Mandrel Position Control for Web Winding Transfer
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Solution Overview
Problem
Conventional turret winders face challenges in precisely positioning the mandrel for efficient web transfer, leading to adhesive waste and potential machine shut-downs, especially when using cores or vacuum systems.
Innovation Solution
A method and apparatus that control the rotational mandrel position using a reference input and position sensor to ensure precise adhesion of the web at a specific circumferential location on the mandrel, allowing for controlled rotational speed adjustments via torque applied at the mandrel ends, facilitating efficient web transfer within ±15 degrees of the target location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glue is applied in rings to the entire circumference of the mandrel, then the web can be transferred, but adhesive is wasted and spaces between glue rings cause missed transfers
Solution Approach 1:
The patent applies glue only at a specific circumferential location on the mandrel rather than around the entire circumference. This localized application ensures reliable web transfer at the transfer point while eliminating adhesive waste in areas where the web does not contact the mandrel.
Solution Approach 2:
The patent segments the mandrel surface into a specific transfer location and non-transfer areas. By concentrating the glue application at the precise circumferential position where web transfer occurs, the system separates the functional requirement (transfer reliability) from the unnecessary adhesive application elsewhere.
2Area of stationary object
If vacuum holes are spread out on the mandrel surface, then coverage is increased, but the overall vacuum level decreases
Solution Approach 1:
The patent concentrates vacuum holes at a specific circumferential location rather than distributing them uniformly across the mandrel surface. This localized arrangement maintains strong vacuum suction at the transfer point while using less total vacuum effort, thereby preserving overall vacuum level.
3Productivity
If the mandrel rotates at high speed, then production output increases, but precise positioning for web transfer becomes difficult
Solution Approach 1:
The patent uses a position sensor to detect a reference mark on the mandrel before the web transfer occurs. This preliminary positioning allows the control system to calculate the exact moment to initiate web transfer, ensuring precision even when the mandrel rotates at high speed.
Solution Approach 2:
The patent employs a position sensor to continuously monitor the mandrel's rotational position and provides feedback to the control system. This real-time feedback enables precise timing of web transfer relative to the mandrel's circumferential position, maintaining accuracy at high rotational 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
This approach reduces adhesive waste, increases production output, and ensures secure attachment of the web to the mandrel, minimizing machine downtime and optimizing the use of adhesive, whether using cores or coreless methods.
Implementation Method 1
A position sensor is used to determine the position of the reference input
Implementation Method 2
The position drive control sets the rotational speed of the mandrel to allow transfer of the leading edge of the moving web near the specific circumferential location
Implementation Method 3
This process enables adhesion of the moving web to the mandrel at a predetermined and specific location
Data Source
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AI summary
A method and apparatus for winding a moving web upon a mandrel is disclosed. A moving web with a leading edge is conveyed towards a mandrel. The mandrel is adapted to allow the moving web to adhere to the mandrel at a specific circumferential location on the mandrel. To enable control of the location of the mandrel, the mandrel further includes a reference input to identify the specific circumferential location. A position sensor is used to determine the position of the reference input. The position of the specific circumferential location of the mandrel is controlled with a position drive control that controls the rotational speed of the mandrel. The position drive control sets the rotational speed of the mandrel to allow transfer of the leading edge of the moving web near the specific circumferential location.