Pendulum Arm Tension Control for Multi-Element Winding
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Solution Overview
Problem
Existing systems for winding multiple elongated elements on a single spool face issues such as twisting, fractures, and processability problems due to variations in diameter, entanglement, and unequal tensions, which lead to unwinding difficulties and require complex tension measurement and control systems.
Innovation Solution
A system utilizing a single pendulum arm with actuators and balancing arms, along with reversing pulleys, to maintain equal tensions across multiple elongated elements during winding, eliminating the need for individual dancer arms and complex tension controls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual dancer arms are used to control tension of each elongated element, then tension control precision is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple individual tension control mechanisms into a single shared pendulum arm mechanism. Instead of using separate dancer arms for each elongated element, the invention employs one common pendulum arm that responds to the combined tension of all elements, thereby reducing device complexity while maintaining adequate tension control through the collective action of all elements on the shared mechanism.
Solution Approach 2:
The single pendulum arm serves as a universal tension response mechanism for all elongated elements simultaneously. This multi-functional component replaces multiple specialized dancer arms, each dedicated to a single element, thereby simplifying the overall system architecture while still providing tension regulation across all elements through its collective response to their combined tensions.
2Measurement precision
If tension measurement systems are implemented for each elongated element, then tension control accuracy is improved, but cost increases
Solution Approach 1:
The patent combines multiple individual tension measurement and control systems into a single integrated pendulum arm mechanism. Instead of implementing expensive measurement systems for each elongated element, the invention uses one shared measurement response mechanism that captures the collective tension state, thereby reducing costs while maintaining adequate control accuracy through the aggregated information from all elements.
3Productivity
If multiple elongated elements are wound on a single spool, then productivity is improved, but unwinding difficulties increase due to tension variations
Solution Approach 1:
The patent implements a feedback mechanism through the pendulum arm that continuously responds to variations in tension among the elongated elements during winding. This feedback system automatically adjusts the winding process to maintain equal tensions, preventing the unwinding difficulties that would otherwise arise from tension variations when multiple elements are wound on a single spool, thereby ensuring reliable unwinding while maintaining high productivity.
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
Ensures that multiple elongated elements are wound with substantially equal tensions and lengths, reducing unwinding difficulties and fractures, while simplifying tension control and reducing costs associated with precise measurement systems.
Implementation Method 1
one pendulum arm, and one set of actuators acting on the pendulum arm and balancing with the sume of tensions of each elongated element
Implementation Method 2
one pendulum arm, and one set of actuators acting on the pendulum arm and balancing with the sume of tensions of each elongated element
Implementation Method 3
one set of actuators acting on the pendulum arm and balancing with the sume of tensions of each elongated element
Implementation Method 4
A first set of one or more reversing pulleys is positioned at one side of the (first) balancing arm axis corresponding to the first balancing arm. A second set of one or more reversing pulleys is positioned at the other side of the first balancing arm axis. Each pulley of the first set and of the second set of one or more of the reversing pulleys guides an elongated element to be wound on the single spool
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A system (10) for winding multiple elongated elements (12, 14) simultaneously under a substantially same tension on a single spool (16) comprises one pendulum arm (18) and one set of actuators (22) acting on the pendulum arm (18) and balancing with the sum of tensions of each elongated element (12, 14). The system (10) further comprises one or more balancing arms (26, 40): A first balancing arm (26) is attached to the pendulum arm (18), the other balancing arms (if any) are attached to the first balancing arm (26). Each balancing arm (26) is pivotable upon a balancing arm axis (28). A first set of one or more reversing pulleys (30) is positioned at one side of the first balancing arm axis (28) and a second set of one or more reversing pulleys (32) is positioned at the other side of said balancing arm axis (28). Each of the reversing pulleys (30, 32) guides an elongated element (12, 14) to be wound.