Three-Chuck Wiegand Wire Processing for Continuous Torsion Control
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Solution Overview
Problem
Conventional methods for producing Wiegand wire are not cost-effective and require cutting the wire, limiting continuous production.
Innovation Solution
A device with three clamping chucks, where the wire is fed through in a nonpositive, torsionally fixed manner, allowing for continuous production by applying torsion and tension through linear actuators and electrical insulation, enabling the wire to be processed without cutting, and allowing current application for heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to produce Wiegand wire, then production can be completed, but the process requires cutting the wire and is not cost-effective
Solution Approach 1:
The wire processing system is divided into multiple clamping chucks (first, second, and third clamping chucks) positioned at different locations along the wire. Each chuck independently applies clamping force, torsion, or tension to specific wire sections, enabling continuous processing without cutting while maintaining cost-effectiveness through modular, distributed control of the manufacturing process.
2Productivity
If the wire is retained in a nonpositive manner by clamping chucks, then continuous production is enabled, but the wire must be fed through multiple chucks requiring precise positioning
Solution Approach 1:
The patent replaces complex mechanical positioning systems with a combination of linear actuators for simple back-and-forth movement and electrical insulation principles for wire retention. The clamping chucks use electrical insulation rather than complex mechanical locking mechanisms, and linear actuators provide straightforward positional control, reducing overall device complexity while enabling continuous production.
3Temperature
If current is applied to the wire through clamping chucks, then heat generation is achieved, but the clamping chucks must be electrically insulated from the device
Solution Approach 1:
The clamping chucks serve as intermediary elements between the electrical current source and the wire. By electrically insulating the clamping chucks from the device structure while maintaining their mechanical clamping function, the system enables current application to the wire for heat generation without creating electrical short circuits, thus achieving temperature control while managing electrical isolation requirements.
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
Enables cost-effective, continuous production of high-quality Wiegand wire with controlled tension and torsion, maintaining a defined delivery state and allowing for efficient processing and monitoring of wire quality.
Implementation Method 1
tensile stress is applied to the wire sections to be processed by increasing the distance between the second clamping chuck and the first clamping chuck and also by increasing the distance between the second clamping chuck and the third clamping chuck
Implementation Method 2
The second clamping chuck is rotatably mounted so that a torsion is able to be applied to a first wire section, and the reverse torsion is able to be applied to a second wire section
Implementation Method 3
current may be applied to the wire in that the clamping chucks are fastened to the rest of the device in an electrically insulated manner. Thus, the application of an electrical voltage between the first and the third clamping chucks may be provided in order to apply a current to the wire with the goal of generating heat
Data Source
AI summary
In a device, in particular machine, for producing Wiegand wire from a wire, in particular pulse wire, and a method for operating a device, the device having a first clamping chuck, a second clamping chuck, and a third clamping chuck, the wire being fed through each of the three clamping chucks, in particular so that the wire is able to be connected in a releasable and torsionally fixed manner to the three clamping chucks, in particular able to be connected to the three clamping chucks in a releasable, torsionally fixed and nonpositive manner. The clamping chucks are set apart from one another in the wire direction, and the second clamping chuck is situated between the first and the third clamping chuck in the wire direction. The second clamping chuck is rotatably mounted so that a torsion is able to be applied to a first wire section and the reverse torsion is able to be applied to a second wire section, the first wire section being situated between the first clamping chuck and the second clamping chuck, the second wire section being situated between the third clamping chuck and the second clamping chuck. The distance in the wire direction between the first and the second clamping chuck is controllable and/or regulatable with the aid of a first linear actuator, and the distance in the wire direction between the second and the third clamping chuck is controllable and/or regulatable with the aid of a second linear actuator.