Core Chuck Ball Locking for Tool-Free Spindle Changes
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Solution Overview
Problem
The existing core chuck systems for winding fiber webs require manual operation with tools, leading to increased change time, ergonomic challenges, and safety risks due to the need for manual handling of multiple components and tools, especially when changing core chucks of different diameters.
Innovation Solution
A core chuck system utilizing a ball locking mechanism with a locking button and cone connection, allowing for manual operation without tools, featuring a rotational symmetric design with a low force requirement (less than 150 N) for unlocking, and a cone angle of 1:1-1:10 for secure locking, enabling easy and safe core chuck changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operation with tools is used for core chuck changes, then the locking mechanism can be secure, but the change time increases and ergonomic challenges arise
Solution Approach 1:
The core chuck system performs its own locking and unlocking operations without requiring external tools. The locking balls automatically engage with the locking grooves when the core chuck is mounted on the spindle, and the spring-loaded mechanism automatically resets after unlocking, making the system self-servicing and eliminating manual intervention.
Solution Approach 2:
The locking balls are pre-positioned in a retracted state by the spring mechanism before mounting. When the core chuck is installed, the locking balls are already ready to engage with the locking grooves, eliminating the need for manual positioning or tool-assisted locking during the change process.
2Strength
If manual handling of multiple components and tools is required, then the locking mechanism can be robust, but safety risks increase due to difficult access locations
Solution Approach 1:
The system automatically performs locking and unlocking without requiring operators to manually handle multiple components or tools in difficult-to-reach locations. The spring-loaded locking balls and self-aligning cone connection eliminate the need for manual intervention, thereby removing safety hazards associated with working in confined spaces.
Solution Approach 2:
The locking function is merged with the mounting operation itself. The cone connection and locking balls work together as an integrated system where mounting the core chuck automatically engages the locking mechanism, eliminating the need for separate locking steps and reducing the number of components that require manual handling.
3Adaptability or versatility
If core chucks of different diameters are changed manually, then adaptability is achieved, but the complexity of the change operation increases
Solution Approach 1:
The core chuck system is segmented into interchangeable components - different core chucks can be independently mounted and removed from the spindle. Each core chuck is a self-contained unit with its own locking mechanism, allowing for easy replacement without affecting other parts of the system and simplifying the change operation.
Solution Approach 2:
The spindle and locking mechanism are designed with universal compatibility to accommodate core chucks of different diameters. The cone connection and locking groove geometry are standardized, allowing a single spindle design to work with multiple core chuck sizes, thereby simplifying the change operation while maintaining adaptability.
4Ease of operation
If a simple manual operation is used, then ergonomics improve, but the locking security may be compromised
Solution Approach 1:
The spring-loaded locking balls automatically engage and secure the core chuck without requiring manual manipulation. The operator simply mounts or removes the core chuck, and the locking mechanism self-activates, providing both operational simplicity and reliable locking through the automatic engagement of multiple locking balls with their respective grooves.
Solution Approach 2:
The manual tool-based locking system is replaced with a spring-loaded mechanical system. The spring force automatically drives the locking balls into the locking grooves, providing secure locking without requiring manual tools or complex operational steps, thereby achieving both ease of operation and locking security.
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 system reduces change time and enhances safety and ergonomics by allowing tool-free operation, with a compact design and accurate, firm connections, minimizing the force needed for unlocking the core chuck.
Implementation Method 1
a cone connection between an inner cone surface of the core chuck and an outer cone surface of the spindle
Implementation Method 2
The locking balls are spring-loaded to ensure a firm connection and reliable locking
Data Source
AI summary
A core chuck system (10) comprising a core chuck (11) and a spindle (12) onto which the core chuck (11) is lockable, which core chuck system (10) comprises a ball locking mechanism, a locking button (15) and a cone connection (C).