Stranding Roller Geometry for Cord Twist and Curl Reduction
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Solution Overview
Problem
Conventional stranding machines produce cords with significant twist and a tendency to curl, which complicates further processing, such as winding and crimping, and reduces the number of alternating bending cycles without material fatigue or failure, and impedes continuous extrusion processes.
Innovation Solution
A stranding machine with a deflecting roller having a wedge-shaped recess and a guiding device that presses the cord against specific flanks of the roller to counteract twisting torsion, combined with a pulling device for stretch forming to reduce curling, allowing for selective adjustment based on wire lay and wire direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional stranding machines are used to produce cords, then the stranding process can be completed, but the cord develops significant twist and curling that complicates further processing
Solution Approach 1:
The patent applies preliminary anti-action by introducing a counter-twisting mechanism that acts in opposition to the natural twist generated during stranding. The cord is guided through a curved path with a specific radius and direction that creates a counteracting torque, preventing twist accumulation before it becomes a processing problem. This is achieved by routing the cord through a guide roller arranged at a specific distance from the rotor axis, creating a geometric counter-twist that neutralizes the helical structure.
Solution Approach 2:
The patent solves the twist problem by transitioning from a linear cord path to a curved three-dimensional path. Instead of pulling the cord straight from the rotor, the cord is guided through a curved trajectory in space, adding a spatial dimension to the cord extraction process. This curved path geometry introduces a counteracting rotational component that neutralizes the twist generated during stranding, effectively using dimensional transformation to solve the twist accumulation problem.
2Productivity
If the cord is wound onto a bobbin or directly processed, then production continues, but the twist and curling reduce the number of alternating bending cycles without material fatigue or failure
Solution Approach 1:
The counter-twisting guide mechanism prevents twist accumulation during stranding, which directly improves the cord's fatigue resistance. By neutralizing the helical structure before the cord enters subsequent processing stages like winding or bending operations, the cord maintains its structural integrity and can withstand more alternating bending cycles without developing fatigue failures.
Solution Approach 2:
The patent applies preliminary action by correcting the twist issue at the source during the stranding process itself, rather than attempting to correct it later during winding or assembly operations. The counter-twisting guide roller is positioned to act on the cord immediately after it leaves the rotor, preventing the helical structure from forming in the first place, which ensures the cord is ready for subsequent processing without pre-existing fatigue vulnerabilities.
3Productivity
If conventional stranding machines are used, then cord production is achieved, but the twist impedes continuous extrusion processes
Solution Approach 1:
The counter-twisting guide mechanism neutralizes the helical structure during stranding, creating a straight, stable cord that is suitable for continuous extrusion processes. By preventing twist accumulation before the cord enters the extrusion stage, the cord maintains consistent geometry and stability, enabling continuous bag discharge extrusion methods to operate effectively without interruption or quality issues.
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 solution effectively reduces cord twist and curling, enhancing processing stability and enabling continuous extrusion by minimizing helical structure and material fatigue through controlled deflection and stretching.
Implementation Method 1
the cord is pressed against a first flank of the deflecting roller
Implementation Method 2
the cord can be guided, on a straight line, from the guiding device to the deflecting roller, in such a way that the cord is pressed against a first flank of the deflecting roller
Implementation Method 3
at least one pulling device arranged behind the deflecting roller in the direction of movement of the cord, wherein said pulling device is suitable for exerting a tensile force on the cord running off the deflecting roller
Implementation Method 4
a stretching which leads to a plastic deformation of the cord
Data Source
AI summary
A stranding machine is provided for producing a cord from a plurality of wires, preferably metal wires. The stranding machine has a stranding device for stranding the wires, including at least one rotatably mounted deflecting roller for deflecting the cord and at least one guide device for guiding the cord. The guide device is arranged in such a way that the cord can be guided on a straight line from the guide device to the deflecting roller in such a way that the cord is pressed against a first flank of the deflecting roller. As the cord is deflected by the deflecting roller, the cord moves from the first flank into the roller base of the deflecting roller.