This application claims the benefit of Taiwan application Serial No. 112138088, filed Oct. 4, 2023, the disclosure of which is incorporated by reference herein in its entirety.
TECHNICAL FIELD The disclosure relates to a wire tension control mechanism, a winding system using the same, and a wire tension control method thereof.
BACKGROUND The winding system in the existing winding process could provide a wire to a carrier, so that the wire is wound or braided on the carrier. During the winding process, if the tension of the wire is unstable, it will cause a covering defect in the wire wound on the carrier, such as wire slippage, splitting or twisting. Therefore, proposing a technology that could improve the aforementioned conventional problems is one of the goals of those in this technical field.
SUMMARY According to one embodiment, a wire tension control mechanism is provided. The wire tension control mechanism includes a wire feeding device, a connecting device and a wire guiding device. The connecting device includes a fixing element and a rotor. The fixing element is connected with the wire feeding device. The rotor is disposed on the fixing element and is movable relative to the fixing element. The wire guiding device is connected to the rotor.
According to another embodiment, a winding system is provided. The winding system includes a wire tension control mechanism and a driving mechanism. The wire tension control mechanism includes a wire feeding device, a connecting device and a wire guiding device. The connecting device includes a fixing element and a rotor. The fixing element is connected with the wire feeding device. The rotor is disposed on the fixing element and is movable relative to the fixing element. The wire guiding device is connected to the rotor. The driving mechanism is connected to the wire tension control mechanism and configured to drive a wire passing through the wire tension control mechanism to cover a carrier.
According to an alternative embodiment, a wire tension control method is provided. The wire tension control method includes the following steps: providing a wire tension control mechanism, wherein the wire tension control mechanism includes a wire feeding device, a connecting device and a wire guiding device, the connecting device includes a fixing element and a rotor, the fixing element is connected with the wire feeding device, the rotor is disposed on the fixing element and is movable relative to the fixing element, and the wire guiding device is connected to the rotor; and providing the wire with a resistance, by the wire tension control mechanism, based on a pulling of the wire.
BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1A and 1B illustrate schematic diagrams of a winding system 1 viewed from different angles according to an embodiment of the present disclosure;
FIG. 2A illustrates a schematic diagram of a wire tension control mechanism 100 of the winding system 1 in FIG. 1;
FIGS. 2B and 2C illustrate schematic diagrams of the wire tension control mechanism 100 in FIG. 2A viewed from different viewing angles;
FIG. 2D illustrates a schematic diagram of a cross-sectional view of the wire tension control mechanism 100 in FIG. 2C along a direction 2D-2D′;
FIG. 3 illustrates a schematic diagram of an exploded view of the wire tension control mechanism 100 in FIG. 2A;
FIG. 4 illustrates a schematic diagram of a force of a wire W1 passing through the wire tension control mechanism 100 in FIG. 2A;
FIG. 5A illustrates a schematic diagram of a wire tension control mechanism 200 according to another embodiment of the present disclosure;
FIG. 5B illustrates a schematic diagram of a side view of the wire tension control mechanism 200 in FIG. 5A;
FIG. 5C illustrates a schematic diagram of a cross-sectional view of the wire tension control mechanism 200 along a direction 5C-5C′;
FIG. 6 illustrates a schematic diagram of an exploded view of the wire tension control mechanism 200 in FIG. 5A;
FIG. 7 illustrates a schematic diagram of a wire tension control mechanism 300 according to another embodiment of the present disclosure;
FIG. 8 illustrates a schematic diagram of an exploded view of the wire tension control mechanism 300 in FIG. 7;
FIG. 9 illustrates a schematic diagram of an exploded view of a wire tension control mechanism 400 according to another embodiment of the present disclosure;
FIG. 10A illustrates a schematic diagram of a wire tension control mechanism 500 according to another embodiment of the present disclosure;
FIG. 10B illustrates a schematic diagram of the wire tension control mechanism 500 in FIG. 10A along a direction 10B-10B′;
FIG. 11 illustrates a schematic diagram of a cross-sectional view of the wire tension control mechanism 500 in FIG. 10A;
FIG. 12A illustrates a schematic diagram of a wire tension control mechanism 600 according to another embodiment of the present disclosure;
FIG. 12B illustrates a schematic diagram of an exploded view of the wire tension control mechanism 600 in FIG. 12A;
FIG. 13A illustrates a schematic diagram of a wire tension control mechanism 700 according to another embodiment of the present disclosure; and
FIG. 13B illustrates a schematic diagram of an exploded view of the wire tension control mechanism 700 in FIG. 13A.
In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically illustrated in order to simplify the drawing.
DETAILED DESCRIPTION Passive Swing Type—Using Self-Weight Refer to FIGS. 1A to 4, FIGS. 1A and 1B illustrate schematic diagrams of a winding system 1 viewed from different angles according to an embodiment of the present disclosure, FIG. 2A illustrates a schematic diagram of a wire tension control mechanism 100 of the winding system 1 in FIG. 1, FIGS. 2B and 2C illustrate schematic diagrams of the wire tension control mechanism 100 in FIG. 2A viewed from different viewing angles, and FIG. 2D illustrates a schematic diagram of a cross-sectional view of the wire tension control mechanism 100 in FIG. 2C along a direction 2D-2D′, FIG. 3 illustrates a schematic diagram of an exploded view of the wire tension control mechanism 100 in FIG. 2A, and FIG. 4 illustrates a schematic diagram of a force of a wire W1 passing through the wire tension control mechanism 100 in FIG. 2A.
As illustrated in FIGS. 1A to 1B, the winding system 1 includes a driving mechanism 10 and the wire tension control mechanism 100. The driving mechanism 10 is connected to the wire tension control mechanism 100 and is configured to drive the wire W1 passing through the wire tension control mechanism 100 for covering a carrier C1. The winding system 1 could be applied to various processes that require the wire W1 to be wound or braided on the carrier C1, such as a motor winding process, a yarn bundle spreading process, a rolling process, etc.
As illustrated in FIGS. 1A and 1B, in the present embodiment, the driving mechanism 10 is, for example, a robot arm, but it may also be other mechanisms that could drive the wire tension control mechanism 100. The robotic arm has, for example, six degrees of freedom, such as translations in x, y, and z axes and rotations around x, y, and z axes. The driving mechanism 10 includes a connection element 11 which is rotatable around z axis. The connection element 11 may also be called a flange. The wire tension control mechanism 100 could be disposed on (or fixed to) the connection element 11 to rotate around the z axis along with the connection element 11.
In terms of product category, the carrier C1 is, for example, a component of a transportation device (such as aircraft frame, vehicle frame, bicycle frame, etc.), a component of a sport equipment (such as badminton racket, hockey handle, rafting paddles, etc.), a component of a people's livelihood product (such as liquefied petroleum gas bottle, hydrogen bottle, oxygen bottle and high-pressure pipe) and other product that require high strength (but are not limited to). The wire W1 is, for example, a metal wire, such as any metal element on the periodic table or a composite material, such as carbon fiber, glass fiber and other lightweight and high-strength wire. Alternatively, the wire W1 could be various wires used in the textile industry, such as yarn, cotton thread, etc. In an embodiment, after the wire coating operation for the carrier C1 is completed, the carrier C1 covered with the wire W1 could be solidified and formed. The wire W1 is composed of a wire body (reinforcement material) and a resin (base material). After the wire W1 covers the carrier C1, the resin could be cured through a high-temperature baking to form a high-stress resistant composite material.
As illustrated in FIGS. 2A to 2D and FIG. 3, the wire tension control mechanism 100 includes a wire feeding device 110, a connecting device 120 and a wire guiding device 130. As illustrated in FIG. 2D, the connecting device 120 includes a fixing element 121 and a rotor 122. The fixing element 121 is connected to the wire feeding device 110. The rotor 122 is movably disposed relative to the fixing element 121. The wire guiding device 130 is connected to the rotor 122. As a result, the wire guiding device 130 and the wire feeding device 110 could move relative to each other. When the wire W1 pulls the wire feeding device 110 (for example, during a winding operation), the wire W1 also pulls the wire guiding device 130. The self-weight of the wire guiding device 130 could provide a resistance to the wire W1. Since the wire guiding device 130 could move (for example, swing) relative to the wire feeding device 110, such resistance could be transmitted to the wire feeding device 110 to maintain the tension of the wire W1 at a stable tension value TC1 (the stable tension value TC1 is illustrated in FIG. 4).
As illustrated in FIG. 4, the curve C1 is a stress curve of the wire W1 passing through the wire tension control mechanism 100 in FIG. 1A, and the curve C2 is a stress curve of the wire without the wire guiding device 130. The horizontal axis in FIG. 4 represents an angle of the wire feeding device 110. When the wire guiding device 130 is in a vertical orientation, the angle definition of the wire guiding device 110 is expressed as θ0. For example, when an extension direction of the wire guiding element 131 of the wire guiding device 130 is toward a center of the earth (or perpendicular to a ground), the angle of the wire feeding device 110 could be defined as θ0, at which time the tension of the wire W1 is minimal or even 0. In an embodiment, the extending direction of the wire guiding element 131 of the wire guiding device 130 may be substantially parallel to the Z axis illustrated in FIG. 1B. The Z axis illustrated in FIG. 1B is, for example, a rotation axis of a base 12 of the driving mechanism 10. When the wire feeding device 110 rotates clockwise (for example, changes toward one of θ−MAX and θ+MAX) or counterclockwise (for example, changes toward one of θ−MAX and θ+MAX), the wire W1 passing through the wire feeding device 110 will change in looseness or tightness. Comparing the curves C1 and C2, due to the configuration of the wire guiding device 130, the tension of the wire W1 could remain substantially stable regardless of the angle of the wire feeding device 110.
As illustrated in FIGS. 1B and 4, when the wire guiding element 131 rotates relative to the vertical orientation, the tension of the wire W1 becomes tight or loose. When the angle between the wire guiding element 131 and the vertical orientation is larger, it means that the tension of the wire W1 becomes tighter or looser. In the present embodiment, when the angle between the wire guiding element 131 and the vertical orientation is larger, the torque generated by the self-weight of the wire guiding element 131 is also larger, and the tension correction effect on the wire W1 is also larger, so the tension of the wire W1 could be roughly maintained at the stable tension value TC1.
As illustrated in FIGS. 2D and 3, the wire feeding device 110 includes a flange 111, a connection shaft 112, a bearing 113 and at least one roller 114. The connection shaft 112 is connected to the flange 111. For example, the connection shaft 112 and the flange 111 are fixed to each other. In an embodiment, the connection shaft 112 and the flange 111 are, for example, an integrally formed structure. In addition, the fixing element 121 of the connecting device 120 is connected to the flange 111. For example, the fixing element 121 and the flange 111 are fixed to each other. At least one screw element (not illustrated) could pass through a through hole 111a of the flange 111 and be screwed into a screw hole 121t of the fixing element 121 to fix a relative position between the flange 111 and the fixing element 121. In addition, the rotor 122 has a through hole 122a, and the connection shaft 112 could pass through the through hole 122a of the rotor 122. An inner diameter of the through hole 122a is larger than an outer diameter of the connection shaft 112, so that the connection shaft 112 and the rotor 122 are loosely matched, so the connection shaft 112 and the rotor 122 could rotate relative to each other. Due to the connection shaft 112 and the rotor 122 being loosely matched, when the wire W1 pulls the rotor 122 to rotate around z axis, the rotor 122 could rotate relative to the connection shaft 112 without interfering with the connection shaft 112. As a result, the winding or the braiding path of the wire W1 is not disturbed or changed (if the rotor 122 rotates under the interference of the connection shaft 112, it will drive the wire feeding device 110 to move, which will unexpectedly interfere with or change the winding or braiding path of the wire W1).
As illustrated in FIGS. 2D and 3, the bearing 113 includes a base 1131 and a stopper 1132. The base 1131 is connected to the stopper 1132. For example, the base 1131 and the stopper 1132 are fixed to each other. In an embodiment, the base 1131 and the stopper 1132 are, for example, an integrally formed structure. In the present embodiment, the base 1131 and the stopper 1132 are connected substantially vertically, but an acute or an obtuse angle may be included therebetween. The bearing 113 is connected to the connection shaft 112. At least one screw element (not illustrated) could pass through at least one through hole 1132a of the stopper 1132 and be screwed into the screw hole (not illustrated) of the connection shaft 112 for fixing a relative location between the connection shaft 112 and the stopper 1132. Due to the bearing element 113 being detachably connected to the connection shaft 112, the wire guiding device 130 is allowed to be sleeved on the connection shaft 112 first, and then the stopper 1132 is assembled on the connection shaft 112. After assembly, the connecting device 120 and the wire guiding device 130 are restricted in an area between the stopper 1132 and the flange 111.
As illustrated in FIGS. 2D and 3, a plurality of rollers 114 is rotatably connected to the base 1131, so that the wire W1 passing between the two rollers 114 reduces frictional resistance. In the present embodiment, each roller 114 may include a connection shaft 1141 and a wheel 1142, wherein the connection shaft 1141 may be fixed to the base 1131, and the wheel 1142 is pivotally connected to the connection shaft 1141.
As illustrated in FIGS. 2D and 3, the rotor 122 of the connecting device 120 and the wire guiding element 131 of the wire guiding device 130 are fixed to each other. At least one screw element (not illustrated) could pass through a through hole 131a of the wire guiding element 131 and be screwed into a screw hole 122t of the rotor 122 to fix a relative position between the wire guiding element 131 and the rotor 122. Since the wire guiding element 131 and the rotor 122 are fixed to each other, when the wire W1 pulls the wire guiding element 131 to rotate around z axis, the rotor 122 could rotate accordingly.
As illustrated in FIGS. 2D and 3, the connecting device 120 further includes at least one bearing, such as a first bearing 123 and a second bearing 124. The first bearing 123 and the second bearing 124 are disposed between the fixing element 121 and the rotor 122 to connect the fixing element 121 and the rotor 122 so that the fixing element 121 and the rotor 122 could rotate relative to each other through the bearings. The rotor 122 includes a first connection portion 1221, a second connection portion 1222 and a flange 1223. The first connection portion 1221 and the second connection portion 1222 are respectively disposed on two opposite sides of the flange 1223, and the flange 1223 protrudes relative to a peripheral surface of the first connection portion 1221 and a peripheral surface of the second connection portion 1222. The flange 1223 could define an assembly position of the first bearing 123 and the second bearing 124. For example, due to the stop of the flange 1223, the positions of the first bearing 123 and the second bearing 124 along the z axis could be determined. In an embodiment, the first connection portion 1221, the second connection portion 1222 and the flange 1223 are, for example, an integrally formed structure. In addition, the bearing includes an inner ring, an outer ring and at least one ball, wherein the ball is rotatably accommodated between the inner ring and the outer ring. The inner ring of the bearing is fixed to the rotor 122, and the outer ring of the bearing is fixed to the fixing element 121. As a result, the fixing element 121 and the rotor 122 could rotate relative to each other through the bearing. The bearing could reduce the rotational resistance. As a result, when the wire W1 pulls the rotor 122 to rotate, almost or all of the self-weight of the wire guiding element 131 is reflected to (or transmitted to) the wire W1 (if the resistance is greater, the torque generated by the self-weight will be reduced).
As illustrated in FIGS. 2D and 3, the wire guiding device 130 includes the aforementioned wire guiding element 131 and at least one roller 132. The wire guiding element 131 includes a sleeve portion 1311 and a base 1312. The sleeve portion 1311 is connected to the base 1312. In an embodiment, the sleeve portion 1311 and the base 1312 are integrally formed. The aforementioned through hole 131a is formed in the sleeve portion 1311. The plurality of rollers 132 are rotatably connected to the base 1312, which could reduce the frictional resistance of the wire W1 passing between the two rollers 132. In the present embodiment, each roller 132 includes a connection shaft 1321 and a wheel 1322, wherein the connection shaft 1321 could be fixed to the base 1312, and the wheel 1322 is pivotally connected to the connection shaft 1321.
The method in which the wire tension control mechanism 100 of the disclosed embodiment provides the wire W1 with the resistance through its self-weight belongs to the “passive swing type”. The following describes a tension control method according to another embodiment of the present disclosure.
Passive Damping Swing Type—Using Driving Module (Magnetic Damping Module) Referring to FIGS. 5A to 6, FIG. 5A illustrates a schematic diagram of a wire tension control mechanism 200 according to another embodiment of the present disclosure, FIG. 5B illustrates a schematic diagram of a side view of the wire tension control mechanism 200 in FIG. 5A, FIG. 5C illustrates a schematic diagram of a cross-sectional view of the wire tension control mechanism 200 along a direction 5C-5C′, and FIG. 6 illustrates a schematic diagram of an exploded view of the wire tension control mechanism 200 in FIG. 5A.
The wire tension control mechanism 100 of the aforementioned winding system 1 could be replaced by the wire tension control mechanism 200. The wire tension control mechanism 200 includes the features (for example, material, structure and/or connection relationship) the same as or similar to that as the aforementioned wire tension control mechanism 100, one of the differences is that a connecting device 220 of the wire tension control mechanism 200 is different from the connecting device 120.
As illustrated in FIGS. 5C to 6, the wire tension control mechanism 200 includes the wire feeding device 110, a connecting device 220 and the wire guiding device 130. The connecting device 220 includes a fixing element 221, a rotor 222, a first bearing 123, a second bearing 124 and a driving module 225. The fixing element 221 is connected to the wire feeding device 110. The rotor 222 is movably disposed relative to the fixing element 221. The wire guiding device 130 is connected to the rotor 222. The driving module 225 is connected to the rotor 222 and rotates with the rotor 222. As a result, the wire guiding device 130 and the wire feeding device 110 could move relatively (for example, swing). When the wire W1 pulls the wire feeding device 110 (for example, during the winding operation), the wire W1 also pulls the wire guiding device 130. The driving module 225 could provide the wire guiding device 130 (or the wire W1) with a reverse torque according to a rotation amount of the rotor 222. This reverse torque acts as the resistance to the wire W1, and keeps the tension of the wire W1 at the stable tension value TC1 (the stable tension value TC1 is illustrated in FIG. 4). The aforementioned reverse torque could prevent the wire guiding device 130 from rotating too large or too fast. For example, the aforementioned reverse torque could prevent the pulling angle of the wire W1 from rotating too large or prevent the pulling velocity of the wire W1 from rotating too fast.
The greater the rotation amount of the rotor 222 is, the greater the reverse torque provided by the driving module 225 is. When the wire guiding element 131 rotates relative to the vertical orientation, the tension of the wire W1 becomes tight or loose. When the angle between the wire guiding element 131 and the vertical orientation is larger, it means that the tension of the wire W1 becomes tighter or looser. When the rotation amount of the rotor 222 is greater, the rotation amount of the driving module 225 is also greater, the reverse torque provided is greater, and the tension correction effect on the wire W1 is greater, so that the tension of the wire W1 could be maintained at the stable tension value TC1 (the stable tension value TC1 is illustrated in FIG. 4).
As illustrated in FIGS. 5C to 6, the fixing element 221 includes a body 2211 and a cover 2212. The body 2211 and the aforementioned fixing element 121 include the same or similar structures, and it will not be repeated here. The cover 2212 is connected to the body 2211. The cover 2212 and the body 2211 are, for example, an integrally formed structure. The cover 2212 may cover a portion of the driving module 225.
As illustrated in FIGS. 5C and 6, the rotor 222 includes a first connection portion 1221, a second connection portion 1222 and a flange 2223, wherein the first connection portion 1221 and the second connection portion 1222 are respectively disposed on two opposite surfaces of the flange 2223, and the flange 2223 protrudes relative to the peripheral surface of the first connection portion 1221 and the peripheral surface of the second connection portion 1222. The flange 2223 could define the assembly position of the first bearing 123 and the second bearing 124. For example, due to the stop of the flange 2223, the positions of the first bearing 123 and the second bearing 124 along the z axis could be determined. In the present embodiment, the flange 2223 is, for example, a gear. The flange 2223 is engaged with the driving module 225 and could drive the driving module 225 to rotate.
As illustrated in FIGS. 5C to 6, the driver module 22 5 includes a driver 2251 and a gear 2252. In the present embodiment, the driving module 225 is, for example, a magnetic damping module, and the driver 2251 is, for example, a magnetic damper. The magnet in the driver 2251 is, for example, a permanent magnet. The gear 2252 is connected to the driver 2251 to drive a rotating shaft 2251c of the driver 2251 to rotate. The driver 2251 could generate the aforementioned reverse torque according to the rotation of the rotating shaft 2251c. The greater the rotation amount of the rotating shaft 2251c is, the greater the reverse torque generated by the driver 2251 is.
As mentioned above, the wire tension control mechanism 200 in the embodiment of the present disclosure providing the resistance to the wire guiding device 130 (or wire W1) through the driving module 225 belongs to the “passive damping swing type”. The following describes a tension control method according to another embodiment of the present disclosure.
Passive Damping Swing Type—Using Elastic Element (Elastic Piece) Referring to FIGS. 7 to 8, FIG. 7 illustrates a schematic diagram of a wire tension control mechanism 300 according to another embodiment of the present disclosure, and FIG. 8 illustrates a schematic diagram of an exploded view of the wire tension control mechanism 300 in FIG. 7.
The wire tension control mechanism 100 of the aforementioned winding system 1 could be replaced by the wire tension control mechanism 300. The wire tension control mechanism 300 includes the features (for example, material, structure and/or connection relationship) the same as or similar to that as the aforementioned wire tension control mechanism 100, one of the differences is that a connecting device 320 of the wire tension control mechanism 300 is different from the connecting device 120.
As illustrated in FIGS. 7 to 8, the wire tension control mechanism 300 includes the wire feeding device 110, the connecting device 320 and the wire guiding device 130. The connecting device 320 includes the fixing element 121, the rotor 122, the first bearing 123, the second bearing 124 and an elastic element 325. The fixing element 121 is connected to the wire feeding device 110. The rotor 122 is movably disposed relative to the fixing element 121. The wire guiding device 130 is connected to the rotor 122. The elastic element 325 connects the fixing element 121 with the rotor 122. As a result, the wire guiding device 130 and the wire feeding device 110 could move relatively (for example, swing). When the wire W1 pulls the wire feeding device 110 (for example, during the winding operation), the wire W1 also pulls the wire guiding device 130, and the wire guiding device 130 drives the rotor 122 to rotate, so that the elastic element 325 is deformed to provide the wire guiding device 130 (or the wire W1) with an elastic restoring force. This elastic restoring force acts as the resistance to the wire W1, and keeps the tension of the wire W1 at the stable tension value TC1 (the stable tension value TC1 is illustrated in FIG. 4). The aforementioned elastic restoring force could prevent the wire guiding device 130 from rotating too large or too fast. For example, the aforementioned elastic restoring force could prevent the pulling angle of the wire W1 from rotating too large or prevent the pulling velocity of the wire W1 from rotating too fast.
As illustrated in FIG. 8, the elastic element 325 is, for example, the elastic piece (for example, spring, spring plate, etc.). The elastic element 325 includes a first end 3251, a second end 3252 and an elastic portion 3253. The elastic portion 3253 connects the first end 3251 with the second end 3252. The first end 3251 is fixed to the rotor 122. For example, the first end 3251 is fixed to a protruding portion 1223P of the flange 1223 of the rotor 122. The first end 3251 and the protruding portion 1223P are fixed by, for example, screwing, snapping, welding or other combination techniques. The second end 3252 is fixed to the fixing element 121. The fixing structure and the method of the second end 3252 and the fixing element 121 are the same as or similar to that of the first end 3251 and the rotor 122, and it will not be repeated here.
In addition, when the wire guiding device 130 is in the vertical orientation (for example, its wire guiding element 131 is in the vertical orientation, such as parallel to the Z axis in FIG. 1B), the elastic element 325 is in a free state. When the rotor 122 rotates, the elastic element 325 deforms to provide the elastic restoring force. When the rotation amount of the rotor 122 is greater, the deformation amount of the elastic element 325 is greater, and the 20) elastic restoring force provided is also greater. Furthermore, when the angle of the wire guiding element 131 relative to the vertical orientation is larger, it means that the tension of the wire W1 becomes tighter or looser, the deformation amount of the elastic element 325 is also larger, the elastic restoring force provided is larger, and the tension correction effect on the wire W1 is greater, so that the tension of the wire W1 could be maintained at the stable tension value TC1 (the stable tension value TC1 is illustrated in FIG. 4).
As mentioned above, the wire tension control mechanism 300 in the embodiment of the present disclosure providing the resistance to the wire guiding device 130 (or the wire W1) through the elastic element 325 belongs to the “passive damping swing type”. The following describes a tension control method according to another embodiment of the present disclosure.
Passive Damping Swing Type—Using Elastic Element (Springs) Referring to FIG. 9, FIG. 9 illustrates a schematic diagram of an exploded view of a wire tension control mechanism 400 according to another embodiment of the present disclosure.
The wire tension control mechanism 100 of the aforementioned winding system 1 could be replaced by the wire tension control mechanism 400. The wire tension control mechanism 400 includes the features (for example, material, structure and/or connection relationship) the same as or similar to that as the aforementioned wire tension control mechanism 300, one of the differences is that a connecting device 420 of the wire tension control mechanism 400 is different from the connecting device 320.
As illustrated in FIG. 9, the wire tension control mechanism 400 includes the wire feeding device 110, the connecting device 420 and the wire guiding device 130. The connecting device 420 includes the fixing element 121, the rotor 122, the first bearing 123, the second bearing 124 and an elastic element 425. The connecting device 420 of the wire tension control mechanism 400 includes the features similar to or the same as that of the aforementioned connecting device 320, one of the differences is that the elastic element 425 of the connecting device 420 is a spring, for example, a tension spring or a compression spring. The connection relationship among the elastic element 425, the fixing element 121 and the rotor 122 is similar to or the same as that among the elastic element 325, the fixing element 121 and the rotor 122, and it will not be repeated here.
The method in which the wire tension control mechanism 400 in the disclosed embodiment providing the resistance to the wire guiding device 130 (or the wire W1) through the elastic element 425 also belongs to the “passive damping swing type”. The following describes a tension control method according to another embodiment of the present disclosure.
Active Electronically Controlled Swing Type—Using Driving Module (Motor Module) Referring to FIGS. 10A to 11, FIG. 10A illustrates a schematic diagram of a wire tension control mechanism 500 according to another embodiment of the present disclosure, FIG. 10B illustrates a schematic diagram of the wire tension control mechanism 500 in FIG. 10A along a direction 10B-10B′, and FIG. 11 illustrates a schematic diagram of a cross-sectional view of the wire tension control mechanism 500 in FIG. 10A.
The wire tension control mechanism 100 of the aforementioned winding system 1 could be replaced by the wire tension control mechanism 500. The wire tension control mechanism 500 includes the features (for example, material, structure and/or connection relationship) the same as or similar to that as the aforementioned wire tension control mechanism 200, one of the differences is that a connecting device 520 of the wire tension control mechanism 500 is different from the connecting device 220.
As illustrated in FIGS. 10A, 10B and 11, the wire tension control mechanism 500 includes the wire feeding device 110, the connecting device 520 and the wire guiding device 130. The connecting device 520 includes the fixing element 221, the rotor 222, the first bearing 123, the second bearing 124, a driving module 525 and a controller 526. The fixing element 221 is connected to the wire feeding device 110. The rotor 222 is movably disposed relative to the fixing element 221. The wire guiding device 130 is connected to the rotor 222. The driving module 525 is connected to the rotor 222 and rotates with the rotor 222. As a result, the wire guiding device 130 and the wire feeding device 110 could move relatively (for example, swing). When the wire W1 pulls the wire feeding device 110 (for example, during the winding operation), the wire W1 also pulls the wire guiding device 130, and the wire guiding device 130 drives the rotor 222 to rotate. The driving module 525 could provide a reverse torque to the wire guiding device 130 (or the wire W1) according to the rotation amount of the rotor 222. The reverse torque acts as the resistance to the wire W1, so that the tension of the wire W1 is maintained at the stable tension value TC1 (the stable tension value TC1 is illustrated in FIG. 4). The aforementioned reverse torque could prevent the wire guiding device 130 from rotating too large or too fast. For example, the aforementioned reverse torque could prevent the pulling angle of the wire W1 from rotating too large or prevent the pulling velocity of the wire W1 from rotating too fast.
In the present embodiment, the controller 526 is a sub-component of the connecting device 520. However, in another embodiment, the controller 526 and the connecting device 520 may be components in the same level.
As illustrated in FIGS. 10A, 10B and 11, the driving module 525 includes a driver 5251 and a gear 2252. In the present embodiment, the driving module 525 is, for example, a motor module, and its driver 5251 is, for example, a motor. The gear 2252 is connected to the driver 5251 to drive a rotating shaft 5251c of the driver 5251 to rotate. The controller 526 is electrically connected to the driver 5251, and could sense a torque applying to the rotating shaft 5251c of the driver 5251, and controls the reverse torque applied by the driver 5251 on the rotor 222 according to the torque applying to the driver 5251, so that the tension of the wire W1 is maintained at the stable tension value TC1. The greater the torque applying to the driving module 525 is, the greater the reverse torque provided by the driving module 525 is. In addition, in the present embodiment, the stable tension value TC1 could be set by the controller 526.
As mentioned above, the wire tension control mechanism 500 in the embodiment of the present disclosure providing the resistance to the wire guiding device 130 (or the wire W1) through the driving module 525 belongs to the “active electronically controlled swing type”. The following describes a tension control method according to another embodiment of the present disclosure.
Active Electronically Controlled Swing Type—Using Driving Module and Strain Gauge Referring to FIGS. 12A and 12B, FIG. 12A illustrates a schematic diagram of a wire tension control mechanism 600 according to another embodiment of the present disclosure, and FIG. 12B illustrates a schematic diagram of an exploded view of the wire tension control mechanism 600 in FIG. 12A.
The wire tension control mechanism 100 of the aforementioned winding system 1 could be replaced by the wire tension control mechanism 600. The wire tension control mechanism 600 includes the features (for example, material, structure and/or connection relationship) the same as or similar to that as the aforementioned wire tension control mechanism 200, one of the differences is that the wire tension control mechanism 600 includes further includes a strain gauge 640.
As illustrated in FIGS. 12A and 12B, the wire tension control mechanism 600 includes the wire feeding device 110, a connecting device 620, a wire guiding device 130 and the strain gauge 640. In the present embodiment, the strain gauge 640 and the connecting device 620 belong to the components in the same level. In another embodiment, the strain gauge 640 may be a sub-element of connecting device 620. In addition, the strain gauge 640 could be disposed on any roller of the guide device 130, as long as it could be pressed by the wire W1 and sense the tension change of the wire W1. In an embodiment, as illustrated in FIG. 12A, the strain gauge 640 may be disposed in a middle one of three rollers 132. As a result, a difference between the measured tension value of the strain gauge 640 and the actual tension value of the wire W1 is smaller or minimal, but it is not limited to this disclosure. The tension of the wire W1 will be applied to the strain gauge 640 on the roller 132, and it causes the strain gauge to deform. The deformation of the strain gauge causes an impedance change, and the voltage or current signal generated by the impedance change could be transmitted to the driving module 625 and/or the controller 526.
As illustrated in FIGS. 12A and 12B, the connecting device 620 includes the fixing element 221, the rotor 222, the first bearing 123, the second bearing 124, the driving module 625 and the controller 526. The fixing element 221 is connected to the wire feeding device 110. The rotor 222 is movably disposed relative to the fixing element 221. The wire guiding device 130 is connected to the rotor 222. The driving module 625 is connected to the rotor 222 and rotates with the rotor 222. As a result, the wire guiding device 130 and the wire feeding device 110 could move relatively (for example, swing). When the wire W1 pulls the wire feeding device 110 (for example, during the winding operation), the wire W1 also pulls the wire guiding device 130. The driving module 625 could provide the wire guiding device 130 (or the wire W1) with the reverse torque according to the rotation amount of the rotor 222. This reverse torque acts as the resistance to the wire W1, so that the tension of the wire W1 is maintained at the stable tension value TC1 (the stable tension value TC1 is illustrated in FIG. 4). The aforementioned reverse torque could prevent the wire guiding device 130 from rotating too large or too fast. For example, the aforementioned reverse torque could prevent the pulling angle of the wire W1 from rotating too large or prevent the pulling velocity of the wire W1 from rotating too fast.
As illustrated in FIGS. 12A and 12B, the strain gauge 640 is disposed on one of the rollers 132 for sensing the tension of the wire W1 pressing against it. In an embodiment, as long as the wire W1 could press against the strain gauge 640, the embodiment of the present disclosure does not limit the arrangement position of the strain gauge 640. In addition, the driving module 625 includes a driver 6251 and the gear 2252. The gear 2252 is connected to the driver 6251 to drive the rotating shaft 6251c of the driver 6251 to rotate. In the present embodiment, the magnet (not illustrated) in the driver 6251 is, for example, an electromagnet, which could change the magnetic field according to the received current. Furthermore, the controller 526 could receive the signal from the strain gauge 640 to obtain a measured tension value Td of the wire W1, and then send the control signal S1 according to the measured tension value Td to control a control current for the magnet in the driver 6251. The greater the difference between the measured tension value Td and a preset tension value is, the greater the control current applied to the magnet in the driver 6251 is, and it could maintain the tension of the wire W1 at the stable tension value TC1.
In the present embodiment, the controller 526 is a sub-component of the connecting device 620. However, in another embodiment, the controller 526 and the connecting device 620 may be components in the same level.
As mentioned above, the wire tension control mechanism 600 in the embodiment of the present disclosure controlling the reverse torque, applied by the driving module 625, to the rotor 222 based on the tension of the wire W1 belongs to the “active electronically controlled swing type”. The following describes a tension control method according to another embodiment of the present disclosure.
Active Electronically Controlled Swing Type—Using Driving Module and Strain Gauge Referring to FIGS. 13A and 13B, FIG. 13A illustrates a schematic diagram of a wire tension control mechanism 700 according to another embodiment of the present disclosure, and FIG. 13B illustrates a schematic diagram of an exploded view of the wire tension control mechanism 700 in FIG. 13A.
The wire tension control mechanism 100 of the aforementioned winding system 1 could be replaced by the wire tension control mechanism 700. The wire tension control mechanism 700 includes the features (for example, material, structure and/or connection relationship) the same as or similar to that as the aforementioned wire tension control mechanism 600, one of the differences is that a connecting device 720 of the wire tension control mechanism 700 is different from the connecting device 620.
As illustrated in FIGS. 13A and 13B, the wire tension control mechanism 700 includes the wire feeding device 110, the connecting device 720, the wire guiding device 130 and the strain gauge 640. In the present embodiment, the strain gauge 640 and the connecting device 720 belong to the components in the same level. In another embodiment, the strain gauge 640 may be a sub-element of connecting device 720.
As illustrated in FIGS. 13A and 13B, the wire tension control mechanism 700 includes the wire feeding device 110, the connecting device 720 and the wire guiding device 130. The connecting device 720 includes the fixing element 221, the rotor 222, the first bearing 123, the second bearing 124, the driving module 525 and the controller 526. The connecting device 720 includes the fixing element 221, the rotor 222, the first bearing 123, the second bearing 124, the driving module 525 and the controller 526. The fixing element 221 is connected to the wire feeding device 110. The rotor 222 is movably disposed relative to the fixing element 221. The wire guiding device 130 is connected to the rotor 222. The driving module 525 is connected to the rotor 222 and rotates with the rotor 222. As a result, the wire guiding device 130 and the wire feeding device 110 could move relatively (for example, swing). When the wire W1 pulls the wire feeding device 110 (for example, during the winding operation), the wire W1 also pulls the wire guiding device 130, and the wire guiding device 130 drives the rotor 222 to rotate. The driving module 525 could provide the wire guiding device 130 (or the wire W1) with the reverse torque according to the rotation amount of the rotor 222. This reverse torque acts as the resistance to the wire W1, so that the tension of the wire W1 is maintained at the stable tension value TC1 (the stable tension value TC1 is illustrated in FIG. 4). The aforementioned reverse torque could prevent the wire guiding device 130 from rotating too large or too fast. For example, the aforementioned reverse torque could prevent the pulling angle of the wire W1 from rotating too large or prevent the pulling velocity of the wire W1 from rotating too fast.
In the present embodiment, the controller 526 is a sub-component of the connecting device 720. However, in another embodiment, the controller 526 and the connecting device 720 may be components in the same level.
As illustrated in FIGS. 13A and 13B, the driving module 525 includes a driver 5251 and a gear 2252. The gear 2252 is connected to the driver 5251 to drive a rotating shaft 5251c of the driver 5251 to rotate. In the present embodiment, the controller 526 could receive the signal from the strain gauge 640 to obtain the measured tension value Td of the wire W1, and then send the control signal S1 according to the measured tension value Td to control the reverse torque, applied by the driver 5251, to the rotor 222. When the difference between the measured tension value Td and the preset tension value is greater, the reverse torque applying to the rotor 222 is greater, wherein the reverse torque is applied by the driver 5251 which is controlled by the controller 526. As a result, the tension of the wire W1 is maintained at the stable tension value TC1.
As mentioned above, the wire tension control mechanism 700 in the embodiment of the present disclosure controlling the reverse torque, applied by the driving module 525, to the rotor 222 based on the tension of the wire W1 belongs to the “active electronically controlled swing type”.
In summary, the embodiments of the present disclosure propose the wire tension control mechanism, the winding system using the same, and the wire tension control method. The wire tension control mechanism could make the wire substantially maintain the stable tension value by using the passive (damping) swing type or the active electronically controlled swing type. Whether it is the passive swing type or the active electronically controlled swing type, the wire tension control mechanism could automatically or adaptively adjust the tension value of the wire to keep the wire at the stable tension value.
It will be apparent to those skilled in the art that various modifications and variations could be made to the disclosed embodiments. It is intended that the specification and examples be considered as exemplars only, with a true scope of the disclosure being indicated by the following claims and their equivalents.
