Straightening Rollers With Closed-Loop Control for Wire Straightness
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Solution Overview
Problem
Existing methods for straightening wire or strip material lack precision in achieving targeted straightness, particularly for materials with unknown or variable curvature, as they do not adequately account for real-time measurements of force, temperature, and position during the straightening process.
Innovation Solution
Implementing a closed control circuit that measures the size and direction of forces on straightening rollers, material temperature before and after passing through, and the position of the material post-straightening, with these values entered into a stochastic model to adjust the rollers autonomously, ensuring precise straightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time measurements of force, temperature, and position are implemented during the straightening process, then manufacturing precision of straightness is improved, but device complexity increases
Solution Approach 1:
The patent implements a closed-loop control system where measured values from force sensors, temperature sensors, and position sensors are fed back to the stochastic model in real-time. The model continuously updates roller position commands based on this feedback, enabling dynamic adjustment during the straightening process to achieve precise straightness control despite the added system complexity
Solution Approach 2:
The patent replaces traditional mechanical straightening control with a stochastic model-based control system. Instead of relying solely on mechanical adjustments, the system uses computational algorithms that process sensor data and determine optimal roller positions, substituting mechanical intuition with data-driven decision making
2Reliability
If a stochastic model with multiple measurement parameters is used for autonomous control, then reliability of achieving targeted straightness is improved, but measurement and control difficulty increases
Solution Approach 1:
The stochastic model serves as a universal control mechanism that integrates multiple measurement parameters (force, temperature, position) into a unified decision-making framework. The model processes diverse sensor inputs through a single computational system that determines roller positioning, making the complex multi-parameter control manageable through a unified approach
Solution Approach 2:
The system performs self-calibration and self-adjustment through the stochastic model, which automatically processes sensor data and determines optimal roller positions without requiring external intervention. The model learns from measured values and autonomously adjusts the straightening process, reducing the operational difficulty of managing multiple measurement parameters
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 enhances the reliability of achieving targeted straightness by continuously adapting the straightening process based on real-time data, improving the accuracy and consistency of the straightened material.
Implementation Method 1
the measurement (i) of the forces engaging at the straightening rollers expediently takes place by means of strain gauges arranged at the bearing bolts of the straightening rollers, which strain gauges measure the bending moments in the axial, vertical, and/or horizontal direction
Implementation Method 2
the measurement (ii) of the temperature records the deformation energy incorporated into the material to be straightened
Data Source
AI summary
A method for straightening wire or strip material by a dressing device comprising straightening rollers engaging on opposite sides of the passing-through material in an offset manner, of which, some are automatically activated according to a model which has been stochastically determined on the basis of input data of the material and data relating to the wire and the dressing device that is determined during the passing of the material through the dressing device, such that requirements for straightness are met, wherein the position of at least one straightening roller is continuously adapted on the basis of said data detected during the passage through the dressing device, which data are representative of the target straightness, wherein (i), the size and direction of the forces acting on the straightening rollers and/or (ii) the temperature of the material before and after passing through the assembly of straightening rollers, and/or (iii) the position of the material is measured at each of the straightening rollers and the obtained measurement values are input into the model controlling the adjustment of the adjustable straightening rollers.