Wire Straightening Control with Sensor Feedback for Continuous Alignment
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Solution Overview
Problem
Existing methods for straightening wire or strip material require a free wire end for accurate measurement and adjustment, necessitating a separate test measurement pass and longer machine construction, which is inefficient and impractical for continuous processing.
Innovation Solution
A closed control loop system using three sensors spaced along the X axis to measure material deflection in the Y and Z directions, feeding data into a model to adjust settable aligning rollers without the need for a free wire end or separate test measurement, allowing continuous processing and curvature compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a free wire end is used for measurement and adjustment, then accurate straightening can be achieved, but the wire cannot be further processed in an automated manner and requires separate test measurement pass
Solution Approach 1:
The patent implements a feedback control system where sensors continuously measure the position of the wire after it passes through the aligning rollers, and this measurement information is fed back to automatically adjust the roller positions. This closed-loop feedback enables accurate straightening without requiring the wire end to be free, as the system adapts in real-time during normal production operation.
Solution Approach 2:
The patent replaces the mechanical requirement of a free wire end with an optical/electronic measurement system. Instead of relying on mechanical freedom of the wire end for measurement, the system uses sensors (optical or other non-contact types) to detect wire position, substituting the mechanical measurement approach with a field-based detection method that works during continuous processing.
2Manufacturing precision
If a separate test measurement pass is carried out, then the model can be established for roller adjustment, but this increases processing time and reduces efficiency
Solution Approach 1:
The patent establishes the mathematical model for roller adjustment based on preliminary calibration data, but the key innovation is that this model can then be used in real-time during normal production without requiring repeated test passes. The system performs preliminary characterization of the wire behavior and then uses this knowledge for continuous automatic adjustment, eliminating the need for time-consuming separate test measurement passes for each production run.
Solution Approach 2:
The system enables self-service operation where the aligning device automatically adjusts its own roller positions based on sensor feedback and the pre-established model, without requiring external intervention or separate test passes. The device serves itself by using its own measurement data to make real-time adjustments during normal production operation.
3Measurement precision
If the machine is constructed to accommodate free wire end measurement, then accurate measurement is possible, but the machine becomes longer and more complex
Solution Approach 1:
The patent replaces mechanical extensions and fixtures required for free wire end measurement with compact optical or electronic sensors positioned downstream of the aligning rollers. This substitution allows accurate position measurement without requiring the wire end to be free or extending the machine length, as the sensors can detect wire position in a compact arrangement immediately after the rollers.
Data Source
AI summary
A method and a device for straightening wire or strip material using a straightening device comprising aligning rollers which act on opposite sides of the material being passed through in an offset manner and some of which are automatically set on the basis of a model, which has been ascertained using input data of the material, such that the requirements for straightness are satisfied. The position of at least one aligning roller is continuously adapted on the basis of the aforementioned data which is detected while the material passes through the straightening device and which represents the target straightness, wherein the deflection of the material in the Y and Z direction after passing through the assembly of aligning rollers is measured by three sensors arranged along the X axis, and the obtained measurement values are input into the model which controls the setting of the aligning rollers which can be set.