Low-Tension Coiler with Synchronized Feed and Spindle Control

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Solution Overview

Problem

Existing coiling systems cause damage to delicate materials like hollow profiles or flexible extrusions due to excessive tension and friction, leading to issues such as kinking, curling, and inconsistent winding.

Innovation Solution

A system with a powered feed roller and computer-controlled spindle that synchronizes the material feed with the winding process, minimizing tension and using an articulating lay-on guide arm for precise positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the winder or spindle does the pulling of the elongated material, then the winding process is simple, but too much friction and tension build up on the material causing damage

Engineering Contradiction:

Improvewinding process simplicityVSAvoidtension and friction on material

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

Instead of the winder pulling the material through friction, the invention inverts the approach by using a feed roller to positively push or feed the material onto the winder. This reverses the force application method, eliminating excessive tension and friction that damage delicate materials while still achieving effective winding.

Inventive Principle:

Principle #13The other way round (Inversion)

2Productivity

If high tension is applied during winding, then the material winds onto the reel faster, but the delicate plastic profiles are stretched, curled, or damaged

Engineering Contradiction:

Improvewinding speedVSAvoidmaterial integrity and shape

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The feed roller performs preliminary action by pre-positioning and gently feeding the material onto the winder before the main winding force is applied. This preliminary gentle feeding prevents tension buildup and material damage, allowing the subsequent winding to proceed at higher speeds without compromising material integrity.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If conventional winding is used, then the process is straightforward, but overlapping, excessive gaps, inconsistent orientation, and tangled rows occur

Engineering Contradiction:

Improvewinding process simplicityVSAvoidwinding consistency and row alignment

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The invention incorporates feedback mechanisms that monitor the winding process and adjust parameters in real-time to maintain consistent row alignment, proper spacing, and correct material orientation. This feedback control eliminates overlapping, gaps, and tangled rows while preserving the simplicity of the overall winding process.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12606410B2Low tension application coiler

Publication Date: 2026.04.21 REEL POWER LICENSING CORP

AI summary

An apparatus, system, and method for a low tension application spooler and or coiler system that positively drives the material into the coil and or reel so that the tension is minimum during the winding process.