Multi-Band Coil Forming with Radial Compression and Size Control
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Solution Overview
Problem
The manual process of forming multi-part band coils is physically exhausting, hazardous, and limited by the worker's physical capabilities, as it involves pushing together sharp-edged band coils to achieve the desired size.
Innovation Solution
A device comprising a pulley unit that applies a radially directed compressive force to expand the inner diameter of band coils, allowing for the easy integration of additional coils, and a limiting structure to define the outer dimensions, facilitating the formation of larger multi-part band coils safely and efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual pushing of band coils is used to form multi-part band coils, then the process is simple and requires minimal equipment, but the physical effort required is high and the risk of injury increases
Solution Approach 1:
The patent replaces the manual mechanical pushing system with an automated mechanical system consisting of a pulley unit that applies radially directed compressive forces. This substitution eliminates the need for workers to manually push band coils, thereby reducing physical exhaustion and injury risk while maintaining process functionality.
Solution Approach 2:
The pulley unit acts as an intermediary mechanism between the band coils and the compressive force application. It translates rotational motion into radial compressive forces that expand the inner diameter of band coils and push them together, mediating the formation process without requiring direct manual intervention.
2Device complexity
If manual pushing of band coils is used, then the equipment requirements are minimal, but the size of multi-part band coils is limited by worker physical performance
Solution Approach 1:
By replacing manual mechanical effort with an automated pulley-based mechanical system, the patent enables the formation of larger multi-part band coils that exceed human physical capabilities. The system can apply sustained compressive forces and handle larger coil assemblies without the limitations of worker strength and endurance.
Solution Approach 2:
The pulley unit provides dynamic control over the compressive forces applied to band coils, allowing adjustment of expansion forces and positioning capabilities. This dynamic control enables the system to handle varying coil sizes and configurations, facilitating the creation of larger multi-part band coils with precise dimensional control.
3Productivity
If a pulley unit with radially directed compressive force is used to expand band coil inner diameter, then larger multi-part band coils can be formed, but the device complexity increases
Solution Approach 1:
The pulley unit is designed to perform multiple functions: it applies radially directed compressive forces to expand band coil inner diameters, positions band coils during assembly, and controls the pushing together of multiple coils. This multi-functionality reduces the need for separate specialized components, thereby limiting the increase in overall device complexity.
Solution Approach 2:
The device structure employs a nested arrangement where the pulley unit operates within a framework that provides structural support and guidance. The band coils are nested around the pulley unit during the forming process, and the limiting structure is nested within the overall device architecture, creating a compact and integrated system.
4Manufacturing precision
If a limiting structure is added to define outer dimensions, then dimensional precision is improved, but the device complexity increases
Solution Approach 1:
The limiting structure is implemented as a localized component within the device framework, providing dimensional control at specific critical points where outer dimensions need definition. Rather than a comprehensive complex system, the limiting structure applies precision control locally where needed, maintaining overall device simplicity while achieving dimensional accuracy.
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
The device enables the formation of larger multi-part band coils with reduced physical effort and risk of injury, allowing for precise control over the outer dimensions and enabling the use of the formed coils in subsequent processing and transport steps.
Implementation Method 1
the bandcoil to be rotated both a radial force and a rotational force under the friction between the pulley unit and the bandcoil inner side undergoes
Data Source
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AI summary
The present invention relates to a device (1) for forming a multi-part strip coil from several individual strip coils. The device (1) is characterized by a winding unit (4), wherein a strip coil (3) can be positioned with its inner surface (8) around the winding unit (4), the device (1) being configured to bring about a relative rotation between the winding unit (4) and a strip coil (3), and the winding unit (4) being able to exert a radially directed compressive force against the inner surface (8) of the strip coil during a relative rotation between the winding unit (4) and the strip coil (3). The present invention further relates to an associated method.