Wire tensioner with program controlled bidirectional pulley wheel
First Claim
Patent Images
1. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
- a frame;
means mounted on the frame for receiving the wire from a wire supply;
a pulley wheel that engages the wire and accepts the wire from the means for receiving; and
a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece, the wire between the pulley wheel and the workpiece accordingly having a lower tension than the wire between the pulley wheel and the workpiece would otherwise have, and a second direction such that wire is drawn back from the workpiece, the wire between the pulley wheel and the workpiece accordingly having a higher tension than the wire between the pulley wheel and the workpiece would otherwise have, the drive unit receiving and being responsive to drive signals that control torques applied by the drive unit.
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Accused Products
Abstract
A wire tensioner maintains wire in a winding machine at a substantially constant tension during the process of winding coils for electrical components such as armatures. The tensioner has a pulley wheel that is driven by a bidirectional drive unit. During operation, the pulley wheel either feeds wire toward a workpiece or draws wire back, depending on the nature of the tension correction required.
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Citations
55 Claims
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1. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; and a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece, the wire between the pulley wheel and the workpiece accordingly having a lower tension than the wire between the pulley wheel and the workpiece would otherwise have, and a second direction such that wire is drawn back from the workpiece, the wire between the pulley wheel and the workpiece accordingly having a higher tension than the wire between the pulley wheel and the workpiece would otherwise have, the drive unit receiving and being responsive to drive signals that control torques applied by the drive unit. - View Dependent Claims (2, 3, 4, 5, 6, 7, 11, 12)
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8. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; and a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals that control torques applied by the drive unit, wherein the means for receiving comprises a dancer arm assembly for pretensioning the wire. - View Dependent Claims (9, 10)
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13. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; and a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals that control torques applied by the drive unit, the wire tensioner further comprising a tension sensor mounted on the frame and in contact with the wire for measuring the tension of the wire and for providing corresponding tension feedback signals, the drive unit further comprising a resolver for supplying position signals. - View Dependent Claims (14, 15, 16, 17, 18)
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19. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece, wire between the pulley wheel and the workpiece accordingly having a lower tension than the wire between the pulley wheel and the workpiece would otherwise have, and a second direction such that wire is drawn back from the workpiece, the wire between the pulley wheel and the workpiece accordingly having a higher tension than the wire between the pulley wheel and the workpiece would otherwise have, the drive unit receiving and being responsive to drive signals provided by a main controller that control torques applied by the drive unit; and a tension sensor mounted on the frame and in contact with the wire for measuring the tension of the wire and for providing corresponding tension feedback signals to the main controller. - View Dependent Claims (20, 21, 22)
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23. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals provided by a main controller that control torques applied by the drive unit; and a tension sensor mounted on the frame and in contact with the wire for measuring the tension of the wire between the pulley wheel and the workpiece and for providing corresponding tension feedback signals to the main controller, wherein the means for receiving comprises a dancer arm assembly for pretensioning the wire. - View Dependent Claims (24, 25, 26, 27, 28)
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29. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals provided by a main controller that control torques applied by the drive unit; and a tension sensor mounted on the frame and in contact with the wire for measuring the tension of the wire and for providing corresponding tension feedback signals to the main controller, wherein the dancer arm assembly comprises; a dancer arm pivotably attached to the frame; a dancer arm pulley attached to the dancer arm for engaging the wire; and a spring attached between the frame and the dancer arm for biasing the dancer arm such that the dancer arm pulley pretensions the wire. - View Dependent Claims (30, 31)
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32. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals provided by a main controller that control torques applied by the drive unit; and a tension sensor mounted on the frame and in contact with the wire for measuring the tension of the wire and for providing corresponding tension feedback signals to the main controller, wherein the drive unit is connected to the pulley wheel by a shaft that is rotatably mounted on bearings that are supported within the frame. - View Dependent Claims (33, 34)
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35. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals provided by a main controller that control torques applied by the drive unit; and a tension sensor mounted on the frame and in contact with the wire for measuring the tension of the wire and for providing corresponding tension feedback signals to the main controller, wherein the drive unit is a brushless motor. - View Dependent Claims (36, 37)
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38. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals provided by a main controller that control torques applied by the drive unit; and a tension sensor mounted on the frame and in contact with the wire for measuring the tension of the wire and for providing corresponding tension feedback signals to the main controller; and a support motor for rotating the workpiece in response to support motor control signals from the main controller, such that the motions of the drive unit, the flyer motor, and the support motor may be synchronized according to schedules provided by the main controller.
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39. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; and a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals provided by a main controller in accordance with speed schedules that control speeds at which the pulley wheel rotates. - View Dependent Claims (40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52)
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53. A wire tensioner for maintaining wire at a substantially constant tension in a machine that winds wire around a workpiece, comprising:
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a frame; means mounted on the frame for receiving the wire from a wire supply; a pulley wheel that engages the wire and accepts the wire from the means for receiving; a drive unit mounted on the frame and connected to the pulley wheel for rotating the pulley wheel in a first direction such that wire is fed toward the workpiece and a second direction such that wire is drawn back from the workpiece, the drive unit receiving and being responsive to drive signals provided by a main controller that control torques applied by the drive unit; and a tension sensor mounted on the frame and in contact with the wire for measuring the tension of the wire and for providing corresponding tension feedback signals to the main controller. - View Dependent Claims (54, 55)
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Specification