Wire Processing Device Twist Counteracting Mechanism
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Solution Overview
Problem
Existing wire-processing machines fail to prevent twist in wires during manufacturing, leading to the formation of knots and tangled bundles, which increases production time and reduces the quality of wire connections, especially when handling wires with specific lay configurations and insulation variations.
Innovation Solution
A method and device that mechanically untwist wires by determining the twist using a control system and rotating grippers to eliminate doubled-back loops, ensuring wires are processed without twist, allowing for higher quality connections and reduced manual untangling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If wire is pulled out of rotating drum through straightening track with both ends held by grippers, then wire can be processed automatically, but twist builds up in the wire causing knots and tangled bundles
Solution Approach 1:
The patent applies preliminary anti-action by introducing a twist counteracting device that actively generates opposite twist to counterbalance the twist built up during wire processing. This device rotates the wire in the opposite direction to the natural twist accumulation, preventing knots and tangled bundles from forming in the first place
Solution Approach 2:
The twist counteracting device acts as an intermediary between the wire processing system and the wire itself. It mediates the twist accumulation by providing a controlled counter-rotation mechanism that neutralizes harmful twist while allowing the automatic processing to continue
2Manufacturing precision
If wire ends are held by grippers during advancement, then wire positioning is controlled, but wire cannot freely untwist leading to doubled-back loops
Solution Approach 1:
The patent applies dynamics by making the wire rotation capability dynamic rather than static. The twist counteracting device enables the wire to rotate freely about its longitudinal axis while being held by grippers, transforming the system from a fixed positioning constraint to a dynamic system that can accommodate and control wire rotation
Solution Approach 2:
The patent segments the wire handling function into two independent parts: longitudinal positioning (handled by grippers) and rotational freedom (handled by twist counteracting device). This segmentation allows each function to be optimized independently without interfering with the other
3Ease of manufacture
If twist builds up in wire bundle, then manual untangling is required, but production time increases and quality decreases
Solution Approach 1:
The patent applies self-service by enabling the wire to untwist itself through the twist counteracting device during the processing operation. The device allows the wire to rotate and release accumulated twist automatically, eliminating the need for subsequent manual untangling operations
Data Source
AI summary
In a wire-processing device, the wire executes turns through being pulled out of a drum. The leading wire-end is held by a gripper of a loop-former. A wire that has been cut to length is held at its leading and trailing ends by an untwisting unit, the wire having before the untwisting operation a doubled-backed loop. A transfer unit takes the leading and trailing ends from the loop-former and passes the wire to the untwisting unit. After the untwisting operation, the transfer unit feeds the wire-ends to the processing units that process the wire-ends. A bundling unit takes the processed wires from the transfer unit, the bundling unit forming a wire bundle with the wires. With the untwisted wires, the wire bundle has neither doubled-back loops nor knots.