Border Winder Direct Drive for Compact High-Rigidity Torque Transmission
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Solution Overview
Problem
Conventional winders in metalworking have a large installation space due to complex drive trains, leading to torsional flexibility issues, control accuracy problems, high maintenance costs, and power losses, as well as a non-optimal interface between the winding mandrel and the electric drive.
Innovation Solution
A winder design featuring a direct drive system with a compact electric motor and a stator directly connected to the housing, eliminating the need for complex mechanical components like gears and clutches, and utilizing a torque motor for high torsional rigidity and efficient power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional drive train with gearbox and couplings is used, then the winder can transmit torque to the winding mandrel, but the footprint and installation space become large
Solution Approach 1:
The electric motor is integrated directly with the winding mandrel to form a unified direct drive system, eliminating the need for separate gearbox and coupling components. This merging of drive functions into a single compact unit reduces the overall footprint while maintaining full torque transmission capability.
Solution Approach 2:
The patent replaces the mechanical gearbox and coupling system with a direct electromagnetic drive system. The electric motor's rotor is directly coupled to the winding mandrel, substituting complex mechanical transmission components with a streamlined electromagnetic-mechanical integration that achieves the same torque transmission in a compact form.
2Power
If a complex drive train with multiple moving components is used, then torque can be transmitted to the winding mandrel, but reliability decreases due to more moving parts
Solution Approach 1:
The patent extracts and removes all unnecessary intermediate components (gearbox, couplings, driveshafts) from the torque transmission path. By eliminating these moving parts that are prone to failure, the system achieves higher reliability while the electric motor directly provides the required torque transmission to the winding mandrel.
Solution Approach 2:
The direct drive system replaces complex, maintenance-prone mechanical components with a simpler electric motor design that has fewer wearing parts. While electric motors require maintenance, the elimination of gearboxes and couplings removes multiple failure points, effectively reducing the number of 'short-living' components that need frequent replacement.
3Power
If conventional couplings and gearboxes are used, then torque transmission is achieved, but control accuracy decreases due to torsional compliance
Solution Approach 1:
The patent substitutes flexible mechanical couplings and gearboxes with a rigid direct-drive connection between the electric motor rotor and the winding mandrel. This eliminates torsional compliance and flexibility in the torque transmission path, ensuring that motor control commands are directly and accurately translated to mandrel rotation without phase lag or oscillation.
Solution Approach 2:
By merging the motor rotor and winding mandrel into a directly coupled system, the patent creates a unified mass moment of inertia that responds precisely to control signals. This integration eliminates the compliance issues inherent in separate drive components, achieving superior control accuracy for winding operations.
4Power
If a complex drive train with numerous components is used, then torque can be transmitted to the winding mandrel, but the interface between mandrel and drive is not optimal
Solution Approach 1:
The patent merges the drive system and winding mandrel into a single integrated unit where the motor rotor directly becomes part of the mandrel assembly. This eliminates complex mechanical interfaces between separate components, creating a simple, direct connection that optimizes power transmission while minimizing interface complexity.
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 solution achieves a compact, reliable, and efficient drive system with improved control accuracy, reduced maintenance, and lower costs, while allowing for easier expansion of drive power and integration of cooling and media passage, resulting in a more efficient and space-saving design.
Implementation Method 1
a drive with an electric motor... comprising an electric motor with a stator and a rotor
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3
AI summary
The invention relates to a winder for a strip-type material, preferably a metal strip, in metalworking, said winder comprising: at least one winding spindle (101, 300a, 300b) provided for winding the strip-type material, and a drive (200a, 200b) comprising an electric motor, preferably a torque motor or a synchronous motor, with a stator and a rotor (3, 201a, 201b). According to the invention, the winder also comprises a housing (103, 302), the rotor (3, 201a, 201b) is connected to the winding spindle (101, 300a, 300b), whereby the rotation of the rotor (3, 201a, 201b) is transmitted to the winding spindle (101, 300a, 300b), and the stator is directly mounted on the housing (103, 302) and/or the rotor (3, 201a, 201b) is directly connected to the winding spindle (101, 300a, 300b) or a shaft of the winding spindle (101, 300a, 300b).