Scrap Matrix Winding Device Tension Control
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Solution Overview
Problem
Scrap matrix winding devices for continuous label paper face challenges in maintaining tension stability and preventing breakage due to variations in roll diameter and mechanical losses, leading to potential vibration and reduced winding speed.
Innovation Solution
A scrap matrix winding device with a peeling roller, a separate winding shaft, movement mechanism, detection systems, and a tension adjusting portion to control the winding shaft's position based on roll diameter, and a touch roller to maintain surface flatness, ensuring minimal distance between the winding shaft and peeling roller, thus stabilizing tension and preventing breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the scrap matrix winding shaft is fixed at a constant position, then the device structure is simple, but the tension applied to the scrap matrix varies due to roll diameter changes causing breakage
Solution Approach 1:
The winding shaft is made movable along the conveyance direction instead of being fixed, allowing its position to be dynamically adjusted according to the roll diameter of the wound scrap matrix. This dynamic positioning maintains constant tension by compensating for diameter variations, resolving the contradiction between structural simplicity and breakage prevention.
Solution Approach 2:
A detection mechanism monitors the roll diameter of the wound scrap matrix and provides feedback to control the winding shaft position. This closed-loop feedback system automatically adjusts the shaft position to maintain optimal tension, preventing breakage while managing device complexity through automated control.
2Strength
If strong tension is applied to the scrap matrix during conveying, then the scrap matrix can be wound tightly, but the scrap matrix may be broken due to tension variation and shrinkage
Solution Approach 1:
The tension parameter is kept constant rather than varying strongly, while achieving winding tightness through maintained constant tension and minimized conveyance distance. This parameter optimization prevents breakage while ensuring adequate winding density.
Solution Approach 2:
Instead of controlling winding quality only through tension magnitude, the solution introduces positional control of the winding shaft along the conveyance direction as an additional control dimension. This allows tight winding to be achieved through position optimization rather than excessive tension.
3Length of moving object
If the scrap matrix path is made long to accommodate processing, then more processing space is available, but the amount of shrinkage increases causing load concentration and breakage
Solution Approach 1:
The winding shaft is positioned optimally in advance along the conveyance direction to minimize the scrap matrix path length from peeling to winding. This preliminary positioning prevents excessive shrinkage and load concentration before the matrix enters the winding process, resolving the contradiction between processing space and breakage prevention.
Data Source
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AI summary
A scrap matrix winding device includes a scrap matrix winding shaft, a vertical movement mechanism, a line encoder, a third sensor, a calculation unit, and a control unit. The scrap matrix winding shaft winds the scrap matrix in a roll shape. The vertical movement mechanism moves the scrap matrix winding shaft away from a fixed type peeling roller. The calculation unit obtains a roll diameter of a scrap matrix roll on the basis of detection results of the line encoder and the third sensor. The control unit controls the vertical movement mechanism to move the scrap matrix winding shaft away from the fixed type peeling roller on the basis of the roll diameter obtained by the calculation unit.