Winding Device Automatic Deviation Detection and Correction
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Solution Overview
Problem
Existing winding devices require manual operator intervention to detect and correct deviations of the wire from the predetermined path, leading to inefficiencies and potential damage to the work surface during the wire winding process.
Innovation Solution
A winding device equipped with a control system that includes a target movement speed calculation part, wire feed speed detection part, deviation amount calculation part, and determination part to automatically detect deviations of the wire from the set path, stop the operation, and return the pressing member to the deviation position, allowing for efficient resumption of the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operator monitoring is used to detect wire deviations, then the operator can visually recognize deviations, but the operation efficiency decreases and the work surface may be damaged during correction
Solution Approach 1:
The patent replaces the manual visual monitoring system with an automated detection system using a sensor that detects wire position deviations. This substitution eliminates the need for operator intervention while maintaining detection accuracy, thereby improving operation efficiency and preventing work surface damage during correction
Solution Approach 2:
The system enables self-service by automatically detecting wire deviations and controlling the pressing member to return to the correct path without operator intervention. The winding device monitors and corrects its own operation, improving productivity while maintaining reliability
2Manufacturing precision
If the operator stops the device to correct wire deviations, then the wire path can be corrected, but time is lost and operation efficiency decreases
Solution Approach 1:
The automated detection and correction system allows the winding operation to continue without interruption. The sensor continuously monitors wire position and the control system automatically adjusts the pressing member, maintaining continuous useful action while preserving wire path accuracy
Solution Approach 2:
The system implements feedback control where the sensor detects wire position deviations and feeds this information back to the control system, which then automatically adjusts the pressing member position. This closed-loop feedback eliminates the need for stopping operations while maintaining manufacturing precision
3Reliability
If continuous manual monitoring is implemented, then wire deviations can be detected early, but the complexity of operation increases and efficiency decreases
Solution Approach 1:
The patent replaces the mechanical manual monitoring process with an automated sensor-based detection system. This substitution maintains reliable deviation detection while significantly improving ease of operation, as the system requires no continuous operator attention
Solution Approach 2:
The winding device performs self-monitoring through the integrated sensor system, eliminating the need for operator involvement in deviation detection. This self-service capability maintains detection reliability while simplifying operation to basic system control
Data Source
AI summary
According to one embodiment, a winding device includes a supporting part, a pressing part, a movement part configured to move a positional relationship between the supporting part and the pressing part, a control part, a target movement speed calculation part configured to detect a target relative movement speed of the pressing part with respect to the supporting part, a wire feed speed detection part configured to detect a feed speed of the wire, a deviation amount calculation part configured to calculate a difference between a detection result of the target movement speed calculation part and a detection result of the wire feed speed detection part, and a determination part configured to determine that the wire has deviated from the movement path.