Laying Arm Sensor Feedback for Automated Winding
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Solution Overview
Problem
Existing winding technologies face challenges in automating the winding of strand-like materials, such as continuously extruded plastic tubes, due to unpredictable material properties and geometric irregularities of the winding drums, which require manual intervention and limit winding speeds.
Innovation Solution
A laying arm system that uses a displacement sensor and actuating projection to control the winding process, allowing for automated operation by moving back and forth between the axial ends of the winding drum, with a contact area that rolls or slides on the drum, and a modular design for adapting to different material sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standardized wooden winding drums are used, then cost is reduced and reusability is improved, but geometric irregularities and imbalances occur requiring manual intervention
Solution Approach 1:
The patent employs sensors (optical, capacitive, or inductive) to detect the position of the winding drum flanges and provides feedback signals to the control system. This feedback mechanism enables the automated laying arm to adapt to geometric irregularities and imbalances of standardized winding drums, eliminating the need for manual intervention while maintaining cost-effectiveness.
Solution Approach 2:
The control system automatically adjusts the laying arm's movement and positioning based on sensor feedback, enabling the system to self-correct for drum irregularities without requiring operator intervention. The system serves itself by autonomously compensating for geometric imperfections in standardized drums.
2Ease of operation
If manual monitoring and manipulation is used, then unpredictable material properties and geometric irregularities can be handled, but automation cannot be achieved and winding speed is limited
Solution Approach 1:
The patent replaces manual mechanical control with an automated control system that uses sensors to detect flange positions and electronically controls the laying arm's movement. This substitution of mechanical/manual operations with sensor-based electronic control enables high-speed automated winding while maintaining the ability to handle unpredictable material properties and geometric irregularities.
3Productivity
If known automated winding techniques are used, then winding speed can be increased, but they cannot successfully handle winding materials and drums with unforeseeable geometric and material properties
Solution Approach 1:
The patent implements a dynamic control system that continuously adapts to changing conditions during winding. The sensor system实时 detects flange positions and material properties, and the control system dynamically adjusts the laying arm's movement parameters to accommodate irregular materials and drums, enabling both high speed and high adaptability.
Solution Approach 2:
The control system modifies operational parameters (such as laying arm speed, position, and angle) in real-time based on sensor feedback about material properties and drum geometry. This dynamic parameter adjustment enables the system to handle diverse and irregular winding materials at high speeds.
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
Enables higher automation levels with reduced manual intervention, achieving winding speeds over 80 m/min and accommodating various material dimensions, while maintaining a solid winding layer, even with geometric imbalances and changing material properties.
Implementation Method 1
a displacement sensor, in particular a contactor (37), arranged at the end on the winding side, which, when at least one predefined winding position, in particular a trigger position for the turning operation, of the winding drum end is reached, emits a control signal, in particular a rotation operation trigger signal
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
Disclosed is a laying arm (27) for an apparatus (1) for helically winding an endless material (3) that is to be wound up, e.g. a continuously extruded tube, preferably made of plastic, onto a rotationally driven winding drum (5). The laying arm (27) transfers the material (3) to be wound up to the winding drum (5) when the laying arm (27) performs an especially substantially linear back-and-forth laying motion. According to the invention, in a contact zone (38) which lies at the end (33) of the laying arm closer to the winding drum and which faces a sidewall flange (11a, 11b) of the winding drum (5), the laying arm (27) comes in direct contact, in particular in direct sliding contact, with said sidewall flange (11a, 11b), especially when the laying arm performs a turning operation. Furthermore, a distance sensor (36), such as a contactor (37), which is located at the end of the laying arm closer to the winding drum, emits a control signal, such as a turning operation-triggering signal, at least when the end (33) of the laying arm closer to the winding drum reaches at least one predefined position. Also, in the area of each contact zone (38), the laying arm comprises an actuating projection (101a, 101b) which, in an inactive position, projects from the respective contact zone in the direction of the back-and-forth laying motion and is mounted on the laying arm (27) so as to be movable, in particular pivotable in such a way that in an open position, the actuating projection (101a, 101b) opens said contact zone (38) to allow for the direct contact.