Multilayer Strand Wire Rope Pre-former Positioning
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Solution Overview
Problem
Existing multilayer strand steel wire rope production devices suffer from issues like outward protrusion and core exposure of central steel wires, leading to waste and quality issues, especially when changing strand wires or specifications, due to pre-former placement and subtle differences in wire diameters.
Innovation Solution
A multilayer strand steel wire rope production device with a pre-former fixed on the drum's outer surface, adjusted to be closer to the outer winding strand payoff spool, and a specific calculation method to determine its position, ensuring proper pre-deformation and preventing outward protrusion and core exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the pre-former is positioned close to the hub (traditional configuration), then the structure is simple and easy to operate, but outward protrusion and core exposure of central steel wires occur easily
Solution Approach 1:
The pre-former is repositioned from the hub area to a location closer to the payoff spool, performing the pre-deformation action earlier in the wire feeding process. This preliminary action allows the outer winding strand to be pre-deformed before twisting, preventing the central steel wire from protruding or exposing during the twisting operation, thereby eliminating quality defects while maintaining operational simplicity
2Manufacturing precision
If the pre-former is repositioned closer to the outer winding strand payoff spool, then outward protrusion and core exposure are prevented, but the device structure becomes more complex
Solution Approach 1:
The pre-former serves multiple functions: it pre-deforms the outer winding strand to prevent core exposure, guides the wire from the payoff spool, and maintains proper wire tension. By consolidating these functions into a single repositioned component rather than adding separate devices, the structural complexity is minimized while achieving the desired manufacturing precision
3Loss of substance
If the pre-former is repositioned, then waste is reduced and production continuity is improved, but the installation and adjustment difficulty increases
Solution Approach 1:
The pre-former's position parameter is changed from the traditional hub-proximal location to a new location closer to the payoff spool. This parameter change optimizes the wire deformation timing, ensuring consistent pre-deformation that prevents core exposure and eliminates waste from defective products, while the modular design facilitates straightforward installation and adjustment
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
Significantly reduces waste and ensures high-quality multilayer strand steel wire rope production by preventing outward protrusion and core exposure, allowing for continuous normal production even when changing strand wires or specifications.
Implementation Method 1
outer winding strands are pre-deformed in advance by means of pre-formers corresponding to the outer winding strand payoff spools
Data Source
AI summary
A multilayer strand steel wire rope production device is provided. A pre-former is fixed on a drum, and a specific position of the pre-former is defined, a center strand payoff spool and a plurality of outer winding strand payoff spools are provided in the drum. The first wire guide mechanism is close to the corresponding outer winding strand payoff spool. One end of the outer surface of the drum away from the first wire guide mechanism is provided with a second wire guide mechanism, and a hub is additionally provided and located on one side of the drum close to the second wire guide mechanism; outer winding strands drawn from the plurality of outer winding strand payoff spools sequentially pass the first wire guide mechanism, the pre-former, and the second wire guide mechanism, and are guided to the hub for gathering to complete strand wire twisting.