My latest machine went into full production with a few minor glitches as expected but it has joined the team. I now have to start a duplicate that I hadn't planned so soon. Good thing, I guess. So, here are the first of many ideas for improvements I want to incorporate.
Problem: Feed three strands of .110" x .017" wire, 3 to 4 inches in 200-250 ms. This is now done with an air cylinder pushing one-way clutched rollers. It works ok but is persnickety getting the roller tension just right. It's a bitch to make the rollers and they wear out in six months and spoo is a factor in the clutches.
New idea: Imagine a DC gearmotor with a brake driving a pair of 3" dia. intermeshing gears. The gears have a grove cut deep in the faces. The gearmotor drives one gear and an air cylinder forces the gears together with variable force. The wire rides in the groove, pinched between the gears. I know this works. It's dirt proof and holds and pushes the wire well. The question is how to control the gearmotor. One idea is to put a 12 volt potential on the machine and the wire and insulate the adjustable wire stop. The gearmotor starts from a cam operated switch and stops when the wire hits the stop, using a relay. Another idea is to use a proxy on a chopper wheel and a counter that stops the gearmotor. I would greatly appreciate any other ideas! (See if you can guess which of the above is my idea.)