Wire Coil Compacting Machine Rigid Pressure Frame
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Solution Overview
Problem
Existing compacting machines for coils of wire require strong and robust foundations to handle bending moments from hydraulic cylinders, leading to increased costs and larger hydraulic systems due to long stroke lengths and large hydraulic cylinder dimensions.
Innovation Solution
A compacting machine design featuring moveable pressure frame parts that form a rigid and stiff pressure frame to absorb bending moments, reducing the foundation's strength requirements and allowing for smaller hydraulic cylinders by enabling precompacting of the coil before power member actuation, thus reducing stroke length and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If heavy duty hydraulic cylinders are used to compact the coil, then the compacting force is sufficient, but the foundation must be very strong and robust to take up bending moments
Solution Approach 1:
A rigid pressure frame is introduced as an intermediary structure between the hydraulic cylinders and the foundation. The pressure frame absorbs and distributes the bending moments and forces generated during compacting, protecting the foundation from direct stress while enabling sufficient compacting force to be applied to the coil.
Solution Approach 2:
The pressure frame is divided into two separate movable pressure frame parts that can move independently towards each other. Each part is connected to its own hydraulic cylinder, allowing the system to generate high compacting forces while distributing the structural loads away from the foundation.
2Force
If heavy duty hydraulic cylinders with long stroke lengths are used, then the compacting force is sufficient, but the hydraulic system size and volume increase
Solution Approach 1:
The pressure frame parts are made movable rather than fixed, allowing the hydraulic cylinders to operate with shorter stroke lengths. The movement of the pressure frame parts themselves provides the additional displacement needed, enabling the use of more compact hydraulic cylinders with smaller hydraulic system volume.
3Manufacturing precision
If the foundation is not robust enough, then the bending moments cause misalignment of strap track sections, but making the foundation stronger increases cost
Solution Approach 1:
The rigid pressure frame serves as an intermediary that absorbs and isolates the bending moments and forces from reaching the foundation. This protects the alignment of strap track sections mounted on the foundation, ensuring manufacturing precision without requiring an excessively strong and costly foundation.
4Stability of the object's composition
If the pressure frame parts are fixed in position, then the structure is rigid, but the hydraulic cylinders require long stroke lengths
Solution Approach 1:
The pressure frame parts are designed to be movable rather than fixed, allowing them to dynamically adjust their positions during the compacting process. This dynamic capability enables the hydraulic cylinders to have shorter stroke lengths while the movement of the pressure frame parts provides the additional displacement needed for effective compacting.
Data Source
Figure 1a~2a
Figure 1b~2b
Figure 1c~2c
AI summary
A compacting machine for compacting and binding a coil of wire comprising: - a foundation (3); - two compacting elements (4a, 4b) horizontally moveable towards each other by means of a respective power member; - two pressure frame parts (6a, 6b) provided with mating contact surfaces, wherein the compacting elements are moveably mounted to a respective one of these pressure frame parts; and - one or more locking devices for releasably securing the pressure frame parts to each other when they abut against each other via said contact surfaces, wherein the pressure frame parts, when secured to each other by means of said locking device, are configured to form a rigid and stiff pressure frame (13) which surrounds a coil of wire (2) received between the compacting elements. At least one of said pressure frame parts is moveable in relation to the foundation by means of a driving device.