Automatic Winding Facility for Strip Reels
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Solution Overview
Problem
Current spooling processes for flexible products like rubber strips require multiple handling steps and intermediate mandrels, leading to operator risks and product deterioration due to heavy wafer handling and the need for various bars and mandrels.
Innovation Solution
An automatic installation and method for spooling strips from a web that eliminates intermediate handling and mandrels by using a bar with rotating sections for simultaneous winding and unwinding, combined with an automatic gripping system for transferring full or empty bars between cutting modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling of wafers is used to transport between wide slitter and narrow slitter, then flexibility in operation is maintained, but operator safety risks increase and product deterioration occurs due to heavy weights (50-150 kg) handled every 3-5 minutes
Solution Approach 1:
The system uses automatic gripping devices to handle wafers autonomously without operator intervention. The gripping devices are integrated into the conveyor system, allowing the equipment to serve itself by automatically picking up, transporting, and placing wafers between processing stations, thereby eliminating manual handling of heavy objects
Solution Approach 2:
Manual mechanical handling is replaced with automated gripping mechanisms and conveyor systems. The gripping devices use controlled mechanical forces to securely hold and transport wafers, replacing the need for operators to manually lift and move heavy objects weighing 50-150 kg
2Productivity
If multiple intermediate mandrels and bars are used for transporting wafers, then the spooling process can be completed, but device complexity increases and time is lost in manipulating multiple bars and products
Solution Approach 1:
The system merges the functions of multiple intermediate mandrels and transport bars into a single integrated conveyor system. The conveyor continuously transports wafers from the wide slitter directly to the narrow slitter without requiring separate handling devices, thereby reducing the number of components needed
Solution Approach 2:
The conveyor system performs multiple functions: it transports wafers between cutting stations, supports the weight of heavy wafers (50-150 kg), and maintains proper positioning throughout the process. This single multi-functional device replaces what previously required multiple specialized bars and mandrels
3Reliability
If intermediate handling steps are included in the spooling process, then complete processing is achieved, but processing time increases and operator safety risks increase
Solution Approach 1:
The conveyor system enables continuous transport of wafers from the wide slitter through to the narrow slitter without interruption or intermediate handling steps. The automated gripping devices maintain constant contact with the wafers, ensuring continuous motion and eliminating pauses that would otherwise be required for manual transfer operations
Solution Approach 2:
The system autonomously manages the entire transport process without operator intervention. The gripping devices automatically adjust to handle different wafer weights (50-150 kg), and the conveyor system self-regulates to maintain proper speed and positioning, eliminating the need for operators to perform time-consuming manual handling tasks
Data Source
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AI summary
Automatic facility for transverse winding of strips from a coiled web (2), successively comprising: - a first module (3) for cutting the coiled web (2) into a plurality of strips (4); - a second module (5) for winding the strips (4) around the same bar (6) to form reels (7); - a third module (17) for cutting a strip (4) from a reel into a plurality of strips; - a fourth module (19) for transversely winding the strips around mandrels to form coils, the facility being characterised in that the bar (6) which receives the reels (7) comprises a shaft (9) around which a plurality of sections (10) spaced apart from each other are mounted, each section (10) being intended to receive a reel (7), the sections (10) being rotatable by the shaft (9) in the same direction so as to be able to simultaneously wind all of the strips (4) into reels (7), and mounted so as to be free to rotate in an opposite direction in order to be able to unwind the reels (7) one by one, and in that the facility (1) comprises an automatic gripping system (14) which is capable of gripping a bar (6) full of reels (7) from the second winding module (5) and capable of depositing a bar (6) full of reels (7) on a displaceable carriage (15) in front of the third module (17) for unwinding and cutting the strips (4) one by one from the reels (7) into a plurality of strips.