Automated Post-Tension Tendon Coiling for Safer Bundle Handling
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Solution Overview
Problem
Manual labor in cutting, coiling, and tying post-tension tendons is costly and poses safety risks, particularly due to the stress on tendons during manual handling and the labor-intensive nature of cutting tightly coiled steel strands.
Innovation Solution
An automated system comprising a conveyor, cutter, and control unit that cuts tendons to a predetermined length, coils them into bundles, and ties them to a predefined diameter, with optional movable seater stations and manipulators for enhanced automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual labor is used for cutting, coiling, and tying tendons, then flexibility and simplicity of operation are maintained, but labor costs increase and worker safety risks arise
Solution Approach 1:
The automated system is divided into distinct functional modules: a conveyor system for feeding tendons, a cutting mechanism for severing tendons at predetermined lengths, a coiling mechanism for forming loops, and a tying mechanism for securing the loops. Each module operates independently but coordinates through the control unit, allowing the complex automation task to be managed through modular components.
Solution Approach 2:
The automated system performs multiple functions (cutting, coiling, and tying) using a single integrated apparatus. The control unit coordinates these diverse operations, and the system can handle different tendon specifications by adjusting parameters through the user interface, making the device universally applicable to various post-tension tendon manufacturing requirements.
2Productivity
If automated cutting, coiling, and tying is implemented, then labor costs decrease and worker safety improves, but device complexity increases
Solution Approach 1:
The cutting, coiling, and tying operations are merged into a single automated workflow within one integrated system. The conveyor feeds tendons sequentially through all three operations without manual intervention, and the control unit coordinates the timing and sequencing of each operation, achieving high productivity through consolidated automated processing.
Solution Approach 2:
The automated system operates autonomously once initiated, with the control unit automatically sequencing the conveyor, cutting, coiling, and tying operations without requiring continuous human intervention. The system serves itself by maintaining the production workflow automatically, reducing labor requirements while maintaining high productivity.
3Reliability
If tendons are manually coiled and handled, then equipment requirements are minimized, but stress on tendons increases and worker safety risks arise
Solution Approach 1:
The automated system acts as an intermediary between the tendon material and the final coiled product, eliminating direct human contact with the tendon during critical operations. The robotic manipulators and automated coiling mechanism handle the tendon with controlled precision, reducing stress concentrations that could compromise tendon integrity while eliminating exposure to worker safety risks.
Data Source
AI summary
Automated systems and processes for manufacturing post-tension tendons may comprise a catapuller configured to introduce a pre-determined length of a tendon into a tub; a cutter configured to cut the tendon when it meets the pre-determined length; and (c) a control unit configured for a user to input the pre-determined length and a pre-determined bundle diameter. The control until is typically operably connected to the cutter and to the tub. Advantageously, the tub is configured to coil the tendon to form a tendon bundle and tie the tendon bundle in the predefined bundle diameter. A movable seater station may be employed to fasten an anchor to one end of the strand and the seater station may be configured to move among two or more tubs. A manipulator may be employed to move and hang coiled tendons