Wire Straightening Apparatus with Offset Grooved Rollers
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Solution Overview
Problem
Existing wire straightening apparatuses face challenges in maintaining kink straightening effectiveness while the wire feeding mechanism is suspended, often resulting in bending kinks, and spacing rollers apart to prevent kinks reduces the straightening effect.
Innovation Solution
A wire straightening apparatus with multiple straightening mechanisms, each comprising first and second support portions with rotatably mounted rollers having grooves that deepen towards the bottom, where the bottom portions of the grooves are offset from the wire feeding path, allowing the wire to bend and contact the rollers' outer surfaces, maintaining straightening effectiveness even during suspension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rollers are spaced far apart to prevent bending kinks during suspension, then wire kinks are suppressed during suspension, but the kink straightening effect deteriorates
Solution Approach 1:
The straightening mechanism is divided into multiple rollers (first straightening rollers and second straightening rollers) arranged in sequence along the wire feeding path. This segmentation allows the wire to undergo progressive straightening through multiple contact points, maintaining effective straightening even when rollers are spaced apart to prevent suspension-induced bending kinks.
Solution Approach 2:
The rollers are arranged not only in the wire feeding direction but also in the radial direction with grooves that deepen toward the bottom portion. This multi-dimensional arrangement creates alternating contact points that effectively straighten kinks while maintaining sufficient spacing to prevent bending kinks during suspension.
2Manufacturing precision
If multiple straightening rollers are used to maintain kink straightening effect, then wire kinks are effectively straightened, but the device complexity increases
Solution Approach 1:
The first straightening rollers and second straightening rollers are integrated into a single straightening mechanism that works together to straighten wire kinks. The alternating arrangement of rollers from first and second support portions creates a unified straightening action that reduces the need for separate, complex straightening devices.
Solution Approach 2:
The straightening mechanism with alternating first and second straightening rollers serves multiple functions: it straightens wire kinks during feeding, prevents bending kinks during suspension, and accommodates wires of various diameters. This multi-functionality reduces the need for additional specialized devices.
3Manufacturing precision
If rollers are positioned close together to improve straightening effect, then kink straightening effectiveness increases, but the space requirements and device complexity increase
Solution Approach 1:
The alternating arrangement of first and second straightening rollers in the radial direction, combined with grooves that deepen toward the bottom portion, creates effective straightening action without requiring rollers to be positioned closely together in the wire feeding direction. This dimensional arrangement maintains straightening effectiveness while reducing space requirements.
Data Source
AI summary
A wire straightening apparatus that straightens kinks of a wire that is fed along a wire feeding path includes one or a plurality of straightening mechanisms. Each straightening mechanism includes a plurality of first straightening rollers and one or a plurality of second straightening rollers. Each roller has a groove along its outer periphery, the groove gradually deepening toward a bottom portion. The bottom portion of the groove of each first straightening roller is spaced from the wire feeding path in a first direction, and the bottom portion of the groove of each second straightening roller is spaced from the wire feeding path in a second direction opposite to the first direction. With this structure, the wire can be made to follow a path that meanders as viewed from a direction perpendicular to axes of the straightening rollers.