Adjustable Torque Core Drive for Secondary Flooring Installation
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Solution Overview
Problem
Existing systems for rolling and unrolling artificial turf and other secondary flooring surfaces are inadequate, as they often result in creasing, tearing, and directional issues due to limited speed control, and are not suitable for taller pile heights or wider rolls, requiring extensive storage space and labor for installation and removal.
Innovation Solution
A conversion system featuring a core driven by motors with adjustable torque and speed, supported by free-spinning and driven rollers, along with a transducer for position control, and an optional winch and cable system for efficient rolling and unrolling of secondary flooring surfaces, allowing for various types and sizes of flooring materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If existing installation systems are used to unroll artificial turf, then the system can accommodate short pile knitted nylon turf, but it cannot deploy taller pile heights or polyethylene fiber turf
Solution Approach 1:
The system employs variable speed control mechanisms that allow the roll to dynamically adjust its rotation speed based on the specific turf type and pile height being installed. This dynamic adjustment prevents excessive speed that could cause damage to taller pile heights or polyethylene fiber turf, while maintaining sufficient speed for efficient installation.
Solution Approach 2:
The invention changes key operational parameters including rotation speed, torque, and tension control to accommodate different turf types. By adjusting these parameters based on the specific turf characteristics (pile height, fiber material), the system can reliably install various turf types without causing damage.
2Area of stationary object
If conventional systems roll up artificial turf with the machine moving and turf stationary, then narrow sections can be handled, but wide rolls require lift trucks and extensive storage space
Solution Approach 1:
The system inverts the conventional approach by making the turf roll move with the machine while keeping the turf surface stationary relative to the installation area. This allows wide rolls to be handled without requiring lift trucks or extensive storage space, as the roll is actively transported and installed in a controlled manner.
Solution Approach 2:
The installation system is designed to handle rolls of various widths without requiring different equipment (such as lift trucks for wide rolls). The single system can accommodate both narrow and wide rolls, eliminating the need for multiple handling methods and reducing storage space requirements.
3Manufacturing precision
If existing systems operate at one fixed speed, then the system is simple, but the turf creases, tears, and distors due to directionality issues
Solution Approach 1:
The system incorporates feedback mechanisms that monitor the installation process in real-time and adjust the roll speed accordingly. This feedback control prevents creases, tears, and distortion by maintaining optimal speed and tension levels throughout the installation, ensuring high quality results.
Solution Approach 2:
Rather than operating at a fixed speed, the system dynamically adjusts its operation speed based on the specific installation conditions, turf type, and pile height. This dynamic speed control prevents directionality issues that cause creases and tears while maintaining operational efficiency.
Data Source
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AI summary
Systems and methods of rolling and unrolling secondary flooring surfaces, such as tall pile polyethylene turf, are provided. The system includes a drive system that allows for the conversion of a primary surface into a secondary flooring surface in a relatively short period of time. The drive system includes core adjustable speed drive units for controlling the speed and torque of the motors that drive the core, as well as roller adjustable speed drive units for controlling the speed of the front roller. The core adjustable speed drive units control the torque of the core motors during roll up and control the speed of the core motors during roll out.