Automatic Wire Tension Adjustment During Coil Winding
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Solution Overview
Problem
Existing wire tensioners struggle to maintain constant wire tension during the winding of electric coils, particularly during accelerations and decelerations, which cause oscillations and potential damage to damping elements, especially when winding wires with larger diameters.
Innovation Solution
A device with a supporting structure, a takeup arm that rotates, and a pushing and braking element with adjustable torque, combined with a load cell for tension detection and an angular transducer for rotation detection, allows for automatic adjustment of wire tension through feedback loops to maintain constant tension during varying coil rotation speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brake and load cell are used to detect wire tension and automatically adjust braking action, then wire tension can be kept constant during winding at constant speed, but the system cannot maintain constant tension during accelerations and decelerations of coil rotation
Solution Approach 1:
The patent applies dynamics by making the takeup arm movable rather than fixed, allowing it to rotate about an axis to compensate for wire demand variations. The arm's position is dynamically adjusted based on wire tension feedback, enabling the system to adapt to changing speed conditions during coil rotation accelerations and decelerations.
Solution Approach 2:
The patent uses feedback by detecting takeup arm rotation position and using this information to automatically adjust the braking action on the wire. The detection means monitor the arm's angular position, and this feedback signal controls the brake to maintain constant wire tension despite variations in coil rotation speed.
2Reliability
If a takeup arm with damping element is used to compensate for wire demand variations, then wire tension can be maintained during constant speed winding, but the takeup arm oscillates during accelerations and decelerations causing damage to the damping element
Solution Approach 1:
The patent eliminates harmful oscillations by implementing feedback control that detects the takeup arm's angular position and automatically adjusts braking action. This active control prevents the arm from overshooting and oscillating, thereby protecting the damping element from damage while maintaining wire tension constancy during speed transitions.
Solution Approach 2:
The patent replaces the passive mechanical damping system with an active control system using detection means and automatic brake adjustment. Instead of relying solely on the damping element to control oscillations mechanically, the system uses electrical/electronic detection and control to actively prevent oscillations, reducing stress on the damping component.
3Device complexity
If a fixed braking force is applied to the wire, then the structure is simple, but the wire tension cannot be adjusted during different winding steps requiring accelerations and decelerations
Solution Approach 1:
The patent introduces dynamics by making the braking force adjustable rather than fixed. The brake's braking action is dynamically controlled based on feedback from the detection means that monitor takeup arm position, allowing the system to adapt braking force to match the requirements of different winding steps including accelerations and decelerations.
Solution Approach 2:
The patent applies parameter changes by varying the braking force parameter in response to changing operational conditions. The detection means monitor the takeup arm's angular position and use this information to adjust the brake's braking torque, changing the braking parameter to maintain constant wire tension during transitions between different winding phases.
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 effectively keeps wire tension constant during all winding steps, including accelerations and decelerations, by promptly adjusting thrust or braking actions, ensuring the takeup arm remains stationary and preventing damage from oscillations.
Implementation Method 1
a load cell for detecting the tension of the wire
Implementation Method 2
a damping element that has the function of damping the oscillations of the takeup arm about its own axis induced by the variations in the tension of the wire
Implementation Method 3
The takeup arm is connected to springs that have the function of contrasting the rotation of the takeup arm when the demand for wire increases
Data Source
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AI summary
A device for automatic wire tension adjustment during the various steps of winding in machines for winding electric coils, comprising a supporting structure (2) that 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 means (5) for detecting the tension of the wire (3) and a takeup arm (6) that can rotate about an axis (7) with respect to the supporting structure (2) due to the variations of the tension of the wire (3); the device further comprises, along the path for the wire (3), an element (4) for pushing and braking the wire (3) and means (8) for detecting the rotation of the takeup arm (6) about the axis (7) relative to the supporting structure (2) and the means (8) for detecting the rotation of the takeup arm (6) are connected functionally 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 (6) about the axis (7).