Wire Laying Device Tension Control for Complex Paths
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Solution Overview
Problem
Existing devices for depositing metal wires on laminated panes, particularly those used for wire-heated windows, face issues with maintaining constant wire tension due to variations in the speed of the wire reserve spool and drum, leading to irregular wire waves and oscillations.
Innovation Solution
The introduction of a clamping device in the yarn path between the spool and the push roller, which includes a movable and elastically prestressed clamping roller, allows for significant compensation of wire length and tension variations, ensuring constant tension before laying and reducing the influence of spool rotation and inertia.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a braking system and undulation mechanisms are provided in the wire laying device, then the wire can be laid on complex paths with variable speeds, but oscillations arise from wire deformation and relative inertia of the reserve coil that lead to irregular waves
Solution Approach 1:
A tensioning device is introduced as an intermediary element between the reserve coil and the wire laying mechanism. This tensioning device actively maintains constant wire tension during extraction, serving as a mediator that decouples the variable speed rotation of the reserve coil from the wire laying process, thereby eliminating oscillations and irregular waves while enabling complex path laying
Solution Approach 2:
The tensioning device incorporates a feedback mechanism that continuously monitors and adjusts wire tension during extraction. By providing real-time feedback control, the system maintains constant tension despite variations in reserve coil rotation speed, preventing the formation of irregular waves and ensuring uniform wire laying on complex paths
2Adaptability or versatility
If the ratio between the speed of rotation of the yarn reserve spool and the speed of rotation of the drum is not constant, then the drum can accommodate variable speed requirements for complex paths, but the tensile force under which the thread is extracted from the bobbin is not constant
Solution Approach 1:
The tensioning device employs a feedback control mechanism that continuously monitors extraction tension and adjusts the wire extraction speed accordingly. This feedback loop ensures that tension remains constant despite variable drum speeds, allowing the system to accommodate complex path requirements while maintaining force stability
Solution Approach 2:
The tensioning device automatically regulates wire extraction tension through its own control mechanism, without requiring external intervention. The device self-adjusts to maintain constant tension as the drum speed varies, enabling the system to handle variable speed requirements for complex paths while keeping extraction force stable
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
This solution effectively maintains constant wire tension, reducing oscillations and irregular waves, enabling uniform wire laying on complex paths and variable speeds, and is particularly advantageous for laying wires in curves, divergent paths, and non-circular paths with varying density.
Implementation Method 1
a movable and elastically prestressed clamping roller, allows for significant compensation of wire length and tension variations
Data Source
Figure 1
Figure 2
AI summary
A device for laying a thin metal wire taken from a coil of wire stock onto a surface, in particular onto the surface of a sheet, using a presser. The device includes a mechanism exerting mechanical tension in a region of the wire that lies between the rotary coil of wire stock and the presser, and a wire-guiding device provided in the region. The wire-guiding device includes a tensioning device that acts directly on the wire taken off the coil of wire stock. That makes it possible effectively and appreciably to compensate for changes in relative speeds at which the wire and the sheet progress.