Wire Straightening Rollers With Staged Push-In Warpage Control
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Solution Overview
Problem
Existing wire material shaping methods, such as those described in PTL 1, do not effectively reduce warpage in wire materials during the manufacturing process, indicating a need for improved straightening techniques.
Innovation Solution
A method and device that utilize two roller groups, where the first roller group driven by a motor applies a larger push-in amount than the second roller group, with the push-in amount decreasing sequentially from upstream to downstream in the first group and reaching zero in the second group, to reduce warpage by controlling tension and strain in the wire material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional straightener with fixed and movable rolls is used, then the wire material can be straightened, but the warpage reduction is insufficient and the straightening effectiveness is limited
Solution Approach 1:
The straightening process is divided into multiple sequential steps, each with progressively smaller push-in amounts. The first step uses a large push-in amount to address severe warpage, followed by subsequent steps with gradually reduced push-in amounts to refine straightness, ensuring stable and comprehensive warpage reduction across different severity levels
Solution Approach 2:
Different sections of the wire material receive differentiated treatment through varying push-in amounts at different processing stages. The push-in amount is locally optimized for each step: large in the first step for severe warpage areas, and progressively smaller in subsequent steps for refined straightening, ensuring each section is treated according to its specific warpage condition
2Manufacturing precision
If a large push-in amount is applied to reduce warpage, then straightening effectiveness improves, but the wire material may experience excessive tension and strain leading to elongation
Solution Approach 1:
The total push-in amount required for straightening is segmented into multiple steps with progressively decreasing magnitudes. The first step applies a large push-in amount to address severe warpage, while subsequent steps apply smaller push-in amounts to complete the straightening process, distributing the total deformation across multiple controlled stages to prevent excessive tension in any single step
Solution Approach 2:
The first step with the larger push-in amount serves as a preliminary action that addresses the most severe warpage conditions first. This preliminary straightening reduces the overall warpage to a level where subsequent steps with smaller push-in amounts can effectively complete the process without requiring excessive force, thereby preventing elongation
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 approach stably reduces warpage in wire materials by applying controlled tension and strain, ensuring uniform mechanical properties and improved followability, resulting in more effective straightening and reduced elongation.
Implementation Method 1
a first roller group (11) that presses the wire material fed by the feeding device (700)
Implementation Method 2
A push-in amount that is the difference between the outer dimension of the wire material and the gap between rollers through which the wire material passes is larger in the first step than in the second step
Data Source
AI summary
A method for shaping a wire material that moves from the upstream side to the downstream side includes a first step of feeding the wire material while pressing the wire material by a first roller group including a plurality of rollers driven by a motor and a second step of feeding the wire material while pressing the wire material by a second roller group including a plurality of rotatably supported rollers. The first step is provided upstream side of the second step, and a push-in amount that is the difference between the outer dimension of the wire material and the gap between rollers through which the wire material passes is larger in the first step than in the second step.