Added-Material Wire Winding Machine with Motorized Gripper Adjustment
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Solution Overview
Problem
Existing automatic winding machines for wire of added material face inefficiencies due to manual format changes, machine downtime, and complex mechanical adjustments, particularly in adapting the position of grippers for different reel sizes, leading to reduced operating efficiency and increased operator expertise requirements.
Innovation Solution
An automatic winding machine with distinct electric linear actuators connected to a central control unit, allowing for automatic, progressive, and continuous adjustment of gripper positions, reducing manual intervention and simplifying format changes by enabling precise adjustments of the insertion and cutting grippers relative to the winding body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustments are performed to change the format of flanged reels, then the machine can adapt to different reel sizes, but machine downtime increases and operating efficiency decreases
Solution Approach 1:
The patent applies dynamics by making the tools group movable and adjustable through motorized actuators rather than fixed mechanical components. The insertion gripper and cutting gripper can be automatically repositioned along the horizontal axis based on the diameter of the flanged reel, enabling quick adaptation without manual intervention and reducing machine downtime during format changes
Solution Approach 2:
The patent replaces manual mechanical adjustment operations with an automated control system. A control unit receives signals about the reel diameter and automatically actuates motors to adjust the position of the tools group, substituting human-operated mechanical adjustments with automated electromechanical control, thereby reducing operator dependency and minimizing downtime
2Adaptability or versatility
If complex mechanical adjustments are performed on flanges and mechanical stops, then the machine can be adapted to different formats, but the complexity of operations increases and operator expertise requirements increase
Solution Approach 1:
The system performs self-service by automatically adjusting its own configuration based on input parameters. The control unit calculates the required positions of the tools group and actuates the appropriate motors without requiring operator intervention, making the system self-configuring and eliminating the need for complex manual adjustments
Solution Approach 2:
The patent changes operational parameters through automated control rather than physical reconfiguration. By receiving the reel diameter as an input parameter and automatically adjusting the position of the tools group accordingly, the system uses parameter-driven control to simplify operations, replacing complex mechanical adjustments with simple digital parameter input
3Reliability
If multiple distinct machines are arranged in a line to perform specific functions, then each function can be performed with precision, but the overall device complexity increases
Solution Approach 1:
The patent merges multiple distinct machines into a single integrated winding machine. The unwinding unit, winding unit, and tools group with insertion and cutting grippers are combined into one machine structure, reducing the number of separate devices while maintaining all necessary functions through coordinated operation of integrated components
Solution Approach 2:
The integrated winding machine performs multiple functions within a single device. The tools group with its insertion gripper and cutting gripper can handle various operations including wire insertion, winding control, and cutting, adapting to different reel sizes and formats, thereby replacing multiple specialized machines with one multi-functional device
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
Enhances operating efficiency by minimizing manual adjustments, reducing machine downtime, and simplifying format changes, resulting in improved productivity and reduced complexity in handling different reel sizes.
Implementation Method 1
each comprises at least one electric linear actuator electrically connected to a central processing and control unit which manages its actuation
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
An automatic winding machine (1) of wire of added material (F) comprising a support structure (2) which insists on a support surface (S), a loading station (3), contained in the support structure (2) and receiving flanged reels (R) one after the other coming from a loader arranged upstream of the automatic winding machine (1) and provided with a plurality of flanged reels (R), a tools group (4) fixed inside the support structure (2) and comprising a main gripping and translation gripper cooperating with first actuator means, which actuate it to at least pick up one by one the flanged reels (R) from the loading station (3) and apply them to a winding body (6) coupled to the support structure (2); the tools group (4) further includes an insertion gripper (7) cooperating with second actuation means (8) which actuate it in vertical (Y) and horizontal (X) directions and manipulating an initial end of the wire of added material (F) unwound from a skein and direct it towards the flanged reels (R) supported by the winding body (6) at which the wire of added material (F), due to the rotation of the body winding (6), is wound in a stratified manner about a central drum (T) of each of said flanged reels (R) forming a plurality of coils (B) of wire of added material (F); a cutting gripper (9) arranged downstream said insertion gripper (7), which obtains a final end of the wire of added material (F) of each of the coils (B) and cooperating with third actuation means (10), which actuate it in vertical (Y') and horizontal (X) directions. In detail, the second actuation means (8) and/or the third actuation means (10) are distinct from each other and each one includes an electric linear actuator (12, 13, 14) electrically connected to a central processing and control unit which manages its actuation so as to vary, by means of an automatic, progressive and continuous adjustment, the distance between the second actuation means (8), the third actuation means (10) and the winding body (6) when the format of the flanged reels (R) to be subjected to the winding of said wire of added material (F) varies.