Wire Coating Bank Alignment for Uniform Layer Thickness
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Solution Overview
Problem
Existing systems for producing coated wires face challenges in achieving homogeneous coating thickness due to varying wire geometries and properties, leading to issues like inhomogeneous curing, dielectric breakdowns, and instability in system settings, which are difficult and costly to adjust.
Innovation Solution
A coating device with a sliding device and leveling device for precise adjustment of the coating bank, allowing centralized passage of the wire and ensuring homogeneous coating thickness, using adjusting screws and leveling screws for easy, reproducible alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the coating device uses fixed positioning of the coating bank, then the structure is simple, but the coating thickness becomes inhomogeneous due to varying wire geometries
Solution Approach 1:
The coating bank is made adjustable through sliding devices and leveling devices with adjusting screws, allowing dynamic repositioning to adapt to different wire geometries and maintain homogeneous coating thickness
Solution Approach 2:
The position parameters of the coating bank (horizontal and vertical) can be changed through the adjustment mechanisms to optimize coating uniformity for different wire types and geometries
2Manufacturing precision
If the system settings are adjusted frequently to accommodate varying wire properties, then coating quality improves, but adjustment time and costs increase
Solution Approach 1:
The adjustment mechanisms (sliding devices with adjusting screws and leveling devices) allow pre-positioning of the coating bank for different wire types, enabling quick setup without frequent readjustments during production
Solution Approach 2:
The adjustable coating bank can be quickly repositioned using screw mechanisms to adapt to different wire geometries, reducing adjustment time compared to fixed positioning systems
3Reliability
If the coating bank position is not precisely adjustable, then the device is simpler to operate, but coating thickness becomes inconsistent leading to dielectric breakdowns
Solution Approach 1:
The coating bank incorporates sliding devices and leveling devices with adjusting screws that enable precise positional adjustment, ensuring consistent coating thickness and preventing dielectric breakdowns
Solution Approach 2:
The adjustment mechanisms are designed to be operator-friendly with screw-based controls that allow straightforward positioning of the coating bank for different wire types
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 flexible and stable application of coating layers with high temporal stability, ensuring consistent coating thickness and reducing the risk of dielectric breakdowns by allowing easy and precise adjustment to varying wire properties.
Implementation Method 1
a support roller for supporting and conveying the wire in a wire conveying direction, wherein the support roller is rotatably mounted about a support roller axis
Implementation Method 2
at least one application unit for applying coating material to the wire and for removing excess coating material from the wire
Implementation Method 3
at least one collection basin for collecting removed excess coating material, the application unit being arranged on or in the collection basin
Implementation Method 4
an oven for solidifying the applied layer, wherein the oven is arranged in the wire conveying direction downstream of the at least one application unit
Data Source
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AI summary
Coating device (2) for applying at least one layer of a coating material to a wire (3), comprising: - a base body (7); - a support roller (8) for supporting and conveying the wire (3) in a wire conveying direction (5); - a base plate (10), wherein the base plate (10) is arranged on the base body (7); - a coating bank (11) arranged on the base plate (10) with: - an application unit (6) for applying coating material to the wire (3) and for removing excess coating material from the wire (3); - at least one collection basin (13) for collecting removed excess coating material; - at least one sliding device (14) arranged on the base plate (10) with an adjusting screw (15) for moving the coating bank (11) parallel to the support roller axis (9) along the base plate (10);and/or - a leveling device (16) for leveling the base plate (10), wherein the base plate (10) has a threaded bore (17) with an internal thread, wherein the leveling device (16) has at least one leveling screw (18).