Wire Binding Machine Variable Grip Mechanism
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Solution Overview
Problem
Existing wire binding machines for reinforced concrete construction consume excessive power due to constant high gripping force required for wire tension, which reduces battery life and increases motor torque during both wire feeding and retraction phases.
Innovation Solution
A mechanical wire feed mechanism with rollers that adjust gripping force based on wire tension, using a drive gear and roller gear system where the gripping force increases as wire tension rises, allowing lower power consumption during the feeding phase without compromising the tightness of the wire loop during the retraction phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If constant high gripping force is applied during wire feeding, then sufficient tension can be applied during retraction phase, but motor torque and current consumption are higher than necessary during feeding phase
Solution Approach 1:
The gripping mechanism transitions from static constant grip to dynamic variable grip. The roller's mounting allows its axis to pivot relative to the drive gear, enabling the gripping force to dynamically increase as wire tension increases during retraction, rather than maintaining constant high grip throughout both phases.
Solution Approach 2:
The gripping force parameter changes based on operational phase and wire tension. During feeding, lower grip is sufficient; during retraction, the grip automatically increases as tension rises. This parameter adaptation resolves the contradiction between sufficient tension and energy consumption.
2Reliability
If constant high gripping force is used to ensure tight wire loop during retraction, then wire binding reliability is improved, but power consumption increases
Solution Approach 1:
The gripping mechanism serves itself by using the wire tension force to automatically increase the gripping force. The tension in the wire during retraction phase naturally drives the roller tighter against the wire through the gear separation force, eliminating the need for external control systems while ensuring adequate grip when needed.
Solution Approach 2:
The system incorporates mechanical feedback where wire tension during retraction automatically increases the gripping force through the gear-roller mounting arrangement. The higher the tension, the greater the gripping force becomes, creating a self-regulating feedback loop that ensures tight binding without excessive power consumption.
3Use of energy by moving object
If lower gripping force is used during wire feeding phase, then power consumption is reduced, but sufficient grip during retraction phase must be maintained
Solution Approach 1:
The gripping force dynamically adapts to operational requirements. During feeding, the roller operates at lower grip reducing power consumption. During retraction, the same mechanism automatically increases grip in response to wire tension, maintaining reliability without requiring separate control for each phase.
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 reduces power consumption and maintains the tightness of the wire loop around reinforcement bars by dynamically adjusting the gripping force, extending battery life and enabling a smaller, lighter battery, while ensuring effective wire binding.
Implementation Method 1
a pair of rollers urged together to grip the wire therebetween and drive it in the appropriate direction
Implementation Method 2
a gear which is driven by a drive gear, such as a pinion, connected to a motor
Data Source
AI summary
A machine (4) for tying a length of wire (46) around one or more objects (2) comprising a wire feed mechanism adapted to feed wire (46) from a spool during a first phase; and to withdraw the wire (46) during a second phase, said wire feed mechanism comprising a gripping mechanism (102, 103) including a pair of rollers urged together to grip the wire (46) therebetween and drive it in the appropriate direction, said gripping mechanism (102, 103) being configured such that during said second phase, increasing tension in the wire (46) automatically increases the gripping force on the wire (46).