Reel Take-Out Gripper Alignment for Angled Transport Shafts
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Solution Overview
Problem
The process of taking out reels from transport carts is inefficient and prone to damage due to the reels' high load and the angled shafts, leading to increased labor costs and difficulty in handling.
Innovation Solution
A reel take-out device with a gripper unit, first and second driving units, and a controller that adjusts to the shaft's angle to safely remove reels by calculating height differences using sensors, ensuring precise alignment and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the shaft is disposed upward at a certain angle to accommodate high load of the reel, then the reel can be transported, but the reel cannot be taken out in a straight line and may be damaged
Solution Approach 1:
The gripper unit is made movable in both vertical (first direction) and horizontal (second direction) directions, allowing it to dynamically adjust its position and orientation during the reel take-out process. This dynamic capability enables the gripper to accommodate the angled shaft configuration while still achieving straight-line reel extraction, resolving the contradiction between load capacity and ease of operation.
Solution Approach 2:
The invention introduces a second direction of movement (horizontal direction) in addition to the vertical direction, allowing the gripper unit to move in a two-dimensional plane. This dimensional expansion enables the gripper to compensate for the shaft's upward angle by moving horizontally to align with the reel core, thereby enabling straight-line take-out despite the angled mounting.
2Measurement precision
If the worker directly checks the position or direction of the reel, then the reel can be identified, but the time required for work is increased and labor cost increases
Solution Approach 1:
The sensor unit automatically detects the reel's position, direction, and identification information without requiring worker intervention. The system performs self-measurement and automatically controls the gripper unit's movement and the transport cart's operation, eliminating the time-consuming manual checking process while maintaining precise measurement capabilities.
Solution Approach 2:
The invention replaces the manual mechanical checking process with an automated sensor-based detection system. The sensor unit electronically detects reel information and transmits it to the controller, which automatically adjusts the gripper unit's position and the transport cart's movement, substituting human labor with an automated electromechanical system.
3Ease of operation
If the core of the reel is gripped to take it out in a straight line, then the reel can be removed, but the core and shaft may be caught in or fitted to each other
Solution Approach 1:
The sensor unit performs preliminary detection of the reel's position, direction, and identification information before the gripper unit engages with the reel core. This advance information gathering allows the controller to pre-calculate the appropriate movement trajectory and gripper positioning, preventing the core and shaft from becoming entangled during the extraction process.
Solution Approach 2:
The sensor unit continuously monitors the reel's position and the gripper unit's movement, providing real-time feedback to the controller. This feedback mechanism allows the system to dynamically adjust the gripper's position and movement speed, ensuring that the reel core is gripped and extracted without causing the core or shaft to become caught together.
Data Source
AI summary
A reel take-out device and method is provided, in which a reel may be taken out in response to an arrangement angle of a shaft of a transport cart to prevent the reel from being damaged during a take-out process and to increase take-out workability. The reel take-out device comprises a gripper unit gripping a reel core of one or more reels sequentially fitted to a shaft of a transport cart; a first driving unit connected to the gripper unit to elevate the gripper unit in a first direction; a second driving unit connected to the first driving unit to move the first driving unit in a second direction; and a controller controlling driving of the gripper unit, the first driving unit and the second driving unit, wherein the controller controls the first and second driving units to be simultaneously driven to take out the reel in response to an arrangement angle of the shaft along the second direction in a state that the gripper unit grips the reel core.