Twisting Device for Electrical Lines with Constant Tensile Force Control
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Solution Overview
Problem
Existing twisting devices face challenges in maintaining a constant tensile force during the twisting process due to material tolerances and dynamic fluctuations, leading to difficulties in process automation and quality control, especially with short cables that have minimal axial damping.
Innovation Solution
A twisting device with a motor-driven length-compensating carriage and a path-compensating carriage equipped with a force-generating element, such as a pneumatic cylinder, applies a constant tensile force throughout the twisting process, allowing for precise control and monitoring of the twisting process through displacement sensors and evaluation devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a constant tensile force is applied during twisting to maintain quality, then twisting quality improves, but process automation becomes difficult due to material tolerances and dynamic fluctuations
Solution Approach 1:
The patent implements feedback control by continuously measuring the actual cable length during twisting and comparing it with the target length profile. The carriage position is automatically adjusted based on this feedback to compensate for material tolerances and maintain constant tensile force, enabling automated high-quality twisting despite material variations.
Solution Approach 2:
The system uses the cable's own shortening behavior during twisting as feedback to automatically adjust the carriage position. The cable essentially regulates its own tension by shortening the distance between twisting heads, creating a self-regulating system that maintains constant force without complex external control.
2Length of moving object
If the distance between twisting heads is reduced to compensate for cable shortening, then cable length is maintained, but tensile force fluctuates due to dynamic process variations
Solution Approach 1:
The patent employs dynamic adjustment of the carriage position during the twisting process. Rather than using a fixed distance reduction profile, the system continuously adapts the carriage position based on real-time cable length measurements, enabling both length maintenance and force stabilization through dynamic control.
3Speed
If fast signal processing is used to control tensile force in real-time, then response speed improves, but control accuracy decreases due to delayed reaction and force fluctuations
Solution Approach 1:
The system performs preliminary action by pre-positioning the carriage according to a calculated shortening profile before twisting begins. This proactive approach anticipates cable shortening and establishes the initial geometric conditions for constant force, reducing the need for reactive corrections during the dynamic twisting process.
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 enables easy monitoring and automation of the twisting process with a constant tensile force, reducing load peaks and improving twisting quality by compensating for material-related tolerances and allowing for immediate quality control.
Implementation Method 1
a force-generating element, in particular a pneumatic cylinder (6), with a force (F) acting essentially parallel to the axis of rotation
Data Source
Figure 1~3
Figure 4
AI summary
A twisting device for cables comprises at least one twisting head (1) that can be rotated about a rotary axis by a motor and a clamping device for the cables (3). The twisting head (1) can be moved towards the clamping device in the direction of its axis of rotation to compensate for length differences. For this purpose, it is mounted on a first, motor-driven length-compensating slide (2), and the clamping device is mounted on a displacement-compensating slide (4) that is movable parallel to the axis of rotation relative to the length-compensating slide (2). This displacement-compensating slide can be subjected to a force acting parallel to the axis of rotation via a force-generating element. After the cables (3) have been cut to length and transferred to the twisting head (1) and the clamping device, the cables (3) are tensioned. Subsequently, the twisting head (1) is activated to rotate about an axis of rotation parallel to the cables (3), while simultaneously moving towards the clamping device according to a travel profile.The clamping device is subjected to a force directed away from the twisting head (1) and the driving and/or force profile for the clamping device is determined and evaluated.