Steel Coil Wrapping With Parallel Film Rolls and Auto Roll Change
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Solution Overview
Problem
Existing coil-wrapping systems for steel coils are inefficient and require manual film roll replacement, limiting their speed and protection capabilities during transit.
Innovation Solution
A coil-wrapping system that utilizes multiple film rolls simultaneously, with mandrels to maintain tension and an automated film-roll-change system for seamless operation, enhancing efficiency and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single film roll is used to wrap the coil, then the system is simple to operate, but the wrapping speed is slow and requires manual intervention to replace empty film rolls
Solution Approach 1:
The system divides the wrapping function into multiple independent film rolls (first film roll, second film roll, third film roll, fourth film roll) that operate simultaneously on different sides of the coil. Each film roll is applied by a separate applicator arm, allowing parallel wrapping operations that dramatically increase productivity without requiring complex coordination mechanisms.
Solution Approach 2:
The system combines multiple film application operations into a single integrated wrapping process. All four film rolls are applied to the same coil simultaneously during one rotation cycle, merging what would traditionally be four separate wrapping operations into one unified process, thereby quadrupling the effective wrapping speed.
2Productivity
If multiple film rolls are used simultaneously, then the wrapping efficiency increases, but the device complexity increases requiring automated mandrel handling systems
Solution Approach 1:
The system implements self-service through automated mandrel grippers that detect when a film roll is depleted and automatically replace it with a fresh film roll from a storage magazine. The mandrel grippers grasp the mandrel, transfer it between positions, and secure it in place without human intervention, allowing the wrapping process to continue uninterrupted.
Solution Approach 2:
The system uses sensors to detect the film roll status (when film is depleted) and triggers the automated replacement mechanism. The mandrel gripper system responds to feedback signals by initiating the film roll change sequence, ensuring the wrapping process maintains continuous operation without manual intervention.
3Speed
If manual film roll replacement is used, then the system is easier to maintain, but the wrapping process is interrupted and speed is reduced
Solution Approach 1:
The automated film roll replacement system performs the replacement task itself without requiring operator intervention. The mandrel grippers and magazine system work autonomously to swap film rolls, eliminating the need for operators to stop the machine and manually replace film, thereby maintaining high wrapping speed continuously.
4Reliability
If multiple film rolls are applied simultaneously, then the coil receives better protection during transit, but the amount of film material used increases
Solution Approach 1:
The coating system applies different film materials to different portions of the coil surface simultaneously. The first and second film rolls apply coating to the outer surface, while the third and fourth film rolls apply coating to the inner surface, ensuring comprehensive protection of all coil surfaces during transit.
Data Source
AI summary
Various embodiments of the present disclosure provide a coil-wrapping system (30) that simultaneously employs separate multiple film rolls (FR1, FR2) to simultaneously wrap separate films around a single coil while the coil is rotated about its longitudinal axis.