Wire Tension Control Actuator for Coil Winding
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Solution Overview
Problem
Conventional wire tension adjustment devices struggle to maintain constant tension during high acceleration and deceleration phases of winding, particularly in multi-layer coil windings, leading to 'slow turns' due to oscillations and damage to dampers.
Innovation Solution
A device with a supporting structure, a takeup arm, and an actuator connected to a piezoelectric linear actuator, which adjusts the angular position of the takeup arm based on detected tension and angular position, using feedback loops to maintain constant tension and limit takeup arm rotation, preventing 'slow turns'.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wire stretchers with dampers are used to maintain constant tension, then tension stability is improved, but the system fails under high acceleration and deceleration conditions causing oscillations and damper damage
Solution Approach 1:
The patent replaces the mechanical damper system with an electronic control system comprising load cells for tension detection, a microprocessor for signal processing, and a servo motor for brake control. This substitution eliminates mechanical oscillations and damper failures by using electronic feedback to maintain tension stability during high acceleration and deceleration phases.
Solution Approach 2:
The patent implements a closed-loop feedback system where load cells continuously detect wire tension, the microprocessor compares detected tension with target tension, and the servo motor adjusts brake force accordingly. This feedback mechanism prevents oscillations and maintains constant tension even during rapid acceleration and deceleration, resolving the reliability issue with conventional dampers.
2Productivity
If high accelerations and decelerations are used during multi-layer winding, then productivity is improved, but wire tension cannot be maintained causing 'slow turns'
Solution Approach 1:
The patent employs a dynamic control system that continuously adapts brake force during winding operations. The servo motor adjusts braking torque in real-time based on feedback from load cells, enabling the system to maintain constant wire tension even during high-speed acceleration and deceleration phases required for multi-layer winding productivity.
Solution Approach 2:
The patent dynamically changes the braking parameter (torque) in response to varying winding conditions. The microprocessor modifies brake force parameters based on detected tension deviations, allowing the system to maintain uniform wire tension across different winding speeds and acceleration phases, preventing slow turns while preserving high productivity.
3Reliability
If the takeup arm is allowed to rotate freely to compensate for wire demand variations, then wire tension compensation is improved, but oscillations occur during reel acceleration and deceleration
Solution Approach 1:
The patent uses load cells to detect wire tension and provides feedback to a microprocessor that controls a servo motor. This feedback system regulates takeup arm rotation precisely, allowing the arm to compensate for wire demand variations while preventing oscillations during reel acceleration and deceleration by actively controlling rather than freely allowing arm movement.
Solution Approach 2:
The patent replaces the purely mechanical takeup arm suspension system with an electro-mechanical control system. The servo motor, controlled by microprocessor based on load cell feedback, substitutes for passive mechanical elements, enabling precise control of takeup arm position and eliminating unstable oscillations while maintaining effective tension compensation.
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 device ensures constant wire tension and stable takeup arm position, preventing 'slow turns' even under high acceleration and deceleration conditions, enhancing winding regularity and reliability.
Implementation Method 1
an actuator which is connected to said takeup arm and is adapted to vary the angular position of said takeup arm about said axis
Data Source
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AI summary
A device for automatically adjusting wire tension during the various steps of winding in machines for winding electrical coils, comprising a supporting structure (2) which supports a series of elements that define a path for the wire (3) to be fed to the coil being wound. Along this path there are: - an element (4) for pushing and braking the wire (3); - a takeup arm (5) which is supported so that it can rotate by the supporting structure (2) about an axis (6) and which can rotate about the axis (6), with respect to the supporting structure (2), owing to variations in the tension of the wire (3); - means of detecting the tension (7) of the wire (3); the device in question further comprising means of detecting the angular position (8) of the takeup arm (5) about the axis (6) with respect to the supporting structure (2), such means of detecting the angular position (8) of the takeup arm (5) are functionally connected to the pushing and braking element (4) for an automatic adjustment of the degree of thrust or braking applied to the wire (3) as a function of the detected value of the rotation of the takeup arm (5) about the axis (6); the device comprises an actuator (9) which is connected to the takeup arm (5) and which is adapted to vary the angular position of the takeup arm (5) about the axis (6), the actuator (9) is functionally connected to the means of detecting the tension (7) of the wire (3) in order to vary the angular position of the takeup arm (5) as a function of the tension of the wire (3) detected by the means of detecting the tension (7) of the wire (3).