Wire Roller Speed Control for Wire Cutting Machines
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Solution Overview
Problem
Existing wire cutting machines fail to address the issue of wire jumping or wire breakage, which can lead to wire jumping or wire breakage during processing due to changes in wire roller diameter, affecting processing speed and quality.
Innovation Solution
A control method for wire cutting machines that adjusts the rotational speed of the wire roller based on preset shaft diameter change conditions to maintain a set difference in wire speed between the wire roller and main roller, ensuring uniform tension and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wire roller diameter changes during unwinding and winding processes, then the wire speed consistency deteriorates, but maintaining constant rotational speed is simple
Solution Approach 1:
The patent applies dynamics by making the rotational speed of the wire roller adjustable and variable during operation. The control system dynamically modifies the rotational speed based on the wire roller diameter changes during unwinding and winding processes, ensuring consistent wire speed despite diameter variations. This transforms a static control approach into a dynamic one that adapts to changing conditions.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the wire roller diameter changes and using this information to adjust the rotational speed. The control system receives feedback about the current diameter state and modifies the rotational speed accordingly to maintain constant wire speed, creating a closed-loop control system that automatically compensates for diameter variations.
2Reliability
If the rotational speed of wire roller is not adjusted, then the control system is simple, but wire jumping or breakage occurs
Solution Approach 1:
The patent applies preliminary action by pre-establishing the control strategy that accounts for diameter changes before they occur. The system is configured with predetermined control logic that anticipates the diameter variations during unwinding and winding, and proactively adjusts the rotational speed to prevent wire jumping or breakage before these issues can manifest.
Solution Approach 2:
The patent uses feedback control to continuously monitor wire roller diameter and adjust rotational speed in real-time. This closed-loop system detects diameter changes and automatically compensates by modifying rotational speed, ensuring wire stability and preventing jumping or breakage through continuous adaptation to changing conditions.
3Manufacturing precision
If the wire speed difference between wire roller and main roller is not controlled, then the operation is simple, but processing quality deteriorates
Solution Approach 1:
The patent implements feedback control by monitoring the wire speed difference between the wire roller and main roller, and using this information to adjust the wire roller's rotational speed. This closed-loop control ensures that the wire speed remains consistent throughout the system, maintaining high processing quality while automatically compensating for diameter changes without requiring complex manual intervention.
Solution Approach 2:
The patent applies self-service by enabling the control system to automatically adjust the wire roller rotational speed based on detected diameter changes. The system serves itself by autonomously maintaining wire speed consistency without requiring external intervention, thereby preserving processing quality while keeping the operation simple through automation.
Data Source
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AI summary
A control method for a wire cutting machine, comprising: judging whether a preset shaft diameter change condition is met or not; if the preset shaft diameter change condition is met, calculating a target rotational speed of a wire roller (41); and causing the current rotational speed of the wire roller (41) to be the target rotational speed, so that the linear speed difference between a linear speed of a cutting wire (3) on the wire roller (41) and a linear speed of a cutting wire (3) on a main roller (1) is within a set difference. By means of the arrangement, the consistency between the linear speed of the cutting wire (3) on the wire roller (41) and the linear speed of the cutting wire (3) on the main roller (1) can be improved, thereby ensuring that the tension on a cutting wire net is more uniform and a tension swing rod is more stable, so that the probability of wire jumping or wire breakage in the machining process can be reduced to ensure the machining speed and the machining quality. The present invention further relates to a control apparatus and a wire cutting machine.