Strand Manufacturing Machine Dual Support Axial Movement
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Solution Overview
Problem
Existing machines for manufacturing strands or cables are limited by the need for bulky and costly rotors and mechanical components to support heavy bobbins, leading to increased size, cost, and risk of malfunctions, especially when handling large or heavy strands.
Innovation Solution
A machine design featuring a rotatable bobbin support with two independent supports that move alternately along the main axis, maintaining a constant distance between them, allowing for the use of standard-sized bobbins and reducing structural complexity, with the rotor rotating only around the main axis, and incorporating a mechanical connection to control bobbin movement and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single support supports the bobbin from one side only, then the structure is simple, but big bobbins cannot be used and heavy strands cannot be wound
Solution Approach 1:
The single support is divided into two separate supports (first support and second support) that can independently move along the main axis. Each support has its own driving mechanism, allowing them to coordinate their movements to accommodate different bobbin sizes and weights without requiring a single oversized support structure.
Solution Approach 2:
The supports are made dynamically adjustable along the main axis through independent driving mechanisms. This dynamic capability allows the supports to adapt to various bobbin sizes and weights, transforming a static single-support design into a flexible multi-support system that can handle diverse manufacturing requirements.
2Adaptability or versatility
If two supports are used to support the bobbin, then big bobbins and heavy strands can be handled, but the structure becomes more complex and costly
Solution Approach 1:
The two supports are merged into a coordinated system where both supports work together to handle the bobbin. They share common control mechanisms and can synchronize their movements, allowing the system to handle heavy and large bobbins while maintaining structural efficiency through the integration of their functions.
Solution Approach 2:
The supports incorporate dynamic adjustment capabilities along the main axis, allowing them to adapt their positions independently or in coordination. This dynamic design enables the system to handle varying bobbin sizes and weights flexibly without requiring overly complex fixed structures.
3Device complexity
If the bobbin is supported only from one side, then the support structure is simple, but control of bobbin movement is limited and malfunctions occur with heavy bobbins
Solution Approach 1:
The single-point support is segmented into two separate support points that can independently control different aspects of bobbin movement. This segmentation provides redundant control pathways, improving reliability by preventing malfunctions that would occur with a single support point handling heavy bobbins alone.
Solution Approach 2:
The second support acts as an intermediary that assists the first support in controlling bobbin movement. Together, they provide balanced control and stabilization, particularly for heavy bobbins, preventing malfunctions that would occur with unbalanced single-sided support.
4Manufacturing precision
If a rotor comprises mechanical and electrical means for moving the pulley, then the strand can be uniformly distributed, but the rotor becomes heavier and bulkier with increased cost and risk of malfunctions
Solution Approach 1:
The complex mechanical and electrical means for moving the pulley are extracted from the rotor. Instead, the supports move along the main axis to achieve uniform strand distribution, simplifying the rotor structure while maintaining the required manufacturing precision for even strand placement.
Solution Approach 2:
The system uses dynamic movement of the supports along the main axis rather than complex rotor mechanisms. This dynamic approach achieves uniform strand distribution through the coordinated motion of lightweight supports, eliminating the need for heavy rotor components dedicated to pulley movement.
5Manufacturing precision
If the feeding speed of wires and strand is changed to compensate for pulley movement, then uniform distribution is achieved, but control problems and quality issues occur
Solution Approach 1:
The need to change feeding speed for compensation is eliminated by extracting the pulley movement mechanism from the rotor. The supports directly move along the main axis to achieve uniform distribution, removing the complex control requirements for speed adjustment and simplifying operation.
Solution Approach 2:
The system uses direct dynamic movement of the supports along the main axis to achieve uniform strand distribution. This eliminates the need for complex feedback control of feeding speed, as the physical position of the supports naturally ensures even distribution, greatly simplifying the control system.
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 machine supports heavy bobbins and strands using standard-sized points, reduces the size and cost of the rotor, and enhances manufacturing efficiency by simplifying the structure and maintaining precise control over bobbin movement, while allowing for easy mounting and unmounting of bobbins of varying widths.
Implementation Method 1
a rotor 5 can rotate around a main axis 3 for stranding one or more wires 7 and winding around the main axis, namely around the bobbin 2, a strand 8 obtained by stranding these wires 7
Implementation Method 2
The first support 1 can move axially with an alternate movement (shown by arrow 12) along main axis 3 for uniformly distributing strand 8 around bobbin 2
Implementation Method 3
The first support 1 is mechanically connected to second support 16, so as to control the mutual distance between first support 1 and second support 16 during the rotation of rotor 5, in particular by controlling that this mutual distance is substantially constant
Data Source
AI summary
A machine for manufacturing strands from wires is disclosed. The machine comprises a first support for supporting a bobbin, wherein a rotor can rotate around a main axis for stranding wires and winding or unwinding around the main axis a strand or the like comprising these wires, while the first support can move along the main axis, which rotor is provided with a second support which rotates with the rotor around the main axis and can move along the main axis for supporting the bobbin, wherein the first support and/or the second support rotate the bobbin around the main axis when the rotor rotates around the main axis.