Splicing Strip Automation for Continuous Roving Processing
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Solution Overview
Problem
Existing methods for processing rovings, such as splicing, often require manual intervention and disrupt the production process when connecting reserve rovings to working rovings, leading to inefficiencies and potential inconsistencies in the fiber composite semi-finished products.
Innovation Solution
A method and device that automate the splicing process by using a splicing strip aligned at 90° to the roving main conveying direction, where reserve rovings are fixed, decelerated, and accelerated to match the working roving speed, allowing for synchronized splicing with compressed air, and subsequent detachment, enabling continuous production without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual splicing methods are used to connect reserve rovings to working rovings, then the splicing process can be completed, but the production process is interrupted and manual intervention is required
Solution Approach 1:
The splicing device is divided into multiple independent splicing units arranged in a splicing strip, with each unit capable of processing one or more roving pairs. This modular segmentation enables automated processing of multiple rovings simultaneously while maintaining manageable device complexity through standardized reusable components
Solution Approach 2:
A splicing strip serves as an intermediary carrier that holds multiple splicing units and facilitates the automated splicing process. The splicing strip enables systematic organization and movement of splicing units through the production line, automating the previously manual process of connecting reserve rovings to working rovings
2Manufacturing precision
If splicing is performed while maintaining basic conveying speed, then production continuity is maintained, but synchronization and alignment precision are difficult to achieve
Solution Approach 1:
The splicing units are designed with dynamic speed adjustment capability, allowing them to be accelerated to match the basic conveying speed of the working rovings. This dynamic speed matching enables precise synchronization and alignment during splicing while maintaining overall production continuity and high productivity
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the position and speed of splicing units relative to the working rovings. This feedback enables real-time adjustments to ensure precise alignment and synchronization, achieving high manufacturing precision without sacrificing production speed
3Productivity
If multiple reserve rovings are spliced simultaneously using a splicing strip, then productivity is improved, but the device complexity increases
Solution Approach 1:
The splicing device is segmented into multiple identical or standardized splicing units that can process multiple roving pairs simultaneously. This segmentation increases throughput while keeping individual unit complexity manageable, allowing for easier maintenance and operation
Solution Approach 2:
The splicing units are designed with universal characteristics, where each unit can handle one or more roving pairs using similar mechanisms and components. This multi-functionality allows the device to process varying numbers of rovings without requiring completely different mechanisms for each, balancing increased productivity with controlled device complexity
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
Enables the automatic binding of multiple reserve rovings to working rovings without interrupting the production process, ensuring stable connections and high process purity, with minimal operator intervention, allowing for efficient production of fiber composite semi-finished products.
Implementation Method 1
During splicing, splicing air, i.e. compressed air, is used, with which fibers or filaments of the roving ends to be connected are entangled, hooked, swirled and/or twisted.
Implementation Method 2
in at least one alignment step, the splicing strip with the reserve roving(s) fixed thereto is/are accelerated from a basic position to the splicing speed and brought into a splicing plane
Implementation Method 3
in a moving step, at least one of the splice unit parts is moved towards the other splice unit part
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a method and a device (1) for the continuous processing of single or multiple rovings. In this process, working rovings (6) and reserve rovings (5) are supplied by a spool creel (56), and the respective working rovings (6) are spliced with their respective assigned reserve rovings (5) by means of a splice strip (30) in at least one splice unit of the splice strip, each splice unit comprising two splice unit parts (31, 32) and assigned to the working roving/reserve roving pair(s) to be formed. The reserve roving(s) (5) is/are first fixed to the splice strip (30); then the feed rate of the working roving(s) (6) is decelerated to a splicing speed; the splice strip (30) with the reserve roving(s) (5) fixed to it is accelerated from a home position to the splicing speed and brought into a splice plane.then at least one of the splice unit parts (31) is moved towards the other splice unit part (32); thereupon the working roving(s) is/are spliced with the reserve roving(s) by supplying compressed air; and the splice unit parts (31, 32) are moved away from each other; finally, the reserve roving(s) spliced with the working roving(s) is/are detached from the splice strip and reused as the new working roving(s); and finally, the splice strip is returned to its initial position.