Pivotable Wire Deflector Clamp for Tool-Free Release and Tension Control
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Solution Overview
Problem
Existing wire saws face challenges in maintaining wire tension due to inhomogeneities in structural elements being cut, and in dusty environments, the release of wire deflectors is often difficult due to gumming up with dust and slurry, requiring tools for release.
Innovation Solution
A pivotable wire deflector with a clamping and spreading mechanism that allows manual adjustment of the clamp's circumference, and a wire saw design with a tensioning system using a feed device to manage wire tension, including pneumatically or mechanically driven rollers to adapt to varying structural elements and prevent wire damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the clamp is fixed tightly to secure the wire deflector, then the fixing reliability is improved, but the release becomes difficult due to gumming up with dust and slurry
Solution Approach 1:
The clamp is designed with a dynamic spreading mechanism that allows the circumferential length to be actively increased from the first position to the second position. This dynamic adjustment enables the clamp to transition from a tightly fixed state to a easily releasable state, resolving the contradiction between secure fixing and easy release in dusty environments
Solution Approach 2:
The invention changes the geometric parameter of the clamp by increasing its circumferential length from the first position to the second position. This parameter change allows the clamp to be spread apart actively, reducing the gripping force and enabling easy release without tools even when gummed up with dust and slurry
2Force
If the clamp circumferential length is reduced to secure the tube, then the clamping force is improved, but the release requires additional tools due to dust ingress
Solution Approach 1:
The clamp incorporates a dynamic mechanism that allows active spreading from the first position to the second position. This dynamic capability provides high clamping force when needed while enabling tool-free release by simply increasing the circumferential length, avoiding the need for complex release tools
Solution Approach 2:
The spreading mechanism allows the clamp to be released by its own structural adjustment - increasing the circumferential length from first to second position enables the clamp to open itself without requiring external tools, even when dust and slurry are present
3Device complexity
If the wire store uses a fixed arrangement, then the structure is simple, but it cannot adapt to inhomogeneities in structural elements being cut
Solution Approach 1:
The wire store is designed with a displaceable second package of deflection rollers that can move relative to the first package. This dynamic arrangement allows the wire store to adapt to inhomogeneities in structural elements by adjusting the wire path length, while maintaining relatively simple structure through guided displacement along a predetermined direction
Solution Approach 2:
The wire store is divided into two packages of deflection rollers - a first fixed package and a second displaceable package. This segmentation allows independent movement of the second package to adapt to structural variations, while the first package remains stationary, balancing adaptability with structural simplicity
4Productivity
If the wire tension is increased to maintain cutting performance, then the cutting efficiency is improved, but the wire may be damaged by inhomogeneities in structural elements
Solution Approach 1:
The wire store with its displaceable second package provides dynamic adjustment capability that allows the system to maintain optimal wire tension for cutting efficiency while adapting to structural inhomogeneities. The displacement mechanism absorbs tension variations, preventing wire damage while preserving cutting performance
Solution Approach 2:
The wire store arrangement provides a cushioning effect by allowing displacement of the second package, which absorbs tension spikes and shocks before they can damage the wire. This beforehand cushioning protects wire integrity while maintaining the tension needed for efficient cutting
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 solution enables efficient wire tension management, reducing the need for tools to release the deflector and protecting the saw wire from damage by adapting to varying structural element inhomogeneities and maintaining wire tension without friction losses.
Implementation Method 1
The clamp of the pivotable wire deflector is preferably designed to be elastically deformable
Implementation Method 2
The clamping and spreading mechanism has a shaft which is oriented along a longitudinal axis of the tube and which has an eccentric cam
Implementation Method 3
A lever can be moved manually between a first position and a second position. The lever exerts, in the first position, a pulling force for reducing the circumference of the clamp and, in the second position, a pushing force for increasing the circumference of the clamp
Data Source
AI summary
A pivotable wire deflector 19 for a saw wire 3 of a wire saw 1 has a deflection roller 32, a pivot joint 60 and a clamping and spreading mechanism. The defection roller 32 has a running groove 45 for guiding the saw wire 3 of the wire saw 1. The pivot joint 60 has a rotary bearing block with a cylindrical receptacle 65, and a tube 63 which is arranged so as to be rotatable in the cylindrical receptacle, wherein the deflection roller 57 is attached to the one of rotary bearing block 62 or tube 63. A clamp 70 is fastened to the rotary bearing block 62 and arranged so as to enclose the tube 63. A lever 68 can be moved manually between a first position and a second position.