Wire Winding Speed Control for Peak Valley Defects
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Solution Overview
Problem
Existing methods for winding wires on spools often result in peaks and valleys due to irregular spool surfaces, incorrect flange positioning, and wire dispensing issues, leading to suboptimal winding quality and requiring expensive sensor systems for control.
Innovation Solution
A method utilizing synchronous electric motors, load cells or take-up rolls to measure wire tension, and sensors to adjust the wire dispensing speed based on calculated winding diameter and wire pulling action, allowing for real-time correction of peaks and valleys during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If speed sensors are used to control wire winding and detect peaks/valleys, then winding precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the speed sensing function from dedicated speed sensors and relocates it to the existing wire dispensing device motor controller, which already has capability to measure motor speed and position. This eliminates the need for separate speed sensors while maintaining the ability to detect winding defects through speed variations.
Solution Approach 2:
The motor controller of the wire dispensing device is given multiple functions: it continues to control wire dispensing speed while also serving as the speed sensor for detecting peaks and valleys in the winding. This multi-functional approach reduces overall system complexity by eliminating redundant components.
2Measurement precision
If multiple sensors are used to detect spool position and wire speed, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of multiple sensors into integrated measurement capabilities within the motor controllers. The wire dispensing device motor controller measures both wire speed and position, while the spool motor controller measures spool speed and position. This consolidation eliminates the need for separate dedicated sensors for each parameter.
Solution Approach 2:
The motor controllers perform self-measurement of their own operational parameters (speed, position) without requiring external sensors. Each motor controller uses its own internal encoders and feedback mechanisms to accurately measure its performance, making the system simpler while maintaining measurement precision.
3Productivity
If wire dispensing speed is kept constant, then productivity is improved, but winding quality deteriorates due to peaks and valleys
Solution Approach 1:
The patent implements dynamic speed control where the wire dispensing device speed is continuously adjusted based on real-time feedback from the motor controller about winding conditions. When peaks or valleys are detected through speed variations, the system automatically modifies the dispensing speed to correct the defect, maintaining both high productivity and winding quality.
Solution Approach 2:
The system establishes a closed-loop feedback mechanism where the motor controller continuously monitors wire dispensing speed and spool rotation, detects deviations that indicate peaks or valleys, and automatically adjusts the wire dispensing speed to correct these defects, thereby maintaining constant productivity while improving winding quality.
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
This approach ensures reliable, high-quality wire laying with reduced operator intervention and lower costs by using fewer sensors, improving winding efficiency and reducing waste.
Implementation Method 1
uses the combination of effects due to the type of motors used, the installation of one or more control sensors to check the presence of the spool, and the correlation between the linear speed of the incoming wire (determined by a capstan), the 'calculated winding diameter' (also called 'servodiameter') and the wire pulling measurement detected by means of an appropriate sensor. In particular, this sensor is a load cell.
Implementation Method 2
The method according to the present invention is based on a different system, which makes use, preferably, but not necessarily, of synchronous electric motors (particularly brushless motors with integrated drive, or decentralized in relation to size and control in space)
Implementation Method 3
In the presence of a valley or of a peak, and thus of an instant change in the winding diameter in relation to the servodiameter, the wire pulling action changes, generating a signal variation that is construed as the presence of a peak or a valley
Data Source
AI summary
A method for implementing a correct winding of a wire on a spool. The method is characterized in that it comprises a step for calculating the angular speed of a motor displacing a wire dispensing device according to the wire winding pitch and according to the pulling error, detected in relation to a given pre-set set-point and to a tolerance value, in order to determine the presence of a possible “valley error”, or of a possible “peak error”. Furthermore, if during the spool winding a “valley error” or a “peak error” is detected, the control device decides whether to slow down or to increase the speed of the wire dispensing device with the aim of filling the valley or of skipping the peak.