Sequential Rope Coiling via Mandrel Rotation and Basket Release
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Solution Overview
Problem
Existing rope coiling technologies face disruptions in symmetry when coiling long ropes in a stop-and-go manner, particularly in applications like mooring ropes on ship decks, due to frequent stops and starts, which is undesirable for maintaining a neat and functional coil.
Innovation Solution
A method and machine that use a cylindrical mandrel with a rotating basket, where a grab is attached to the rope, forming coils that are then released into a basket without disrupting the symmetry, allowing for continuous coiling in segments with minimal disruption, using a rope guide assembly with a lead screw and half-nut mechanism for consistent coiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the rope is coiled in a stop-and-go manner with frequent stops and starts, then the rope can be handled in segments for work operations, but the symmetry of the coiled rope is disrupted
Solution Approach 1:
The coiling process is divided into discrete segments where the rope is coiled in controlled sections. Each segment is formed by rotating the mandrel a specific number of times to create a predetermined number of coils, then stopping to allow work operations. This segmentation enables both stop-and-go operation and maintains symmetry within each segment.
Solution Approach 2:
The mandrel is pre-positioned and the rope is initially attached to it before coiling begins. This preliminary setup ensures that the rope starts from a controlled position, allowing symmetric coil formation even when the process is interrupted and resumed later.
2Manufacturing precision
If the rope is coiled continuously without stops, then the symmetry of the coil is maintained, but work operations on the rope cannot be performed
Solution Approach 1:
The coiling process follows a periodic cycle: rotate mandrel to form coils, stop for work operations, resume rotation to continue coiling. This periodic action allows regular intervals for maintenance work while maintaining overall coil symmetry through consistent rotational patterns.
Solution Approach 2:
The coiling action continues throughout the process with minimal interruptions. Even when stopped for work operations, the mandrel remains in position and the rope remains attached, allowing immediate resumption of coiling without losing symmetry or requiring repositioning.
3Productivity
If the mandrel rotates at high speed to increase productivity, then more rope can be coiled per unit time, but control over coil symmetry becomes difficult
Solution Approach 1:
The mandrel rotation speed is dynamically adjusted based on the coiling phase. During active coiling, the mandrel rotates at optimized speeds for productivity. During transition phases (starting, stopping, segment completion), the speed is reduced or halted to maintain precision and symmetry.
Solution Approach 2:
The system monitors the coiling process and adjusts mandrel rotation accordingly. The controlled rotation mechanism responds to the position and tension of the rope, ensuring that speed variations do not compromise coil symmetry while maximizing overall productivity.
Data Source
AI summary
A method for sequentially coiling a rope by segments, comprising the steps of attaching a first grab in a rope to the lower rim of a cylindrical mandrel; rotating the mandrel about a vertical axis and forming a plurality of coils including a last coil on the mandrel; stopping a rotation of the mandrel; releasing the first grab and the plurality of coils from the mandrel into a basket rotating under the mandrel. While releasing the first grab, holding a second or subsequent grab along a tail end of the last coil on the mandrel, and repeating the above steps of attaching; rotating; forming; stopping; releasing; holding and repeating, with the second or subsequent grab, until an entire length of the rope has been coiled in the basket. In another aspect, a step of working the rope is carried out between the step of stopping and the step of releasing.