Coil Stacker Lifting Head with Expanding Mandrel
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for stacking and transporting coils from a conveyor system are inefficient, lacking a reliable mechanism to automatically lift and stack coils for further transportation.
Innovation Solution
A system utilizing a coil stacker lifting head with an expanding mandrel and actuating cylinders to lift coils from a conveyor, followed by a carriage assembly for transport, where the mandrel collapses to release the coils upon reaching the destination, incorporating wedges and lifter feet for secure handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stacking methods are used, then operational simplicity is maintained, but productivity and efficiency deteriorate
Solution Approach 1:
The mandrel is divided into multiple expandable sections that can independently adjust to different coil sizes. The stacking system is segmented into separate functional modules including the lifting head, carriage assembly, and control system, allowing for improved productivity while managing complexity through modular design
Solution Approach 2:
The mandrel incorporates dynamic expansion and contraction capabilities through hydraulic or pneumatic actuators, allowing it to adapt its inner diameter to different coil sizes. This dynamic adjustment mechanism enables automated handling of various coil dimensions, significantly improving stacking efficiency without requiring multiple fixed-size mandrels
2Productivity
If automated lifting mechanisms are introduced, then productivity improves, but device complexity increases
Solution Approach 1:
The coil stacker lifting head is designed as a universal device that can handle multiple coil sizes and weights through the expandable mandrel mechanism. The carriage assembly serves multiple functions including transport, positioning, and support, reducing the need for separate specialized equipment and managing overall system complexity
Solution Approach 2:
The automated lifting mechanism utilizes hydraulic or pneumatic cylinders to provide controlled expansion and contraction of the mandrel, as well as vertical lifting motion. This fluid power system enables smooth, controlled automation of the lifting process while consolidating multiple actuation functions into integrated components
3Reliability
If the mandrel expands to secure the coil, then handling reliability improves, but the force required increases
Solution Approach 1:
The mandrel and coil interfaces utilize curved and rounded surfaces that distribute the expansion force evenly around the coil inner diameter. This curvature-based design prevents stress concentration points, allowing the mandrel to securely grip the coil with reduced peak forces compared to flat or angular contact surfaces
Solution Approach 2:
The mandrel expansion mechanism controls the force application by gradually increasing the inner diameter from the initial coil size, creating a progressive gripping action. The expansion ratio and rate are carefully controlled to achieve reliable securing while minimizing the peak force required, optimizing the balance between holding reliability and actuation force
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 automatic and efficient stacking and transportation of coils, reducing manual intervention and ensuring secure handling through controlled expansion and contraction of the mandrel, facilitating precise positioning and unloading.
Implementation Method 1
The coil stacker lifting head can be automatically actuated using a actuating cylinder and a counter balance cylinder
Implementation Method 2
The mandrel can include four sections of wedges to expand within the coil to contact an inner surface of the coil thereby eliminating the weight of the coil
Implementation Method 3
a counter balance cylinder
Data Source
AI summary
A method and system for stacking coils in which a coil stacker lifting head can be used to raise one or more coils from a conveyor assembly. The coil stacker lifting head can be automatically actuated using a actuating cylinder and a counter balance cylinder. The coil stacker lifting head can include an expanding mandrel to grab opposite edges of the coil and lift the coil. One or more of the coils can be lifted from a conveyor assembly by the coil stacker lifting head. After the one or more coils are lifted, a carriage assembly can transport the lifted one or more coils to a desired position. Once the one or more coils reach the desired position, the one or more coils are lowered to a surface. Upon reaching the surface, the mandrel automatically collapses to release the one or more coils and the mandrel is released from the coils.