Wire Feed Pressure Control to Prevent Slippage and Wear
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Solution Overview
Problem
Existing wire-feed devices for thermal joining apparatuses require manual setting of contact pressure, which often results in excessive pressures leading to mechanical wear, poor weld quality, and increased energy consumption.
Innovation Solution
A wire-feed device with an actuator controlled by a control unit to variably set the contact pressure, allowing for precise adjustments and preventing slippage, while also reducing mechanical wear and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual setting of contact pressure is used, then the device complexity is reduced, but the manufacturing precision and reliability deteriorate due to excessive pressure application
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated actuator system controlled by a control unit. The actuator mechanically adjusts the contact pressure of the drive roller onto the wire based on feedback from sensors that detect wire slippage, eliminating the need for manual setting while achieving precise pressure control.
Solution Approach 2:
The patent implements a feedback control mechanism where sensors detect wire slippage at the drive roller and transmit this information to a control unit. The control unit then adjusts the actuator to modify the contact pressure accordingly, creating a closed-loop system that automatically maintains optimal pressure without manual intervention.
2Reliability
If higher contact pressure is applied to prevent slippage, then the reliability of wire feeding is improved, but the mechanical wear and energy consumption increase
Solution Approach 1:
The patent transforms the static, fixed contact pressure setting into a dynamic adjustment system. The contact pressure is continuously adapted based on actual wire feeding conditions and slippage detection, allowing the system to apply only the necessary pressure to prevent slippage rather than maintaining a constantly high pressure level, thereby reducing mechanical wear.
Solution Approach 2:
The patent changes the contact pressure parameter dynamically based on detected wire slippage conditions. When slippage is detected, the control unit increases the contact pressure through the actuator; when slippage is prevented, the pressure is reduced to minimal necessary levels, optimizing the balance between reliability and wear prevention.
3Reliability
If higher contact pressure is applied to prevent slippage, then the reliability of wire feeding is improved, but the energy consumption increases
Solution Approach 1:
The patent transforms the static, fixed contact pressure setting into a dynamic adjustment system. The contact pressure is continuously adapted based on actual wire feeding conditions and slippage detection, allowing the system to apply only the necessary pressure to prevent slippage rather than maintaining a constantly high pressure level, thereby reducing mechanical wear.
Solution Approach 2:
The patent changes the contact pressure parameter dynamically based on detected wire slippage conditions. When slippage is detected, the control unit increases the contact pressure through the actuator; when slippage is prevented, the pressure is reduced to minimal necessary levels, optimizing the balance between reliability and wear prevention.
4Ease of operation
If manually adjustable spring mechanisms are used to exert pretension, then the ease of operation is improved, but the manufacturing precision deteriorates due to inability to achieve optimal pressure settings
Solution Approach 1:
The patent replaces the manually adjustable spring mechanism with an automated actuator system controlled by a control unit. The actuator mechanically adjusts the contact pressure of the drive roller onto the wire based on feedback from sensors that detect wire slippage, eliminating the need for manual setting while achieving precise pressure control.
Solution Approach 2:
The patent implements a feedback control mechanism where sensors detect wire slippage at the drive roller and transmit this information to a control unit. The control unit then adjusts the actuator to modify the contact pressure accordingly, creating a closed-loop system that automatically maintains optimal pressure without manual intervention.
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 optimal setting of contact pressure, preventing slippage and excessive wear, thereby improving weld quality, reducing energy consumption, and extending the service life of the wire-feed device.
Implementation Method 1
at least one drive element (1, 4) which can be placed onto a wire (13) passing through the wire-feed device (11), in order to frictionally transmit a driving movement (14)
Data Source
AI summary
The invention relates to a wire-feed device for conveying a wire and to a method for feeding wire using a wire-feed device, in particular for a thermal joining apparatus, having at least one a drive element which can be operated by a feed drive and can be placed against a wire guided through the wire-feed device, exerting a contact pressure, in order to transfer drive movement by friction. According to the invention, an actuator which is coupled to the at least one drive element and can be controlled by a controller using the values measured for the contact pressure, is provided for variably setting the contact pressure acting on the wire.