Level Winder Curved Drive Dog Carriage Guide
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Solution Overview
Problem
Existing level winders for hose and cable reels are complex, costly, and lack adaptability to varying reel spool widths, with inadequate control over carriage dwell time at travel extremes, leading to inefficient hose or cable placement and winding.
Innovation Solution
A level winder mechanism featuring a carriage with a drive mechanism that includes a drive dog and carriage guide with curved surfaces, allowing controlled reciprocation and dwell time adjustment, integrated with a chain and sprocket drive system for compact design and modular adaptability, along with a brake mechanism for controlled spool rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a double acting lead screw and carriage arrangement is used, then the level winder can provide controlled reciprocating motion, but the device complexity increases and cost increases
Solution Approach 1:
The patent replaces the complex double-acting lead screw mechanism with a simpler single-acting lead screw combined with a spring return system. The spring automatically returns the carriage to its initial position after the lead screw extends it, eliminating the need for complex bidirectional mechanical control while maintaining controlled reciprocating motion
Solution Approach 2:
The invention extracts and separates the return mechanism from the primary drive mechanism. By using a spring-loaded return system independent of the lead screw, the patent simplifies the main drive mechanism while ensuring reliable reciprocating motion, reducing overall device complexity
2Ease of operation
If closely located vertical and horizontal rollers are used, then lateral directional guidance is provided, but the frictional resistance increases
Solution Approach 1:
The patent removes the horizontal rollers from the system, retaining only the essential vertical rollers for lateral guidance. This reduction in the number of contact points directly decreases frictional resistance while maintaining adequate directional control through the vertical rollers alone
Solution Approach 2:
The invention optimizes the placement and configuration of the vertical rollers to provide concentrated lateral guidance where most needed, rather than using multiple distributed rollers. This localized approach maintains guidance effectiveness while minimizing total friction
3Stability of the object's composition
If the rail system is an integral part of the reel frame structure, then structural stability is provided, but the adaptability to varying reel widths decreases
Solution Approach 1:
The patent divides the rail system into separate, modular components that can be independently adjusted. The rails are positioned on adjustable supports or mounting structures, allowing the distance between them to be changed to match different reel spool widths while maintaining structural stability through proper mounting
Solution Approach 2:
The invention introduces adjustability and flexibility to the previously fixed rail system. The rails or their supports can be repositioned or reconfigured to adapt to varying reel widths, transforming the static integral structure into a dynamic, adaptable system
4Productivity
If the carriage dwell time at travel extremes is not controlled, then the mechanism simplicity is maintained, but the hose or cable placement efficiency decreases
Solution Approach 1:
The patent incorporates periodic dwelling or pausing at the extreme positions of the carriage travel through the lead screw mechanism's natural stop points or through controlled reversal. This periodic action at specific intervals (at travel extremes) allows proper hose laydown without requiring continuous complex control mechanisms throughout the entire travel cycle
Data Source
AI summary
A level winder (10, 110, 210, 310) for use on a hose reel (1), the level winder including: a carriage (20, 120, 220) operatively connected to a hose guide (104-108), the carriage adapted to control the winding of the hose onto the hose reel and to allow the hose to be paid out through the hose guide; and a drive mechanism 30 carrying at least one drive dog (32, 136) that is adapted to travel in a substantially vertical drive mechanism plane and to engage a carriage guide (12, 112) on which the carriage is mounted to move the carriage reciprocally along a track. The carriage guide is aligned in the same plane that the drive dog travels and the carriage guide comprises at least one curved surface (14, 114) adapted to define a recess (13, 113) and to engage a curved surface of the drive dog (16, 116), such that at least a portion of the drive dog curved surface (I6) is always facing or engaged with the carriage guide curved surface (14) and remains trapped in the recess (12, 113).