Endless Wire Saw Tensioning With a Displaceable Wire Store
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Solution Overview
Problem
Existing wire saws face challenges in maintaining consistent wire tension due to inhomogeneities in the structural elements being cut, leading to rapid and strong variations in wire tension, which can affect the service life and cutting efficiency.
Innovation Solution
The wire saw design incorporates a housing with a wire drive and store, featuring a feed device that applies tension through pneumatically or mechanically driven deflection rollers, allowing for adaptive tensioning of the saw wire. This includes a pivotable wire deflector with a clamping and spreading mechanism to manage dust and debris, ensuring smooth operation and reduced wear on sealing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the wire saw operates on inhomogeneous structural elements, then cutting capability is improved, but wire tension varies rapidly and strongly, reducing service life
Solution Approach 1:
The wire store is designed with a displaceable second package of deflection rollers that can dynamically adjust its position along the longitudinal direction. This dynamic adjustment allows the wire store to compensate for tension variations caused by inhomogeneous structural elements, maintaining consistent wire tension while cutting through varied materials
Solution Approach 2:
The feed device acts as an intermediary mechanism between the wire drive and the wire store. It exerts a controlled feed force on the second package of deflection rollers, mediating the tension transmission and preventing sudden tension spikes that would otherwise occur when cutting through inhomogeneous materials
2Device complexity
If the second package of deflection rollers is fixed, then device complexity is reduced, but the length of stored saw wire cannot be increased
Solution Approach 1:
The second package of deflection rollers is mounted on a displaceable support structure that allows it to move along the longitudinal direction. This dynamic configuration enables the wire store to accommodate varying lengths of saw wire by adjusting the position of the second package, while maintaining a relatively simple overall device structure
3Reliability
If sealing elements contact both stationary and rotating elements, then sealing effectiveness is improved, but high rotational speed induces wear in the sealing element
Solution Approach 1:
The sealing element is designed with differentiated contact zones: one zone contacts the stationary axle to provide sealing, while another zone contacts the rotating deflection roller. The local geometry and material properties are optimized for each contact zone, allowing effective sealing while minimizing wear on the rotating contact surface
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
The solution effectively maintains consistent wire tension, protecting the saw wire from excessive stress and extending its service life while ensuring efficient cutting performance across varying structural materials.
Implementation Method 1
The feed device is pneumatically designed or exerts the feed force on the second package by way of a mechanical spring
Implementation Method 2
The feed device is pneumatically designed or exerts the feed force on the second package by way of a mechanical spring
Implementation Method 3
The wire saw pulls the saw wire in the circulating direction, resulting in a tensile stress on the saw wire running into the wire saw
Implementation Method 4
The wire store can exert a tensioning force on the running-out saw wire as far as possible without friction losses or similar losses
Data Source
AI summary
A wire saw 1 according to the invention for an endless saw wire 3 has a housing 6, a wire drive 9, and a wire store 7. The wire drive 9 is for pulling the saw wire 3 in a circulating direction 8. The wire store 7 has a first package 31 of deflection rollers 32 and a second package 33 of deflection rollers 32. The second package 33 is mounted so as to be displaceable with respect to the first package 31 along a direction 14 in order to increase a length of the saw wire 3 stored on the wire store 7. A feed device 38 exerts a feed force on the second package 31 in the direction 14. The wire store 7 is arranged downstream of the wire drive 9 in the circulating direction 8. The wire saw pulls the saw wire 3 in the circulating direction 8, resulting in a tensile stress on the saw wire 3 running into the wire saw 1. By contrast, the saw wire 3 running out of the wire saw 1 is largely without tension. The relative arrangement of wire drive 9 and wire store 7 allows tensioning of the running-out saw wire 3 by the wire store 7.