Automatic Core Charging and Bobbin Discharging in Plastic Film Winding
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Solution Overview
Problem
Current plastic film winding machines require human intervention for adapting to variably-sized cores and bobbins, leading to potential errors, production slowdowns, and mechanical stress on the spindle during bobbin extraction.
Innovation Solution
An automatic core-charging and bobbin-discharging system that uses a linear actuator with a rotating supporting plate and a conveyor belt with an extendable portion, controlled by motors and potentiometers, to align and insert cores and discharge bobbins without manual intervention, ensuring precise positioning and minimizing spindle bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If human intervention is used to select and set core dimensions, then flexibility in handling different core formats is achieved, but human error risk increases and production efficiency decreases
Solution Approach 1:
The system uses sensors to automatically detect core dimensions and the controller autonomously adjusts guide system positions and winding parameters without human intervention. The machine serves itself by making real-time adjustments based on detected core characteristics, eliminating human error while maintaining flexibility.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect core dimensions and electronically controls the positioning of guide systems and winding parameters, substituting human mechanical operations with automated mechanical and electronic systems.
2Adaptability or versatility
If manual adjustment of guide systems is performed for different core dimensions, then adaptability to various core formats is achieved, but production time is lost and operator specialization is required
Solution Approach 1:
The system pre-programs multiple core format specifications with their corresponding optimal settings for guide system positions and winding parameters. When a core is detected, the controller automatically retrieves and applies the pre-configured settings, eliminating the need for manual adjustment and reducing production time.
Solution Approach 2:
The guide systems are designed with dynamic positioning capabilities that allow automatic adjustment of positions based on real-time detection of core dimensions. The system transitions from static manual positioning to dynamic automated positioning, enabling rapid adaptation to different core formats without production stoppage.
3Adaptability or versatility
If robust mechanisms are used for discharging bobbins of various diameters, then handling capability is improved, but device complexity increases and human intervention is still required
Solution Approach 1:
The discharging mechanism is designed as a universal system that can handle bobbins of various diameters through a single automated apparatus. The mechanical arm with adjustable positioning and the conveyor system with variable speed control provide multi-functional capability, eliminating the need for multiple specialized mechanisms for different bobbin sizes.
Solution Approach 2:
The patent replaces complex manual discharging mechanisms with an automated mechanical arm controlled by sensors and a controller. The system uses electronic control and sensor feedback to manage the discharging process, reducing mechanical complexity while maintaining versatility through programmable operations.
4Stability of the object's composition
If the spindle is firmly held during winding, then winding stability is achieved, but spindle bending occurs during bobbin extraction and requires complex discharging systems
Solution Approach 1:
The spindle system employs dynamic clamping that automatically adjusts the firmness of the hold based on the operational phase. During winding, the spindle is firmly clamped for stability. During extraction, the clamping force is automatically reduced or released, allowing the spindle to be extracted without excessive bending forces, eliminating the need for complex discharging systems.
Solution Approach 2:
The system applies preliminary anti-action by pre-positioning the conveyor belt to support the bobbin weight before extraction begins. This preliminary support prevents sudden loading and bending of the spindle during extraction, allowing for simpler spindle design and reduced complexity in the discharging system.
Data Source
AI summary
An automatic core-charging and bobbin-discharging group in a plastic film winding machine, positioned partially juxtaposed and partially below a winding reel includes a core charging portion having a motorized linear actuator carrying a guide-support which houses a certain number of cores suitable for receiving plastic film, the guide-support being movable, backwards and forwards, between a position associated with a core charger and a juxtaposed position, axially parallel to a spindle of the winding reel, with the cores inserted on the spindle, the linear actuator also being vertically liftable with a variation in an external diameter of the cores, and a bobbin discharging portion having a motorized conveyor belt, equipped with an extendable portion, movable between a position below a spindle carrying the wound bobbins and a discharging portion of the bobbins, the conveyor belt being vertically liftable with a variation in an external diameter of the bobbins.