Dual Mandrel Winding Apparatus for Flexible Material Throughput
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Solution Overview
Problem
Existing REELEX-type winding systems are limited in throughput due to constraints in the winding process, including time for winding, applying plastic film, inserting payout tubes, removing coils, and preparing the apparatus for subsequent winding.
Innovation Solution
An apparatus with a support frame, a rotating vertical plate assembly, and two mandrel parts mounted on rotary shafts, allowing for coordinated rotation of the plate assembly with counter rotation of the mandrel parts, enabling simultaneous winding and packaging operations with transition operations to optimize throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single mandrel winding system is used, then the structure is simple, but the throughput is limited due to sequential operations
Solution Approach 1:
The winding apparatus is divided into two independent mandrel systems (first mandrel and second mandrel) that can operate simultaneously. Each mandrel has its own drive mechanism and can perform winding operations independently, effectively segmenting the production process to increase throughput while maintaining manageable complexity through modular design
Solution Approach 2:
The dual-mandrel configuration enables continuous winding operations where while one mandrel is completing a coil, the other mandrel is already starting the next coil. This eliminates idle time between winding cycles and maintains continuous productive action, significantly increasing overall throughput
2Productivity
If transition operations between winding cycles are performed, then the apparatus can prepare for subsequent winding, but downtime between cycles increases
Solution Approach 1:
The apparatus performs preliminary actions during active winding operations - while the first mandrel is winding a coil, the second mandrel is already positioned and ready to begin the next winding cycle. This preliminary preparation eliminates idle transition time and maintains continuous production flow
Solution Approach 2:
The transition operations for one mandrel are merged with the active winding operations of the other mandrel. While one system transitions between cycles, the other continues productive winding, effectively combining the transition phase with productive time rather than having separate idle transition periods
3Productivity
If manual operations for film application and payout tube insertion are used, then the process is simple, but the time required for these operations increases
Solution Approach 1:
The winding apparatus incorporates automated mechanisms that perform film application and payout tube insertion without requiring separate manual operations. The system serves itself by integrating these auxiliary functions into the main winding process, reducing cycle time while the automation level remains moderate and manageable
Data Source
AI summary
Apparatus and methods for winding flexible material include a rotatable plate assembly rotatably driven by a first rotary shaft, the assembly supporting second and third rotary shafts with corresponding first and second mandrel parts mounted thereon. The first and second mandrel parts each form at least part of a winding spool. The second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, the rotational axis of the first rotary shaft. The rotation of the plate assembly is coordinated with counter rotation of the first and second mandrel parts. In embodiments, such coordinated rotation occurs during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other. The flexible material can be cable, wire, tubing, hose, rope, or other filamentary material. Other aspects are described and claimed.