Coil Wrapping Robot Control With Variable Overlap Protection
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Solution Overview
Problem
Existing coil wrapping processes are time-consuming and prone to damage the coil or wrapping material, often requiring additional protection devices, and fail to efficiently manage overlap in wrapping turns to prevent mechanical and chemical damage.
Innovation Solution
A robot system with a control system that adjusts the angular velocity of the coil and robot movements to vary the overlap between wrapping turns, applying multiple layers of film to critical segments to enhance protection and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the coil rotates at constant high speed during wrapping, then productivity is improved, but the wrapping material may not provide sufficient protection at critical segments and overlap control becomes difficult
Solution Approach 1:
The patent applies dynamics by transitioning from constant rotational speed to variable rotational speed during the wrapping process. The control system dynamically adjusts the coil's angular velocity based on the robot's position and the required overlap, enabling both high productivity and reliable protection quality throughout the wrapping process.
Solution Approach 2:
The patent changes the parameter of rotational speed from constant to variable. By modifying the angular velocity parameter according to the wrapping phase and required overlap, the system achieves both high productivity during normal wrapping and sufficient protection at critical segments where reduced speed allows for better material application.
2Reliability
If the overlap between wrapping turns is increased to provide better protection, then reliability is improved, but the wrapping process becomes slower and productivity decreases
Solution Approach 1:
The patent applies local quality by providing different overlap levels at different segments of the coil. Critical segments receive increased overlap and protection, while non-critical segments maintain standard overlap, thereby achieving reliable protection where needed without sacrificing overall productivity.
3Extent of automation
If linear robots are used for wrapping as shown in WO 2016/195578 and U.S. Pat. No. 6,705,060B1, then the wrapping process can be automated, but the process remains time-consuming and productivity is limited
Solution Approach 1:
The patent employs periodic action through the coordinated cyclic motion of the rotating coil and the oscillating robot arms. This periodic coordination enables continuous wrapping at high speed while maintaining precise control over material application and overlap, thereby improving productivity compared to linear robot approaches.
4Adaptability or versatility
If robots with more degrees of freedom are used as shown in EP 3 070 008 A1, then configuration flexibility is improved, but practical implementation becomes complex and difficult
Solution Approach 1:
The patent achieves universality by designing a wrapping system that can handle various coil sizes and wrapping requirements through coordinated control of rotational speed and robot motion, rather than requiring complex reconfiguration. The system maintains flexibility through software control while avoiding excessive mechanical complexity.
Data Source
AI summary
A robot system and a method for packaging coils of sheet metal. The method and robot system for coil packaging, having two industrial robots, each robot being provided with a robot arm provides for a solution where the angular velocity of the coil is adjusted during the wrapping process to thereby provide reinforcement of a certain cylindrical sector segment of the coil.