Steel Wire Rubber Coating Temperature Control via Heat Transfer Rollers
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Solution Overview
Problem
Existing steel wire rubber coating devices struggle to maintain the temperature of the steel wire within a suitable range, particularly when the wire feeding stops, leading to excessive heating and potential denaturation of the rubber.
Innovation Solution
A rubber coating device that uses a heating device to heat a heat medium, which is then transferred to the steel wire via heat transfer rollers, maintaining the temperature within a predetermined range by controlling the heat medium's temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electromagnetic induction heating coil or coil heater is used to heat steel wire, then the steel wire temperature can be raised to soften rubber for coating, but the temperature may exceed the suitable range and denature the rubber when wire feeding stops
Solution Approach 1:
The patent introduces a heat transfer member as an intermediary between the heating device and the steel wire. The heating device heats the heat transfer member, which then transfers heat to the steel wire through thermal conduction. This intermediary structure allows for better temperature control and prevents direct overheating of the wire, thereby protecting the rubber coating quality.
Solution Approach 2:
The patent replaces the electromagnetic induction heating system with a thermal conduction-based heating system using a heat transfer member. This substitution allows for more stable and controllable temperature distribution, preventing localized overheating that could denature the rubber while maintaining sufficient temperature for rubber softening and coating.
2Manufacturing precision
If heating temperature is controlled based on rubber coating diameter, then coating quality can be maintained, but temperature control fails when rubber coating diameter does not change
Solution Approach 1:
The patent implements a feedback control system that continuously monitors the rubber coating diameter and adjusts the heating device accordingly. When the coating diameter deviates from the target value, the system automatically adjusts the heating temperature to maintain proper coating quality, providing reliable temperature control even when diameter changes are minimal.
3Productivity
If direct heating of steel wire is used, then heating efficiency is high, but temperature control complexity increases and rubber denaturation risk increases
Solution Approach 1:
The heat transfer member serves as a mediator that simplifies the temperature control system. By heating the heat transfer member uniformly and allowing it to conduct heat to the steel wire, the system achieves efficient heating without requiring complex localized temperature control mechanisms, thereby reducing overall system complexity while maintaining productivity.
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 solution effectively maintains the steel wire's temperature within a suitable range, preventing rubber denaturation and simplifying the heating process by using water as a heat medium, thus reducing the complexity of the device and ensuring efficient heat transfer.
Implementation Method 1
a heating device that heats a heat medium to a predetermined temperature range
Implementation Method 2
the heat transfer member heated by the heat medium transmits heat to the steel wire
Data Source
AI summary
A rubber-coating device for a steel wire is provided with: a heating device for heating water to a specified temperature range; heat transfer rollers, which contact the steel wire and inside which a water passage is formed; and an extruder for coating rubber on the steel wire that is heated by the heat transfer rollers.