Saddle-Stitch Reel Rotation Detection for Accurate Wire Presence
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Solution Overview
Problem
Existing sheet bundle binding apparatuses face issues with erroneous detection of wire presence on reels due to reduced variation in spring plate guide position and increased manufacturing costs, especially when using various reel shapes, leading to potential wire depletion during binding operations.
Innovation Solution
A sheet bundle binding apparatus with a rotation detecting mechanism that includes a reel support unit, a rotation detecting mechanism with an adhering member and rotating member, and a control unit to accurately detect reel rotation and wire presence, preventing transport and binding operations when the reel is not rotating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the spring plate guide position variation method is used to detect wire presence, then the detection system is simple, but erroneous detection occurs when the remaining wire amount is reduced
Solution Approach 1:
The patent introduces a reel rotation detection mechanism as an intermediary to indirectly detect wire presence. Instead of directly detecting wire presence through spring plate guide position, the system detects reel rotation through an adhering member and rotating member, which serves as a mediator between the wire unwinding process and the detection system. This resolves the contradiction by providing more reliable detection accuracy while maintaining reasonable system complexity.
2Measurement precision
If direct wire detection method is employed, then manufacturing cost increases and detecting part wears due to contact with wires
Solution Approach 1:
The patent uses the reel rotation as an intermediary indicator of wire presence. The adhering member adheres to the reel bottom face and rotates together with the reel, transferring rotational motion to the rotating member without direct contact between the detection system and the wire. This non-contact detection method eliminates wear on detecting parts and reduces manufacturing costs compared to direct wire detection methods.
Solution Approach 2:
The patent replaces direct mechanical contact detection with a rotational detection mechanism. Instead of using detecting parts that physically contact the wire, the system uses a rotation detection mechanism that detects reel rotation through magnetic or optical sensors, substituting mechanical contact with a non-contact sensing method that reduces wear and manufacturing complexity.
3Measurement precision
If reel rotation is detected using a sensor, then wire presence can be detected, but it is difficult to suitably detect rotation of various shapes of reels
Solution Approach 1:
The patent designs a universal detection mechanism where the adhering member adheres to the bottom face of the reel regardless of its shape. The rotating member with an insertion hole that receives the support shaft creates a universal interface that works with reels of various shapes. This universal design allows the same detection mechanism to accurately detect rotation of different reel types, resolving the contradiction between detection accuracy and adaptability.
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 apparatus effectively detects reel rotation and wire presence, preventing binding operations when the reel is empty, reducing erroneous detections and maintaining operational efficiency across various reel shapes.
Implementation Method 1
an adhering member rotated about the axis together with the reel while adhered to a bottom face of the reel
Data Source
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AI summary
Provided is a saddle stitch folding apparatus including: a stitcher unit; a reel support unit 20 configured to support a reel 200 rotatably about the axis A with a support shaft 21 being inserted in a through-hole 201 formed in the reel 200; and a rotation detecting mechanism 30 configured to detect a rotation state of the reel 200, and the rotation detecting mechanism 30 has an adhering member 31 that is rotated while adhered to a bottom face 202 of the reel 200, a rotating member 32 having an insertion hole inserted in the support shaft 21, and a rotation detecting unit 33 configured to detect the rotation state of the rotating member 32.