Reel-to-Reel Working Table With Dynamic Balance Control
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Solution Overview
Problem
In reel-to-reel processes, the long distance between supply and collection reels leads to a high risk of wrinkles in flexible workpieces due to folding or bending, and existing solutions do not adequately address the weight variations and imbalance issues during processing.
Innovation Solution
A working table with a base, balance adjusters, and a controller to maintain balance by adjusting the weight distribution between supply and collection reels, using a balance drive unit and sensors to ensure stable processing and prevent wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the supply reel and collection reel are arranged adjacent to each other, then the structure is compact, but the workpiece must travel a long distance and pass through many rollers causing wrinkles
Solution Approach 1:
The patent changes the spatial arrangement from a linear/planar configuration to a three-dimensional configuration by placing the supply reel and collection reel at different heights (vertical dimension) and using guide rollers arranged in multiple levels. This dimensional change allows the workpiece to travel a shorter path while maintaining compact footprint, reducing the number of rollers the workpiece must pass through and minimizing wrinkle formation.
2Manufacturing precision
If the supply reel and collection reel are arranged far apart, then the workpiece travel path is short, but the machine occupies more space
Solution Approach 1:
The patent utilizes vertical stacking and multi-level arrangement of rollers to create a compact three-dimensional work path. The supply reel and collection reel are positioned at different heights, and guide rollers are arranged in multiple levels, allowing the workpiece to traverse a short effective path while the machine maintains a small footprint area.
3Adaptability or versatility
If the supply reel and collection reel have different weights during processing, then the reels can operate independently, but the base becomes unbalanced causing processing errors
Solution Approach 1:
The patent employs a balance weight mechanism that includes adjustable counterweights on the base. These counterweights can be positioned and adjusted to compensate for the weight difference between the supply reel and collection reel during processing, maintaining the center of gravity of the base and preventing processing errors caused by base imbalance.
Solution Approach 2:
The balance weight mechanism is designed to be adjustable during operation. As the supply reel empties and the collection reel fills, creating dynamic weight changes, the balance weights can be repositioned to maintain equilibrium throughout the processing cycle, allowing independent reel operation while preserving base stability.
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 solution maintains the center of gravity constant, improving processing quality and reducing wrinkles by precisely controlling the balance and tension of the workpiece, enhancing the precision and quality of processed products.
Implementation Method 1
at least one balance adjuster installed on the base and configured to be moved according to weight variations of the supply reel and the collection reel
Implementation Method 2
At least one sensor may be stalled on the base to measure inclination of the base
Data Source
AI summary
A working table for a reel-to-reel process includes: a supply reel configured to supply a workpiece; a collection reel configured to collect the workpiece after the workpiece is processed; a base on which the supply reel and the collection reel are installed; a processing workbench installed on the base to process the workpiece thereon; at least one balance adjuster installed on the base and configured to be moved according to weight variations of the supply reel and the collection reel; a balance drive unit configured to drive the at least one balance adjuster; and a controller configured to control the balance drive unit.