Automatic Core Feeding for Winding Shafts
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Solution Overview
Problem
Current methods for loading cores onto slitting and winding machines are inefficient and labor-intensive, especially when dealing with a large number of winding rolls, and are not economically viable for narrow cutting widths, as they require manual handling and specialized tools for precise positioning.
Innovation Solution
A method for automatically loading and positioning winding cores onto winding shafts using a conveyor belt system and modified push-off shields with tongs and a pneumatic cylinder, allowing for precise positioning and efficient handling of multiple cores without the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual handling and specialized tools are used for loading cores, then positioning precision can be achieved, but labor intensity and time consumption increase significantly
Solution Approach 1:
The system uses automatic detection and positioning mechanisms that enable the core loading process to self-regulate without manual intervention. The detection device automatically identifies core positions and the control system coordinates the transfer mechanism to position cores accurately on winding shafts, achieving both precision and efficiency simultaneously
Solution Approach 2:
Manual mechanical handling is replaced by an automated control system that integrates detection devices, control units, and transfer mechanisms. This substitution eliminates labor-intensive operations while maintaining positioning accuracy through coordinated mechanical and electronic control
2Manufacturing precision
If specialized core boxes are used for each cutting width, then positioning accuracy is ensured, but device complexity and cost increase
Solution Approach 1:
The detection and positioning system is designed to be universal, accommodating different core sizes and cutting widths through programmable control. The control unit stores multiple positioning parameters and automatically selects the appropriate settings based on the required cutting width, eliminating the need for multiple specialized core boxes
Solution Approach 2:
The system transitions from static, fixed-purpose core boxes to a dynamic, adaptable positioning system. The control unit can dynamically adjust positioning parameters and the transfer mechanism can accommodate varying core dimensions, providing flexibility for different cutting widths without requiring physical reconfiguration
3Ease of operation
If push-off shields are used to move winding rolls, then handling capability improves, but positioning precision of new cores deteriorates
Solution Approach 1:
The system separates the functions of moving winding rolls and positioning new cores into distinct operational phases. The push-off shield handles the ejection of finished rolls, while the detection device and control system independently manage the positioning of new cores, preventing interference between these two functions
Solution Approach 2:
The detection device acts as an intermediary between the push-off shield operation and the core positioning process. It detects the position of newly loaded cores and provides feedback to the control system, ensuring accurate positioning regardless of the push-off shield's mechanical actions
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
Enables fully automatic and precise positioning of winding cores on winding shafts, significantly reducing time and effort while maintaining high accuracy, even with varying core lengths and tolerances, and is adaptable for different cutting widths.
Implementation Method 1
A conveyor belt, which is equipped with webs fastened transversely to its direction of belt travel, successively picks up winding cores from the magazine and brings them into a coaxial position with the respective winding shaft
Implementation Method 2
A sliding device, such as a pneumatic cylinder or an electrically operated linear drive, now pushes the winding sleeve onto the winding shaft and immediately withdraws again
Implementation Method 3
The fork moves over the winding shaft and reaches a position in which it acts against an end face of the winding sleeve, which is located directly above the winding shaft, so that the winding sleeve can be displaced over the winding shaft
Implementation Method 4
The tongs are fastened to the deportation plate and can also be set against the winding shaft and can be set so far against the winding shaft that the grippers of the tongs can grasp the winding sleeve, hold it and move it over the winding shaft
Data Source
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AI summary
The invention relates to a method for automatically loading cores onto a winding shaft (5) on roll slitting and winding machines, wherein, in one embodiment, in a first step at least two empty winding cores (2, 7, 13) are pushed onto a free end (6) of a winding shaft (5) so that the winding cores (2, 7, 13) are in contact with each other; in a second step the last wound core (2, 7, 13) is moved along the winding shaft (5) by means of a fork (14) of a freely programmable ejector plate (10) which can be freely positioned along the winding shaft (5) until the last wound core (2, 7, 13) has reached a predetermined position; in a third step the penultimate wound core (2, 7, 13) is grasped by means of a gripper (12) which can be freely positioned along the winding shaft (5) and moved along the winding shaft (5) untilthat in a fourth step the fork piece (14) can be inserted into the gap (15) created by the pliers (12), so that the penultimate winding sleeve (2, 7, 13) can be positioned along the winding shaft (5) by means of the fork piece (14).