Pipe Shell Winding With Belt Discharge and Hot-Air Core Heating
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Solution Overview
Problem
Existing methods for manufacturing pipe shells from insulating material result in high cycle times and poor control over the pressing force, leading to suboptimal bulk density and quality of the finished product due to the high wrap-around angle of the belt around the core.
Innovation Solution
The method involves removing the wound-up web of insulating material in a radial direction different from its feeding direction, using a single belt for both winding and unwinding, and incorporating a gas-permeable core for internal heating with hot air to rapidly harden the binding agent, allowing for synchronized belt operation and reduced cycle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a high wrap-around angle of the belt around the core is used, then the web of insulating material can be effectively wound and pressed, but the inserting of a new core and the removing of a completely wound core becomes very time-consuming and complex
Solution Approach 1:
The belt path is segmented into distinct sections: a first section that wraps around the core at a reduced angle (less than 180°) for easy core insertion and removal, and a second section that provides the necessary pressing force through deflection rollers. This segmentation allows the belt to perform multiple functions without requiring a high wrap-around angle throughout its entire path, thereby reducing cycle time while maintaining manufacturing precision.
Solution Approach 2:
Deflection rollers are introduced as intermediary elements that redirect the belt path to provide the necessary pressing force without requiring the belt to wrap around the core at a high angle. These rollers act as mediators between the belt and the core, enabling effective compression of the insulating material while keeping the wrap-around angle low for faster core changes.
2Productivity
If a high wrap-around angle of the belt around the core is used, then the web of insulating material can be effectively pressed, but the pressing force can be controlled only poorly
Solution Approach 1:
The pressing force is made dynamic and adjustable through the deflection rollers, which can be positioned at different locations and angles to control the belt's wrapping behavior. This allows the pressing force to be optimized for each specific winding stage, improving bulk density control while maintaining high winding efficiency. The system transitions from a static high wrap-around angle to a dynamic, adjustable pressing mechanism.
Solution Approach 2:
The wrap-around angle and pressing force are changed as parameters throughout the winding process. The belt provides different levels of pressing force at different sections: minimal pressing during initial web placement, and controlled pressing through deflection rollers as winding progresses. This parameter change approach allows efficient winding while maintaining precise control over bulk density.
3Reliability
If the core is heated strongly to harden the binding agent, then the hardening process is effective, but the inner diameter of the pipe shell is burnt in
Solution Approach 1:
The heating function is extracted from the core itself and transferred to a separate heating device positioned in the discharge area. This allows the core to be heated indirectly through the insulating material without direct contact with high-temperature heat sources, preventing the inner diameter from burning while still achieving effective binding agent hardening. The heating function is separated from the core structure to eliminate the harmful effect.
Solution Approach 2:
The insulating material itself acts as an intermediary medium for heat transfer. Instead of directly heating the core at high temperatures, the heating device warms the insulating material, which then conducts heat to the binding agent throughout the pipe shell. This intermediary approach distributes heat more evenly and prevents localized burning of the inner diameter while maintaining reliable hardening.
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 cycle times, improves the quality of the pipe shell by ensuring even temperature distribution and rapid hardening, and minimizes material loss by stabilizing the pipe shell during removal, thus enhancing production efficiency and product quality.
Implementation Method 1
incorporating a gas-permeable core for internal heating with hot air to rapidly harden the binding agent
Data Source
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AI summary
The invention relates to a method and a device for manufacturing a pipe shell from an insulating material by means of which the cycle times can be further reduced while the quality of the pipe shell is simultaneously improved, by at least one web of the insulating material which is provided with a binding agent being wound around a core (19) by means of at least two opposing belts (12, 13) which wrap around the core (19) partially. The method steps are characterized in that the at least one wound-up web of insulating material is removed in a radial direction of the core (19) which is, however, not opposite to the direction in which the at least one web of insulating material was fed by the one belt (12), especially by the wound-up web being discharged by the same belt (12).