Vertical Twisted Wire Manufacturing Apparatus with Variable Speed Control
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Solution Overview
Problem
Conventional twisted wire manufacturing apparatuses require significant horizontal space and impose a high burden on operators due to the need for extensive movement, risking excessive tension and detachment of electric wires during the manufacturing process.
Innovation Solution
The apparatus incorporates a raising and lowering unit with a high-speed/low-speed mechanism, a twisting unit with chucking and co-rotation mechanisms, and a control unit to manage the lifting and twisting of electric wires, allowing for reduced installation space and improved workability by securing the wires vertically and controlling tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the apparatus is configured to hold the one end and the other end of the electric wires respectively on predetermined members in the vicinity of the operator and to automatically move the member on the other end side to a predetermined position, then the movement of the operator can be avoided, but in a case where a large tension is applied to the electric wires upon movement of the member on the other end side, there is a risk of trouble such that the ends of the electric wires may be detached from the members holding the ends of the electric wires
Solution Approach 1:
The patent applies dynamics by making the raising and lowering speed variable rather than constant. The raising and lowering mechanism switches between high speed and low speed modes: high speed is used during initial lifting to improve efficiency, while low speed is used when approaching the target position or when tension may become excessive, thereby preventing wire detachment while maintaining operational efficiency.
Solution Approach 2:
The patent changes the speed parameter of the raising and lowering mechanism dynamically. By switching between high speed and low speed modes, the system optimizes both operational efficiency and wire safety. The speed parameter is adjusted based on the operational phase: high speed for rapid positioning, low speed for precise control and tension management.
2Manufacturing precision
If conventional linear manufacturing method is used, then the twisted wire can be manufactured, but a large horizontal space is required for apparatus installation
Solution Approach 1:
The patent transitions from a horizontal linear manufacturing layout to a vertical three-dimensional configuration. The raising and lowering mechanism enables the wires to be processed in the vertical dimension, allowing the apparatus to be compact in horizontal space while maintaining full manufacturing capability. This dimensional change resolves the space requirement contradiction.
3Productivity
If high speed raising and lowering is used throughout the process, then productivity is improved, but excessive tension may be applied to the electric wires causing detachment
Solution Approach 1:
The patent applies dynamics by making the raising and lowering speed variable rather than constant. The raising and lowering mechanism switches between high speed and low speed modes: high speed is used during initial lifting to improve efficiency, while low speed is used when approaching the target position or when tension may become excessive, thereby preventing wire detachment while maintaining operational efficiency.
Solution Approach 2:
The patent employs periodic action by alternating between high speed and low speed phases during the raising and lowering process. This periodic speed variation optimizes productivity during high-speed phases while ensuring wire safety during low-speed phases, creating a rhythm that balances efficiency and reliability.
Data Source
AI summary
An apparatus (1) is designed to manufacture a twisted wire by twisting a plurality of electric wires (101), and includes an raising and lowering unit (2), an twisting unit (3), and a control unit (4). The raising and lowering unit lifts the plurality of electric wires and lowers the manufactured twisted wire, and includes: a raising and lowering portion (6); a guiding portion (7) vertically guiding the raising and lowering portion; and a raising and lowering mechanism (8) capable of switching a raising and lowering speed of the raising and lowering portion to a high speed or a low speed.