METHOD TO STRAIGHTEN METALLIC FILAMENT

In various exemplary embodiments, the technology described herein provides systems and methods for drawn wire, commonly called filament, to be straightened after cold, warm or hot drawing to a smaller diameter. This technology controls tension on the wire after drawing, while pulling the wire through straightening rollers. A single set of straightening rollers can be used. There is no limit on the total number of sets of straightening rollers can be used. The number of individual rollers in a set of straightening rollers can range from two-to-many rolls. Tension is generally controlled by at least two relatively large diameter synchronizing sets of pulling rollers, one before the straightening rollers and one after the straightening rollers.

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Description
FIELD OF THE INVENTION

The technology described herein relates generally to the physical treatment of metal products such as drawn wire in steel wire manufacturing and cord engineering. More specifically, this technology relates to systems and methods for straightening metallic filament after drawing in producing a steel cord for radial tires or monofilament for tire or other reinforcement applications or other wire applications like music wire.

BACKGROUND OF THE INVENTION

For many applications, filament should be straightened before any subsequent operation is applied. For example, in the manufacture of steel tire cord, utilizing a straightened filament prior to twisting will result in higher fatigue life of the final product. In other applications, straightened wire is required to follow a prescribed path in a subsequent operation. By way of example, when cut filament is automatically guided into a small hole after cutting, filament with a residual bend after drawing can result in the filament missing the hole.

Some wire manufacturers utilize slow filament drawing with in-line large-diameter pulling rollers to help straighten filament. The technology described herein can be used in line with a high speed drawing process or off line after drawing.

BRIEF SUMMARY OF THE INVENTION

In various exemplary embodiments, the technology described herein provides systems and methods for drawn wire, commonly called filament, to be straightened after wet, cold, warm or hot drawing to a smaller diameter. This technology controls tension on the wire after drawing, while pulling the wire through straightening rollers. A single set of straightening rollers can be used. There is no limit on the total number of sets of straightening rollers can be used. The number of individual rollers in a set of straightening rollers can range from two-to-many rolls. Tension is generally controlled by at least two relatively large diameter synchronizing sets of pulling rollers, one before the straightening rollers and one after the straightening rollers as well as a device to measure and control tension. The filament tension must be very low during straightening. The tension measuring device (a strain gauge, for example) is used to send a signal to the synchronized pull capstans to maintain the low tension by changing the speed of one pull roller.

In one exemplary embodiment, the technology described herein provides a system for straightening metallic filament. The system includes: a first pulling roller; a second pulling roller, the first pulling roller and the second pulling roller being synchronized to rotate at a synchronized pace to pull a filament through the system at a predetermined rate; and at least one set of straightening rollers comprising at least two rollers opposed to one another on opposite sides of the filament from one another. The at least one set of straightening rollers is configured to straighten the filament prior to a subsequent operation on the filament.

The first pulling roller can be located prior to the at least one set of straightening rollers and the second pulling roller can be located subsequent to the at least one set of straightening rollers.

The filament can be straightened in line with a drawing operation. Alternatively, the filament can be straightened offline during an operation separate from a drawing process.

The at least one set of straightening rollers can include a first set of straightening rollers and a second set of straightening rollers. Alternatively, the at least one set of straightening rollers can include a first set of straightening rollers, a second set of straightening rollers, and a third set of straightening rollers. There is no theoretical limit to the number of sets of straightening rollers utilized.

The first pulling roller and the second pulling roller are configured to create a tension in the filament. The tension can be controlled to be a low value while using the at least one set of straightening rollers to relive a residual stress on the filament that causes the filament to bend.

A diameter of each of the first pulling roller and the second pulling roller is much larger than a diameter of the filament. A diameter of the at least one set of straightening rollers is much smaller than the size of the pulling rollers and much closer to a size of the filament.

The system for straightening metallic filament can also include a tension measuring device configured to measure a tension on the filament pulled through the system for straightening metallic filament. The tension measuring device sends a signal to the synchronized pulling rollers to maintain a very low tension on the filament. If the tension becomes too high, the wire will not be straightened.

In yet another exemplary embodiment, the technology described herein provides a method for straightening metallic filament. The method includes: utilizing a first pulling roller; utilizing a second pulling roller; synchronizing the first pulling roller and the second pulling roller to rotate at a synchronized pace to pull a filament through a system for straightening metallic filament at a predetermined rate; and utilizing at least one set of straightening rollers comprising at least two rollers opposed to one another on opposite sides of the filament from one another. The at least one set of straightening rollers is configured to straighten the filament prior to a subsequent operation on the filament.

The method for straightening metallic filament can further include: placing the first pulling roller prior to the at least one set of straightening rollers and placing the second pulling roller subsequent to the at least one set of straightening rollers.

The method for straightening metallic filament can further include: straightening the filament in line with a drawing operation. Alternatively, the method for straightening metallic filament further include: straightening the filament offline during an operation separate from a drawing process.

The method provides that the at least one set of straightening rollers can include a first set of straightening rollers and a second set of straightening rollers. Alternatively, the method provides that the at least one set of straightening rollers can include a first set of straightening rollers, a second set of straightening rollers, and a third set of straightening rollers. There is no theoretical limit to the number of sets of straightening rollers utilized in this method.

The method for straightening metallic filament can further include: configuring the first pulling roller and the second pulling roller to create a tension in the filament. The method for straightening metallic filament can further include: controlling the tension in the filament to be a low value while using the at least one set of straightening rollers to relive a residual stress on the filament that causes the filament to bend.

The method provides that a diameter of each of the first pulling roller and the second pulling roller is much larger than a diameter of the filament. The method also provides that a diameter of the at least one set of straightening rollers is much smaller than the size of the pulling rollers and much closer to a size of the filament.

The method for straightening metallic filament can further include: utilizing a tension measuring device configured to measure a tension on the filament pulled through the system for straightening metallic filament. The tension measuring device sends a signal to the synchronized pulling rollers to maintain a very low tension on the filament. If the tension becomes too high, the wire will not be straightened.

There has thus been outlined, rather broadly, the more important features of the technology in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the technology that will be described hereinafter and which will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment of the technology in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The technology described herein is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the technology described herein.

Further objects and advantages of the technology described herein will be apparent from the following detailed description of a presently preferred embodiment which is illustrated schematically in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The technology described herein is illustrated with reference to the various drawings, in which like reference numbers denote like device components and/or method steps, respectively, and in which:

FIG. 1 is a side view schematic diagram of a system to straighten metallic filament, according to an embodiment of the technology;

FIG. 2 is a side view schematic diagram of a system to straighten metallic filament, according to an embodiment of the technology;

FIG. 3 is a side view schematic diagram of multiple sets of straighten straightening rollers to straighten metallic filament, according to an embodiment of the technology;

FIG. 4 is an end view schematic diagram of multiple sets of straighten straightening rollers to straighten metallic filament, according to an embodiment of the technology; and

FIG. 5 is a flowchart depicting a method for straightening metallic filament.

 DETAILED DESCRIPTION OF THE INVENTION

Before describing the disclosed embodiments of this technology in detail, it is to be understood that the technology is not limited in its application to the details of the particular arrangement shown here since the technology described is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.

In various exemplary embodiments, the technology described herein provides systems and methods for drawn wire, commonly called filament, to be straightened after wet, cold, warm or hot drawing to a smaller diameter. This technology controls tension on the wire after drawing, while pulling the wire through straightening rollers. A single set of straightening rollers can be used. There is no limit on the total number of sets of straightening rollers can be used. The number of individual rollers in a set of straightening rollers can range from two-to-many rolls. Tension is generally controlled by at least two relatively large diameter synchronizing sets of pulling rollers, one before the straightening rollers and one after the straightening rollers as well as a device to measure and control tension. The filament tension must be very low during straightening. The tension measuring device (a strain gauge, for example) is used to send a signal to the synchronized pull capstans to maintain the low tension by changing the speed of one pull roller.

Referring now to the Figures, a system 10 for straightening metallic filament 16 is shown. The filament 16 can be straightened in line with a drawing operation. Alternatively, the filament 16 can be straightened offline during an operation separate from a drawing process.

The system 10 includes a first pulling roller 12 and a second pulling roller 14. The first pulling roller 12 and the second pulling roller 14 are synchronized to rotate at a synchronized pace to pull a filament 16 through the system 10 at a predetermined rate. The diameter of each of the first pulling roller 12 and the second pulling roller 14 is much larger than a diameter of the filament 16.

In at least one embodiment, the first pulling roller 12 is located prior to the at least one set of straightening rollers 20, 30, 40, and the second pulling roller 14 is located subsequent to the at least one set of straightening rollers 20, 30, 40. This order can be varied. The first pulling roller 12 and the second pulling roller 14 rotate in direction of arrows 50 to pull the filament 16 through the system 10.

The system 10 includes at least one set of straightening rollers comprising at least two rollers opposed to one another on opposite sides of the filament from one another. As depicted in the Figures, the system 10 can include a first set of straightening rollers 20, a second set of straightening rollers 30, and a third set of straightening rollers 40. There is no theoretical limit to the number of sets of straightening rollers utilized in the system 10. Additionally, as few as one set of straightening rollers can be used to straighten filament 16.

Each set of straightening rollers 20, 30, 40 includes at least two rollers opposed to one another on opposite sides of the filament from one another. By way of example, the first set of straightening rollers 20 includes roller block assembly 22, 24 have at least one roller 26 opposed by at least roller on an opposite side 28. The second set of straightening rollers 30 includes roller block assembly 32, 34 have at least one roller 36 opposed by at least roller on an opposite side 38. The third set of straightening rollers 40 includes roller block assembly 42, 44 have at least one roller 46 opposed by at least roller on an opposite side 48. The number of roller pairs (such as 26, 28) per each set of straightening rollers 20, 30, 40 can vary. In most cases several sets of straightening rollers containing, for example, 12 or more individual rollers should be used.

Each set of straightening rollers 20, 30, 40 can operate at varied angles relative to one another. By way of example (as best depicted in FIGS. 3 and 4), rollers 26 and 28 are opposed to one another and pressing against the filament 16 at generally 0 and 360 degrees. Rollers 36 and 38 are opposed to one another and pressing against the filament 16 at generally 45 and 225 degrees. Rollers 48 and 46 are opposed to one another and pressing against the filament 16 at generally 135 and 315 degrees. These angles can be varied.

Nearly any amount of ring and cast can be straightened. Wire can be straightened by controlling the wire tension to a constant low value and running wire through several sets of straightening rolls 20, 30, 40. As depicted in the Figures the several sets of straightening rolls 20, 30, 40 are utilized on three planes.

The diameter of each roller 26, 28, 36, 38, 46, 48 of each set of straightening rollers, 20, 30, 40, while it can vary amongst rollers and sets of rollers, is much smaller than the size of the pulling rollers and much closer to a size of the filament 16. Each set of straightening rollers is configured to straighten the filament 16 prior to a subsequent operation on the filament 16.

The first pulling roller 12 and the second pulling roller 14 are configured to create a tension in the filament 16. The tension is controlled to be a low value while using the set of straightening rollers 20, 30, 40 to relive a residual stress on the filament 16 that causes the filament 16 to bend. The system 10 can include a tension measuring device 18. The tension measuring device 18 is configured to measure a tension on the filament 16 pulled through the system 16 for straightening metallic filament. The tension measuring device sends a signal to the synchronized pulling rollers to maintain a very low tension on the filament. If the tension becomes too high, the wire will not be straightened.

In operation, the method to straighten metallic filament after drawing utilizes a pulling roller to help remove filament from a wire carrier, spool, drawing machine or other machine to eliminating variations in tension due to the wire carrier, spool, drawing machine or other machine. The wire then travels through at least one set of two straightening rollers slightly bending the filament to reduce or eliminate residual bending in the filament. In most cases several sets of straightening rollers containing for example 12 or more individual rollers should be used. Prior to winding, rewinding or otherwise collecting the filament the wire passes through or over a tension monitoring devise and exits the straightening unit via a second pulling roller the function of which is to pull wire through the straightening rollers at low tension. In this description, the tensioning monitoring device creates an electronic tension signal that synchronizes the two pulling rollers to ensure a constant low tension during straightening.

The systems and methods of this technology can be utilized on filaments of varying diameters and at various line speeds. By way of example, in one exemplary embodiment, the system is utilized on small diameter filaments that are less than 0.35 mm in diameter and straightened at a rate of 15 meters per second.

As depicted in FIG. 5, the method for straightening metallic filament can include the following methods steps: drawing wire filament 502 (in wire direction 518), utilizing a first synchronized pulling roller 504, controlling tension in the filament 506, utilizing a first set of straightening rollers 508, utilizing a second set of straightening rollers 510, utilizing a third set of straightening rollers 512, utilizing an Nth set of straightening rollers 514, and utilizing a second synchronized pulling roller 516. The method steps and the order in which the method steps are taken can be varied.

In one exemplaray embodiment, the method can be carried out by the following steps: utilizing a first pulling roller; utilizing a second pulling roller; synchronizing the first pulling roller and the second pulling roller to rotate at a synchronized pace to pull a filament through a system for straightening metallic filament at a predetermined rate; and utilizing at least one set of straightening rollers comprising at least two rollers opposed to one another on opposite sides of the filament from one another. The at least one set of straightening rollers is configured to straighten the filament prior to a subsequent operation on the filament.

The method for straightening metallic filament can further include: placing the first pulling roller prior to the at least one set of straightening rollers and placing the second pulling roller subsequent to the at least one set of straightening rollers.

The method for straightening metallic filament can further include: straightening the filament in line with a drawing operation. Alternatively, the method for straightening metallic filament further include: straightening the filament offline during an operation separate from a drawing process.

The method provides that the at least one set of straightening rollers can include a first set of straightening rollers and a second set of straightening rollers. Alternatively, the method provides that the at least one set of straightening rollers can include a first set of straightening rollers, a second set of straightening rollers, and a third set of straightening rollers. There is no theoretical limit to the number of sets of straightening rollers utilized in this method.

The method for straightening metallic filament can further include: configuring the first pulling roller and the second pulling roller to create a tension in the filament. The method for straightening metallic filament can further include: controlling the tension in the filament to be a low value while using the at least one set of straightening rollers to relive a residual stress on the filament that causes the filament to bend.

The method provides that a diameter of each of the first pulling roller and the second pulling roller is much larger than a diameter of the filament. The method also provides that a diameter of the at least one set of straightening rollers is much smaller than the size of the pulling rollers and much closer to a size of the filament.

The method for straightening metallic filament can further include: utilizing a tension measuring device configured to measure a tension on the filament pulled through the system for straightening metallic filament. The tension measuring device sends a signal to the synchronized pulling rollers to maintain a very low tension on the filament. If the tension becomes too high, the wire will not be straightened.

Although this technology has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples can perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the disclosed technology and are intended to be covered by the following claims.

Claims

1. A system for straightening metallic filament, the system comprising:

a first pulling roller;
a second pulling roller, the first pulling roller and the second pulling roller being synchronized to rotate at a synchronized pace to pull a filament through the system at a predetermined rate; and
at least one set of straightening rollers comprising at least two rollers opposed to one another on opposite sides of the filament from one another;
wherein the at least one set of straightening rollers is configured to straighten the filament prior to a subsequent operation on the filament.

2. The system for straightening metallic filament of claim 1, wherein the first pulling roller is located prior to the at least one set of straightening rollers and the second pulling roller is located subsequent to the at least one set of straightening rollers.

3. The system for straightening metallic filament of claim 1, wherein the filament is straightened in line with a drawing operation.

4. The system for straightening metallic filament of claim 1, wherein the filament is straightened offline during an operation separate from a drawing process.

5. The system for straightening metallic filament of claim 1, wherein the at least one set of straightening rollers is comprised of a first set of straightening rollers and a second set of straightening rollers.

6. The system for straightening metallic filament of claim 1, wherein the at least one set of straightening rollers is comprised of a first set of straightening rollers, a second set of straightening rollers, and a third set of straightening rollers.

7. The system for straightening metallic filament of claim 1, wherein the first pulling roller and the second pulling roller are configured to create a tension in the filament.

8. The system for straightening metallic filament of claim 7, wherein the tension is controlled to be a low value while using the at least one set of straightening rollers to relive a residual stress on the filament that causes the filament to bend.

9. The system for straightening metallic filament of claim 1, wherein a diameter of each of the first pulling roller and the second pulling roller is much larger than a diameter of the filament, and wherein a diameter of the at least one set of straightening rollers is much smaller than the size of the pulling rollers and much closer to a size of the filament.

10. The system for straightening metallic filament of claim 1, further comprising:

a tension measuring device configured to measure a tension on the filament pulled through the system for straightening metallic filament.

11. A method for straightening metallic filament, the method comprising:

utilizing a first pulling roller;
utilizing a second pulling roller;
synchronizing the first pulling roller and the second pulling roller to rotate at a synchronized pace to pull a filament through a system for straightening metallic filament at a predetermined rate; and
utilizing at least one set of straightening rollers comprising at least two rollers opposed to one another on opposite sides of the filament from one another;
wherein the at least one set of straightening rollers is configured to straighten the filament prior to a subsequent operation on the filament.

12. The method for straightening metallic filament of claim 11, further comprising:

placing the first pulling roller prior to the at least one set of straightening rollers; and
placing the second pulling roller subsequent to the at least one set of straightening rollers.

13. The method for straightening metallic filament of claim 11, further comprising:

straightening the filament in line with a drawing operation.

14. The method for straightening metallic filament of claim 11, further comprising:

straightening the filament offline during an operation separate from a drawing process.

15. The method for straightening metallic filament of claim 11, wherein the at least one set of straightening rollers is comprised of a first set of straightening rollers and a second set of straightening rollers.

16. The method for straightening metallic filament of claim 11, wherein the at least one set of straightening rollers is comprised of a first set of straightening rollers, a second set of straightening rollers, and a third set of straightening rollers.

17. The method for straightening metallic filament of claim 11, further comprising:

configuring the first pulling roller and the second pulling roller to create a tension in the filament.

18. The method for straightening metallic filament of claim 11, further comprising:

controlling the tension in the filament to be a low value while using the at least one set of straightening rollers to relive a residual stress on the filament that causes the filament to bend.

19. The method for straightening metallic filament of claim 11, wherein a diameter of each of the first pulling roller and the second pulling roller is much larger than a diameter of the filament, and wherein a diameter of the at least one set of straightening rollers is much smaller than the size of the pulling rollers and much closer to a size of the filament.

20. The method for straightening metallic filament of claim 11, further comprising:

utilizing a tension measuring device configured to measure a tension on the filament pulled through the system for straightening metallic filament.
Patent History
Publication number: 20100229614
Type: Application
Filed: Mar 15, 2009
Publication Date: Sep 16, 2010
Inventor: Thomas W. Tyl (Siler City, NC)
Application Number: 12/404,315
Classifications
Current U.S. Class: Including Relatively-inclined Successive Rollers (72/162); And Adjustable Carrier For Deflector (72/164); Involving Use Of Claimed Apparatus (72/372)
International Classification: B21F 1/02 (20060101); B21D 3/05 (20060101);