Wire Take-Up Device Aligned Winding Flange Detection
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Solution Overview
Problem
Conventional line body take-up devices struggle to achieve completely aligned winding due to precision issues with the position and shape of the bobbin flanges and the width of the line body, leading to clearances and misalignment, especially when winding flat electric lines with small cross-sections and high density requirements.
Innovation Solution
A line body take-up device utilizing laser-operated position detectors to accurately detect the positions and distance between bobbin flanges, and a control device to calculate the inter-flange distance, allowing for precise selection of the take-up pitch and positioning of the flange roller parts to ensure aligned winding by adjusting the traverse position and providing a gap at the inner edge of the flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional take-up devices use flange rollers and line press blocks to hold the line body, then the line body can be taken up with aligned winding, but clearances and misalignments occur due to precision issues with bobbin flange position and shape
Solution Approach 1:
The patent applies preliminary action by measuring the bobbin flange dimensions and positions before the winding process, calculating the optimal traverse position and take-up pitch in advance, and adjusting the take-up device parameters beforehand to compensate for expected variations, thereby achieving precise aligned winding despite bobbin manufacturing tolerances
Solution Approach 2:
The patent changes parameters by dynamically adjusting the traverse position and take-up pitch based on measured bobbin characteristics. The control device calculates optimal parameters (traverse position, take-up pitch) according to the measured flange width, flange inner edge position, and winding amount, then modifies these parameters during operation to maintain precise alignment
2Productivity
If the bobbin is used repeatedly, then productivity increases, but the flange of the bobbin becomes distorted
Solution Approach 1:
The patent implements feedback by measuring the bobbin flange dimensions and positions before each winding operation, using the measured values to calculate and adjust the traverse position and take-up pitch. This closed-loop approach compensates for flange distortion accumulated through repeated use, maintaining winding precision despite bobbin degradation over time
3Adaptability or versatility
If the effective take-up width of the bobbin is not an integral multiple of the line body width, then the bobbin can be used for various line bodies, but clearances occur between the flange and line body
Solution Approach 1:
The patent applies dynamics by making the traverse position and take-up pitch adjustable and adaptive rather than fixed. The control device calculates optimal values based on the measured bobbin flange width and the specific line body width being wound, allowing the system to dynamically adapt to different line body dimensions and eliminate clearances for each specific combination
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 completely aligned winding of the line body around the bobbin, even with small cross-sections and high wind counts, by correcting traverse positions and selecting appropriate take-up pitches, ensuring consistent and precise winding across all layers.
Implementation Method 1
a line body take-up device utilizing laser-operated position detectors to accurately detect the positions and distance between bobbin flanges
Data Source
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AI summary
The present invention has an object of providing a line body take-up method capable of taking up a line body with completely aligned winding even in the vicinity of an inner edge of a flange of a bobbin. By setting the take-up pitch to 1.01 to 1.25 times the width W of a line body 1 having a rectangular cross-section, the line body 1 can be disposed so that a clearance C in which one wind of the line body 1 is put can be provided with certainty at the inner edge of a flange 6 of a bobbin 6 by a flange roller part 11b of a press roller unit 11. By correcting the winding start position or the traverse inversion position based on detection results on the positions of the flanges 6b of the bobbin 6 and the distance between the flanges 6b, a wound line body layer 17 of the line body 1 can be entirely wound around the bobbin 6 in an aligned manner. By detecting the position of the flange 6b of the bobbin 6, it can be determined whether the bobbin 6 is satisfactory or inferior.