Adjustable Torque Winder for Film Remnants
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Solution Overview
Problem
Existing winders for packaging machines experience undefined slippage during winding of waste strips and residual film lattices, leading to inefficiencies and the need for disposal of winding bodies with the waste, due to varying torque requirements and material properties.
Innovation Solution
A winder with an adjustable torque threshold system using coupling elements and permanent magnets, allowing independent slippage of winding rollers and enabling precise adjustment of torque to match material properties, while using a common drive and minimizing wear and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a common drive is used for multiple winding rollers, then device complexity is reduced, but undefined slippage occurs during winding due to varying torque requirements
Solution Approach 1:
The patent applies the dynamics principle by making the coupling elements adjustable rather than fixed. The coupling elements can be adjusted axially along the winding mandrel to change the magnetic coupling strength, allowing the system to adapt dynamically to different winding conditions and material properties. This resolves the contradiction by enabling a single drive to reliably control multiple rollers with different torque requirements through dynamic adjustment of coupling strength.
Solution Approach 2:
The patent changes the parameter of coupling strength by adjusting the axial position of permanent magnets on the coupling elements. By varying the distance between magnetic couplings, the torque transmission characteristics are modified. This allows the same drive system to accommodate different torque requirements of various winding rollers, maintaining reliability while keeping device complexity low.
2Ease of manufacture
If fixed torque coupling is used between winding mandrel and rollers, then manufacturing precision is simplified, but slippage cannot be adjusted to match different material properties
Solution Approach 1:
The coupling elements are designed with adjustable axial positions, transforming a static coupling system into a dynamic one. This allows the torque threshold for slippage to be adjusted according to different material properties being wound, such as film remnants or waste strips with varying tensile strengths. The adjustment mechanism maintains manufacturing simplicity while dramatically improving adaptability.
Solution Approach 2:
The coupling system is segmented into multiple independent coupling elements, each with its own adjustable permanent magnets. This segmentation allows individual adjustment of each roller's torque coupling without affecting others, enabling precise matching to different material properties while keeping the overall system manufacturable through modular design.
3Device complexity
If winding rollers are constrained to rotate at the same speed, then device complexity is reduced, but process reliability decreases when waste strips wind up differently
Solution Approach 1:
The coupling elements act as intermediaries between the common drive and the winding rollers. They transmit torque while allowing independent rotation of each roller through controlled slippage. The magnetic coupling serves as a mediator that enables both synchronized operation when needed and independent operation when material properties require different winding speeds, maintaining reliability without complex synchronization mechanisms.
4Productivity
If high winding force is applied to all rollers, then productivity is improved, but wear increases and energy consumption rises
Solution Approach 1:
The patent enables parameter changes in the torque coupling strength for each roller independently. This allows the system to apply high winding force (torque) only when and where needed, rather than continuously to all rollers. By adjusting the magnetic coupling distance, the torque threshold can be optimized for each specific winding condition, improving productivity while reducing unnecessary energy consumption and wear.
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
The system ensures reliable winding by allowing slippage above a set torque limit, preventing further winding when necessary, and allowing for different winding roller speeds, improving process reliability and ease of film residue removal.
Implementation Method 1
The adjustment device has at least two interacting permanent magnets. Such a magnetic coupling also works wear-free when the drive is in continuous operation.
Implementation Method 2
EP 1 655 258 A2 discloses a friction element for transmitting a specific torque to a winding core for winding up strip-shaped materials such as adhesive tape.
Data Source
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AI summary
The invention relates to a rewinder (22, 35) for rewinding film remnants (23) for packaging machines (1). The rewinder (22, 35) comprises a drive (24), a winding mandrel (29), and at least two winding rollers (25a, 25b). The invention is characterized by an adjusting device (50) for setting a torque threshold above which slippage occurs between the individual winding rollers (25a, 25b) and the winding mandrel (29) and/or between the individual winding rollers (25a, 25b).