Automated Fiber Bundle Reeling and Wrapping Apparatus

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Solution Overview

Problem

Existing methods for manufacturing fiber bundles, particularly for dialysis filters, face challenges such as manual handling, high cutting losses, and low efficiency due to the need for manual wrapping and processing, which results in reduced precision and increased complexity.

Innovation Solution

An automated apparatus with a rotatable reel carrier and perpendicular axes of reels allows for continuous reeling and processing of fiber bundles, reducing manual handling and enabling quasi-continuous operation, with features like stretch/compression devices and a dancer arrangement to maintain fiber tension and reduce cutting losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual wrapping and handling is used, then device complexity is reduced, but manufacturing precision and productivity deteriorate

Engineering Contradiction:

Improveautomation of reeling and wrapping processVSAvoidcomplexity of reeling apparatus

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The reeling apparatus is divided into multiple functional segments: a reel carrier with rotatable reels for fiber winding, a wrapping unit for applying wrapping film, and a cutting unit for sectioning the fiber bundle. This segmentation allows each component to perform its specific function efficiently while maintaining overall system manageability and precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines the reeling, wrapping, and cutting operations into a single integrated apparatus. The reel carrier, wrapping unit, and cutting unit work together in a coordinated manner to process fiber bundles continuously, eliminating the need for separate manual operations and improving both automation extent and manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If batch-wise winding on reel wheels is used, then manufacturing precision is maintained, but productivity and duration of action deteriorate

Engineering Contradiction:

Improvecontinuous processing capabilityVSAvoidtime for manual handling and processing

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The reeling apparatus enables continuous processing of fiber bundles through automated reeling, wrapping, and cutting operations. The reel carrier can continuously wind fibers onto reels while the wrapping unit continuously applies wrapping film, and the cutting unit continuously sections the bundles, eliminating interruptions and manual handling time.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The apparatus performs preliminary actions by pre-winding fibers onto reels and pre-applying wrapping film before the cutting operation. This sequencing of operations allows for efficient continuous processing, as each step is prepared in advance for the next step, reducing overall processing time and increasing productivity.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If hollow fibers are freely tensioned between winding mandrels, then ease of operation is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improveprecision of fiber bundle dimensionsVSAvoidease of fiber handling

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The apparatus controls and adjusts the tension parameter on the hollow fibers during the reeling process. By dynamically adjusting tension levels, the system maintains fiber stability and positioning precision while ensuring easy handling and continuous operation. The tension control enables precise dimensional outcomes without compromising operational ease.

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If spiral wrapping with fixing tape is used, then ease of manufacture is improved, but device complexity and manufacturing precision deteriorate

Engineering Contradiction:

Improveprecision of wrapped bundle dimensionsVSAvoidcomplexity of wrapping mechanism

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical spiral wrapping system with a simpler automated wrapping unit that applies wrapping film in a controlled manner. This substitution eliminates the need for complex fixing tape mechanisms while achieving precise dimensional control through automated film application and tension control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9387945B2Apparatus and method for manufacturing fiber bundles

Publication Date: 2016.07.12 FRESENIUS MEDICAL CARE DEUTSCHLAND GMBH

AI summary

An apparatus for the reeling up of fiber bundles, in particular of hollow fiber membrane bundles, and in particular for the manufacture of dialysis filters, includes a reel carrier rotatable around a main axis. The apparatus includes at least two reels which are rotatably supported on the reel carrier, with the axes of rotation of the reels being perpendicular to the main axis of the reel carrier. The apparatus can be used for the wrapping of a fiber bundle with a film, having a receiver of first and second side elements and a flexible channel fastened between them for the reception of the film and the fiber bundle. A drive is provided to move at least the first side element transversely to the channel, and at least one folding device movable transversely to the flexible channel for the folding of the film around the fiber bundle.