Horizontal Reel Winding for Stable Product Strip Retention
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Solution Overview
Problem
Conventional vertical winding configurations for product strips onto reels are prone to quality issues due to gravity and centrifugal forces, requiring significant tension and complex robotic arms for handling, which increases costs and complexity.
Innovation Solution
A horizontal winding apparatus with a feeder module, first and second winding module parts, a transfer module, and end-packaging modules, along with an interleaf module and tensioning system, to align and rotate the reel, apply tension, and secure the product strip efficiently, reducing the need for complex robotic arms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a vertical winding configuration is used, then the reel can be mounted vertically with its longitudinal axis parallel to the horizontal axis, but the product strip may come loose due to gravity and centrifugal force, requiring significant tensioning
Solution Approach 1:
The patent inverts the conventional vertical winding configuration by mounting the reel horizontally with its longitudinal axis substantially parallel to the vertical axis of the winding machine. This inversion allows the product strip to be wound in a horizontal plane, eliminating the adverse effects of gravity and centrifugal force that cause the strip to come loose in vertical configurations.
2Reliability
If significant tensioning is applied to maintain product strip on the reel, then the strip remains secured, but the complexity and cost of the tensioning system increases
Solution Approach 1:
By inverting the winding configuration from vertical to horizontal, the patent eliminates the need for significant tensioning forces. The horizontal winding plane naturally counteracts gravity and centrifugal force effects, allowing the product strip to remain securely wound without complex tensioning mechanisms.
3Extent of automation
If complex robotic arms are used for automated reel handling, then automation is achieved, but the footprint and acquisition cost increase
Solution Approach 1:
The horizontally mounted reel serves multiple functions: it enables automated handling with simpler mechanisms, facilitates transport on autonomous vehicles, and allows for compact machine footprint. The horizontal configuration is universally adaptable to various automation schemes without requiring specialized vertical handling equipment.
Solution Approach 2:
The horizontal reel configuration allows for simpler, more compact end-effectors and transfer mechanisms that can be easily replicated and integrated into automated systems, replacing the need for complex, space-consuming robotic arms while maintaining automation capabilities.
4Extent of automation
If complex robotic arms are used for reel handling, then automated transport is enabled, but the maintenance cost increases
Solution Approach 1:
The horizontal reel configuration enables the use of simpler, more universally applicable automation components with fewer moving parts and lower maintenance requirements. The standardized horizontal mounting facilitates easier repair and replacement of handling mechanisms compared to specialized vertical robotic systems.
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
Improves winding quality by maintaining alignment and reducing tension requirements, simplifies handling with autonomous vehicles, and decreases the overall cost and complexity of the machinery.
Implementation Method 1
a tensioning roller for applying tension to the interleaf member
Implementation Method 2
The tension applied is controllable by varying a supply of current and/or voltage to an electromagnetic brake that is coupled to the tensioning roller
Data Source
AI summary
A winding apparatus (200) and a method of winding a product strip onto (202) a reel (204) are provided, the winding apparatus (200) comprises, a feeder module (216) for supplying the product strip to the reel; a first winding module part (218) that is configured to engage the reel, the first winding module part (218) being further configured to move along a first alignment path to align the reel in relation to the feeder module (216) at an operative position for receiving the product strip; wherein first winding module part (218) is configured to align the reel (204) in a horizontal position that is normal to a vertical axis (Y) of the winding apparatus and the reel (204) is rotatable at the operative position about a longitudinal axis passing through the reel; and wherein the feeder module (216) is arranged to convey the product strip (202) for winding onto the reel (204), the product strip (202) being within a vertical plane normal to the ground.