Wire Torsion Control for Tangle-Free Bulk Pack Payout
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Solution Overview
Problem
Existing wire feeding systems face challenges with residual tension in wires after twist-free winding, leading to tangling and production interruptions, especially with aluminum and steel wires, due to factors like equipment defects and incorrect adjustments, which prior retainer plate systems cannot effectively manage.
Innovation Solution
A counter-tension rotating device is positioned between the wire coil and feeder, equipped with wheels that impart a counter-torsional movement to the wire, neutralizing tension and preventing tangling, either mechanically or using an electrical motor controlled by a PLC, allowing for smooth payout without or with a light retainer plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a retainer plate system is used to control wire payout, then wire tangling is prevented, but residual tension causes deformation of soft aluminum wires and the system becomes ineffective
Solution Approach 1:
The patent replaces the traditional mechanical retainer plate system with an active torsional force application system. A wire clutching device with rolls imparts controlled rotational movement to the wire, substituting passive mechanical retention with active mechanical control that accounts for wire material properties.
Solution Approach 2:
The patent changes the control parameter from static retainer plate position to dynamic torsional force application. The wire clutching device applies varying rotational forces based on wire payout conditions, transforming the control mechanism from fixed to adaptive, thereby preventing both tangling and deformation.
2Ease of operation
If twist-free winding is used to store wire in bulk packs, then floor space is reduced and handling is improved, but residual tension remains causing tangling during payout
Solution Approach 1:
The patent applies preliminary counter-torsional action to the wire during payout. The wire clutching device proactively imparts rotational movement to neutralize residual tension before it can cause tangling, rather than reacting to tangling problems after they occur.
Solution Approach 2:
The wire clutching device acts as an intermediary between the bulk pack storage system and the wire feeder. It mediates the residual tension issue by introducing controlled rotational movement that bridges the gap between static storage and dynamic feeding, ensuring smooth wire payout.
3Reliability
If heavy retainer plates are used to prevent wire loops from falling into the pack, then wire tangling is reduced, but soft aluminum wires are deformed
Solution Approach 1:
The patent changes the control parameter from static retainer plate weight to dynamic torsional force application. The wire clutching device applies varying rotational forces based on wire payout conditions, transforming the control mechanism from fixed to adaptive, thereby preventing both tangling and deformation.
Solution Approach 2:
The patent replaces the traditional mechanical retainer plate system with an active torsional force application system. A wire clutching device with rolls imparts controlled rotational movement to the wire, substituting passive mechanical retention with active mechanical control that accounts for wire material properties.
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 a trouble-free wire payout by neutralizing residual tension, reducing the risk of tangling and production interruptions, even with wires like 5000 grade aluminum, which are prone to deformation, thereby enhancing manufacturing efficiency and weld quality.
Implementation Method 1
a wire clutching device mounted on the support and adapted to engage at a wire guided along the wire path, and a rotation mechanism which is adapted for rotating the support with respect to the base... exerts a torsional force onto the wire
Data Source
AI summary
A device for imparting a torsional force onto a wire has a base and a support mounted so as to be rotatable with respect to the base around an axis of rotation. The axis of rotation coincides with a wire path extending through the base and the support. Further, a wire clutching device is mounted on the support and adapted to engage at a wire guided along the wire path, and a rotation mechanism is provided which is adapted for rotating the support with respect to the base.