Wire Loop De-twisting via Sensor Feedback Control
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Solution Overview
Problem
Existing wire-processing machines face challenges in consistently removing twist from wire loops due to unpredictable de-twisting movements and angles, which can result in loop crossing and unsuccessful de-twisting, especially with longer wires.
Innovation Solution
A pull-out gripper and sensor device system that recognizes the direction and twist state of the loop, allowing for controlled de-twisting by maintaining the loop taut and determining the optimal de-twisting direction, preventing loop crossing and ensuring successful twist removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed de-twisting values are used based on trials, then the de-twisting process is simple to implement, but the twist cannot be consistently removed from wire loops of varying lengths
Solution Approach 1:
The patent employs sensor devices to detect the actual twist state of wire loops during processing and uses this feedback information to dynamically adjust de-twisting parameters. This closed-loop control system ensures consistent twist removal across varying wire lengths while maintaining operational simplicity through automated adjustment.
Solution Approach 2:
The invention transitions from static, pre-determined de-twisting values to a dynamic system that continuously adapts to the actual wire loop conditions. The de-twisting apparatus modifies its operation in real-time based on detected twist characteristics, ensuring reliable performance across different wire lengths without complex manual configuration.
2Productivity
If long wire loops are used, then more wire can be processed per loop, but the loops may cross multiple times making de-twisting unsuccessful
Solution Approach 1:
Sensor devices monitor the twist state of long wire loops throughout the de-twisting process, providing real-time feedback that enables dynamic adjustment of de-twisting parameters. This ensures successful twist removal even from extended wire lengths that would otherwise cross multiple times.
Solution Approach 2:
The system dynamically changes de-twisting parameters such as rotation angle, speed, and direction based on the detected twist state of the wire loop. This adaptive parameter adjustment allows effective processing of varying wire lengths while maintaining high success rates.
3Device complexity
If the de-twisting direction is predetermined, then the control process is simple, but the direction may not match the actual twist direction causing failed de-twisting
Solution Approach 1:
The patent uses sensor devices to detect the actual twist direction of wire loops and provides feedback to the control system. This enables automatic determination and adjustment of the de-twisting direction to match the detected twist direction, ensuring reliable de-twisting without complex manual programming.
Solution Approach 2:
The system determines and adjusts the de-twisting direction automatically based on sensor feedback, making the control process self-regulating. The apparatus adapts to each wire loop's specific twist characteristics without requiring external intervention or complex pre-programming.
Data Source
AI summary
An apparatus for the formation of a wire loop comprises a wire drive for advancing a wire and a loop layer to grip a first end of the wire and to lay a wire loop. When the wire is advanced, the wire loop is formed into a selected size. The apparatus also includes a pull-out gripper and a sensor device, the pull-out gripper being configured to grasp the wire of the wire loop and, after grasping the wire of the wire loop, move relative to the loop layer, thereby tensioning the wire loop in a longitudinal direction. The sensor device can detect a twist in the wire loop.