Wire Coil Trimming with End Detection and Distance-Based Cutting
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Solution Overview
Problem
Conventional methods for trimming wire coils in long rolling mills are either manual, leading to ergonomic issues and potential injuries, or rely on high-speed shears that are complex and prone to errors, resulting in inaccurate cutting and waste.
Innovation Solution
An automatic trimming apparatus that uses a rotational member with sensors and actuators to detect the end of the wire coil and measure the distance to a predetermined cutting point, ensuring precise cutting without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual trimming method is used, then operator can identify and remove head and tail sections, but working environment is prone to injuries and has poor ergonomic conditions
Solution Approach 1:
The patent replaces the manual mechanical trimming system with an automated system comprising a rotational member, sensor assembly, distance sensor, and cutting device. The control unit coordinates these components to automatically detect wire ends, measure distances, and perform cutting operations, eliminating the need for manual intervention and associated ergonomic hazards.
2Extent of automation
If high-speed shear is used, then trimming can be automated, but the system becomes very complex and expensive to maintain and operate
Solution Approach 1:
The patent divides the trimming system into distinct functional modules: a rotational member for positioning, a sensor assembly for detecting wire ends, a distance sensor for measurement, and a cutting device for trimming. Each module performs a specific function and can be independently controlled by the control unit, simplifying the overall system architecture compared to conventional high-speed shears.
Solution Approach 2:
The system uses the wire coil itself as a reference for positioning. By detecting the end of the wire and measuring the distance to it, the system automatically determines the cutting position without requiring external complex positioning systems or pre-programmed coordinates, thereby reducing system complexity.
3Productivity
If high-speed shear is used, then trimming can be performed at high speed, but cutting accuracy is compromised and wire damage may occur
Solution Approach 1:
The patent replaces the high-speed mechanical shear with a controlled cutting device that operates based on precise sensor data. The sensor assembly detects the exact wire end position, and the distance sensor measures the precise distance to the cutting point, enabling accurate cutting without the mechanical complexity and accuracy issues of high-speed shears.
Solution Approach 2:
The system incorporates feedback through the sensor assembly and distance sensor that continuously monitor wire position and provide real-time data to the control unit. This feedback mechanism ensures precise positioning and cutting accuracy by allowing the control unit to adjust the cutting operation based on actual measured conditions rather than relying solely on pre-programmed parameters.
4Productivity
If conventional high-speed shear is used, then front and end sections can be removed, but the system fails to perform intended trimming operation requiring backup manual trimming
Solution Approach 1:
The sensor assembly provides real-time feedback on wire end detection, and the distance sensor provides feedback on positioning accuracy. The control unit uses this feedback to verify that cutting conditions are met before executing the trim operation, ensuring reliable performance and eliminating the need for backup manual trimming systems.
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
The apparatus accurately determines the cutting point, reducing waste and ensuring precise trimming, while minimizing the risk of injury and operational complexity.
Implementation Method 1
a sensor assembly arranged for sensing the presence of a wire in a defined area of the space
Implementation Method 2
a distance sensor for sensing a distance travelled along the wire during rotation of the rotational member
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
The present invention relates to an automatic trimming apparatus (1) for wire coils (2) including a plurality of wire loops (3). The apparatus comprises a base frame (4), a rotational member (6) rotatably connected to the base frame (4), a support unit for supporting the wire loop when the rotational member (6) is rotated, a sensor assembly arranged for detecting the end of the wire and a distance sensor for sensing a distance travelled along the wire when the rotational member is rotated. The trimming apparatus is adapted to rotate the rotational member is in a first direction until the end of the wire is detected, rotate the rotational member in an opposite direction when the end of the wire has been detected, determine the distance travelled along the wire, and generate a cutting command based on the distance travelled along the wire from the end of the wire and a predetermined cutting distance.