensures the wire is properly aligned and tensioned, preventing kinking and tangling during the actual stitching operation
3Quantity of substance
If the spool weight is high, then wire storage capacity is sufficient, but the stitching head experiences overload and reduced lifespan
Solution Approach 1:
The wire pulling mechanism serves as an intermediary that bears the load of pulling wire from the heavy spool. This protects the stitching head from direct exposure to high pulling forces, extending its lifespan while maintaining adequate wire storage capacity
Solution Approach 2:
The wire is pre-pulled by the controlled mechanism before reaching the stitching head. This preliminary pulling action reduces the instantaneous load on the stitching head, protecting it from overload even when the spool is fully loaded
4Strength
If the spool weight is reduced, then the stitching head load is reduced, but excessive wire length is pulled out
Solution Approach 1:
The wire feed length is precisely controlled by adjusting the rotation parameters of the pulling and control rollers. This allows accurate control of wire length even with lighter spools, preventing excessive wire extraction while maintaining reduced load on the stitching head
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The present invention relates to a servo controlled stitching apparatus that comprises a servo controlled wire pulling means (4) for pulling the required length of wire for stitching bunch of paper sheets. Said pulling means (4) comprises pulling roller (11) having wire retaining groove (11a) for guiding wire extending from the spool (2) towards the stitching head (1). It also comprises pressure roller (13) that rotates against pulling roller (11) for pulling the wire (16) from the spool (2). The length of wire to be pulled is predefined in the controller means which is communicated with the servo motor (7) that rotates said rollers (11, 13) until the predetermined length of wire is pulled. The stitching head (1) utilize the wire (16) of pulled length without rotating the spool itself to avoid pulling load and to apply even stapling on the bunch of paper sheets.