Wire Straightening Roller Spacing Adjustment During Operation
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Solution Overview
Problem
Conventional wire straightening devices struggle to maintain optimal roller spacing during operation, leading to decreased straightening effectiveness due to varying wire curl and environmental conditions, requiring frequent stops for adjustment, which reduces productivity.
Innovation Solution
A wire straightening device with automatic roller spacing adjustment capabilities, using a combination of preset values and operator-controlled correction values, allowing for real-time adjustment during operation without changing the preset values, ensuring consistent straightening performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the roller spacing is fixed based on preset values for each wire type, then the initial straightening effect is good, but the straightening effectiveness decreases during operation due to varying wire curl and environmental conditions
Solution Approach 1:
The roller spacing is changed from a fixed static value to a dynamically adjustable value. The control unit receives operator input to change the roller spacing during operation, allowing the system to adapt to varying wire curl degrees and environmental conditions while maintaining optimal straightening precision throughout the operation period
Solution Approach 2:
The roller spacing parameter is made changeable during operation based on operator input. The control unit modifies the roller spacing parameter in response to operator commands, enabling adaptation to different wire conditions (inner vs outer portion curl) and environmental changes without stopping the operation
2Manufacturing precision
If the roller spacing is adjusted frequently to maintain optimal straightening, then the straightening quality is maintained, but productivity decreases due to frequent stops for adjustment
Solution Approach 1:
The system enables the operator to self-adjust the roller spacing during operation through an input interface. The control unit processes operator input in real-time and automatically modifies the roller spacing without requiring system stops, allowing continuous operation while maintaining optimal straightening quality
Solution Approach 2:
The operator can observe the wire straightening effect and provide feedback through input operations to adjust the roller spacing. The control unit responds to this feedback by modifying the roller spacing in real-time, creating a closed-loop system that maintains optimal performance without interrupting production
3Manufacturing precision
If the preset value is changed before operation to adjust pressing force, then the straightening effect is improved, but the operation setup time increases and flexibility during operation is reduced
Solution Approach 1:
The roller spacing transitions from a static preset value to a dynamic value that can be modified during operation. The control unit enables real-time adjustment based on operator input, providing both the precision of preset values and the flexibility of dynamic adjustment without requiring pre-operation setup changes
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
Enables continuous and precise wire straightening by automatically setting and adjusting roller spacing based on wire type and conditions, improving productivity by minimizing stops and maintaining optimal straightening quality.
Implementation Method 1
an actuator that moves the first support member in a direction such that the first straightening rollers move closer to the second straightening rollers and in a direction such that the first straightening rollers move away from the second straightening roller
Implementation Method 2
The wire is conveyed while being sandwiched between the upper rollers and the lower rollers, whereby the curl is straightened under the pressing force from these rollers
Implementation Method 3
the curl is straightened under the pressing force from these rollers
Data Source
Figure 1
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AI summary
An object is to provide a wire straightening device and a wire straightening method, with which it is possible to automatically set the roller spacing in accordance with the type of the wire and to further adjust the roller spacing during operation. A wire straightening device (20) includes a preset value obtaining device that obtains a preset value of roller spacing, which is predetermined for each type of wire (2); a roller spacing automatic setting device that drives an actuator (26a) so that the roller spacing becomes equal to the preset value when the type of the wire (2) is input; and a roller spacing changing device that changes the roller spacing based on an operation by the operator while retaining the preset value during operation of a wire processing device (1).