Reel Flange Sensor Control for Automatic Traverse Turnaround
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current spooling and coiling systems require manual adjustment of limit switches for each reel and spool, posing safety hazards and leading to imprecise adjustments, especially during spool changes, and lack automation for precise winding.
Innovation Solution
An apparatus with electrical sensors mounted on a traversing mechanism to detect reel flanges, providing automatic turnaround points and computer control for precise winding without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual adjustable limit switches are used for each reel and spool, then the system can detect turnaround points, but the adjustment process requires operator entry into the machine creating safety hazards and imprecise adjustments
Solution Approach 1:
The patent replaces manual mechanical adjustment of limit switches with an automated optical sensor system. The sensor detects the presence of the reel flange and automatically signals the controller to adjust the turnaround point, eliminating the need for operators to physically enter the machine and manually adjust mechanical switches, thereby resolving the safety hazard while maintaining precision
Solution Approach 2:
The system performs self-adjustment of the turnaround point through automated sensor detection and controller response. The sensor automatically detects the flange position and the controller automatically adjusts the turnaround point without requiring manual intervention, making the system self-servicing and eliminating safety risks associated with manual adjustment
2Ease of operation
If manual adjustment of end stops is performed during spool changes, then the traverse reversal point can be corrected, but the process is time-consuming and leads to non-precise adjustments
Solution Approach 1:
The patent replaces manual mechanical adjustment of end stops during spool changes with an automated optical sensor system. The sensor detects the flange position and the controller automatically calculates and adjusts the turnaround point, eliminating the need for workers to manually readjust end stops and significantly reducing spool changeover time while improving precision
Solution Approach 2:
The system uses feedback from the optical sensor to automatically adjust the turnaround point during spool changes. The sensor provides real-time detection of the flange position, and the controller uses this feedback to automatically calculate the correct turnaround point, eliminating manual adjustment and reducing changeover time
3Reliability
If automated sensor systems are implemented, then precision and safety are improved, but device complexity increases
Solution Approach 1:
The patent replaces complex manual mechanical adjustment systems with a simpler automated optical sensor system. The optical sensor and controller work together to automatically detect flange positions and adjust turnaround points, reducing the need for complex mechanical adjustment mechanisms while improving reliability and consistency of the winding process
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
Enables precise, efficient, and safe winding with reduced manual adjustments, ensuring consistent product quality and increased safety by eliminating the need for manual adjustments and improving ergonomics.
Implementation Method 1
an optical sensor to detect a presence of the flange
Data Source
AI summary
An apparatus, system and method for a new and improved coiling system that provides sensors to a computer control on the traverse while winding wherein the sensors mounted on the traversing mechanism to detect flanges of different width or reel and spools as the flanges are approached during winding that provides an automatically turnaround point without human intervention and is computer controlled with communication from the sensor.