Wire Reel Brake Control for Faster Rebar Binding Machine Stopping

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Solution Overview

Problem

The existing brake systems for wire reels in reinforcing bar binding machines suffer from time lag in braking operation, leading to increased wire reel rotation inertia and reduced braking performance, especially when used outdoors where dust and debris can interfere with the solenoid and braking mechanisms.

Innovation Solution

A brake system that includes a braking mechanism with a solenoid-driven stopper lever, a control system that initiates braking only after a predetermined wire length is fed, and a dust-proof cover to protect the braking components, allowing for earlier braking initiation based on power voltage levels and reducing unnecessary power consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the brake lever is actuated by a solenoid with a link mechanism or spring, then the brake can be engaged with the wire reel, but time lag occurs until the brake operates after the solenoid is actuated

Engineering Contradiction:

Improvebraking operation reliabilityVSAvoidtime lag in braking operation

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent removes the link mechanism and spring from between the solenoid and brake lever, directly connecting the solenoid to the brake lever. This extraction of intermediate components eliminates the time lag caused by mechanical transmission delays while maintaining the braking function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical link mechanism and spring with a direct electromagnetic actuation system. The solenoid directly drives the brake lever without mechanical intermediaries, substituting a complex mechanical transmission system with a simpler electromagnetic-mechanical direct coupling system that responds faster.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If the braking means and solenoid are disposed in the vicinity of the wire reel to facilitate loading, then the wire reel can be easily loaded, but sand and dust can adhere to the solenoid and braking operation cannot be reliably performed

Engineering Contradiction:

Improvewire reel loading easeVSAvoiddust and sand adhesion to solenoid

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent nests the solenoid and braking means inside the machine body housing, creating a nested structure where the braking components are housed within the protective enclosure. This allows the wire reel to remain accessible for easy loading while the sensitive solenoid and brake components are protected from external dust and sand.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent introduces the machine body housing as an intermediary barrier between the solenoid/braking means and the external environment. This intermediary structure allows the braking components to function near the wire reel while protecting them from harmful external factors like dust and sand.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If the wire reel is exposed to the outside of the binding machine body, then loading of the wire reel is facilitated, but the braking means and solenoid exposed outside are susceptible to dust and sand adhesion

Engineering Contradiction:

Improvewire reel loading convenienceVSAvoidbraking operation reliability in dusty conditions

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent segments the machine into distinct functional zones: the wire reel remains accessible outside or at the opening for easy loading, while the solenoid and braking means are housed separately inside the protected machine body. This spatial segmentation allows each component to be positioned optimally for its function while protecting sensitive components from environmental hazards.

Inventive Principle:

Principle #1Segmentation

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 reduces time lag in braking, improves braking performance, extends battery life by optimizing power usage, and ensures reliable operation even in dusty outdoor conditions by preventing dust adhesion on the braking components.

Implementation Method 1

the brake lever is actuated by a solenoid

Methodology Applied

Scientific EffectSolenoid: Solenoid

Implementation Method 2

with the configuration (including a spring) in which the brake lever rotate about a pivot

Methodology Applied

Scientific EffectSpring: Spring

Data Source

PatentUS11780621B2Brake system of wire reel in reinforcing bar binding machine

Publication Date: 2023.10.10 MAX CO LTD

AI summary

A reinforcing bar binding machine is provided with a feed means for feeding a wire from a wire reel rotatably mounted on a binding machine body, a braking means for braking a rotation of the wire reel, and a control means that starts a braking to the rotation of the wire reel by the braking means after the wire is fed to a predetermined amount by the feed means.