Direct-Drive Reel Head for Compact Strip Tension Control
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Solution Overview
Problem
Existing reels for winding or unwinding strip-shaped materials require large installation spaces and are produced individually, making them economically inefficient due to the need for customized drive trains and components.
Innovation Solution
A modular reel system using torque motors or synchronous motors with directly connected rotor shafts, eliminating the need for gearboxes and couplings, and allowing for adjustable power levels through modular ring packages, reducing installation space and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional drive train with gearbox and coupling is used to connect the electric motor to the reel head, then the reel can achieve the required torque, but the installation space increases and the device complexity increases
Solution Approach 1:
The patent extracts and eliminates the gearbox and coupling from the drive train, directly connecting the electric motor shaft to the reel head. This removal of intermediate components reduces installation space while maintaining the required torque transmission capability through direct drive.
Solution Approach 2:
The patent replaces the mechanical gearbox and coupling system with a direct electrical-mechanical connection. The electric motor's rotor shaft is directly coupled to the reel head, eliminating the need for mechanical transmission components and reducing overall system footprint.
2Power
If a conventional drive train with gearbox and coupling is used to connect the electric motor to the reel head, then the reel can achieve the required torque, but the device complexity increases
Solution Approach 1:
The patent removes the gearbox and coupling from the drive train, simplifying the mechanical transmission system. The direct connection between the electric motor shaft and reel head eliminates multiple components, reducing device complexity while maintaining torque transmission.
Solution Approach 2:
The patent merges the function of the electric motor and reel head into a more integrated configuration by eliminating intermediate transmission components. The direct drive arrangement combines the motor shaft and reel head connection into a single streamlined assembly.
3Adaptability or versatility
If the reel is produced individually for a specific application with customized drive train components, then the reel can be optimized for that application, but the manufacturing cost increases
Solution Approach 1:
The patent creates a universal reel design with a standardized direct-drive configuration that can be applied across multiple applications. By eliminating application-specific customization of the drive train and using a modular coil change system, the same basic design serves different rolling mill requirements, reducing manufacturing costs.
Solution Approach 2:
The patent segments the reel into modular components, particularly the coil system that can be independently changed. This segmentation allows the main drive train to remain standardized while only the coil components need to be customized for different applications, reducing overall manufacturing complexity and cost.
4Power
If a more powerful electric motor is used to increase the reel power, then the power increases, but the installation space increases
Solution Approach 1:
The patent replaces the mechanical gearbox system with a direct-drive electric motor configuration. This allows for more compact motor designs that can deliver high torque directly without requiring large gearbox housings and intermediate shafts, thereby increasing power while reducing installation space.
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 solution enables cost-effective manufacturing and operation with reduced installation space, improved efficiency, lower maintenance needs, and precise torque measurement for controlled strip tension, while allowing for adaptable power levels and standardized production.
Implementation Method 1
an electric motor, in particular a torque motor or synchronous motor, having a stator and a rotor
Data Source
AI summary
The invention relates to a reel (10) for winding or unwinding strip-shaped material, in particular a metal strip or the like, and to a method for tensioning a coil (12), the reel comprising a frame (13), at least one reel head (14) for disposing the coil for winding or unwinding material (11), a drive arrangement (15) having at least one electric motor (16) and a shaft (20) which connects the electric motor to the reel head, the electric motor being formed comprising a stator (17) and a rotor (18) and being disposed on the frame, the electric motor being a torque motor or a synchronous motor, the shaft directly connecting the rotor to the reel head, the rotor being mounted on the stator so as to be axially displaceable relative to the stator.