Split Reel Coiling Machine for Heavy Spools

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Solution Overview

Problem

Existing coiling machines for large-size and heavy spools face issues with structural failures due to cantilevered spool support, leading to non-uniform coiling, axial misalignment, and limitations in spool size, as well as difficulties in automatic tying and central unloading.

Innovation Solution

A coiling machine with two displaceable half-reels that rotate about a longitudinal axis, allowing for adjustable internal diameter and height, and a strap-tying mechanism using inner and outer semi-channels and a tying unit to securely coil and tie large-size and heavy spools without preliminary unloading.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the spool is supported in a cantilevered manner by the rotating drum, then the coiling operation can be performed, but high flexural moments are generated causing breakages and structural failures

Engineering Contradiction:

Improvecoiling operationVSAvoidreel structure

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The rotating reel is divided into two separate half-reels (first half-reel and second half-reel) that can be displaced independently along the axis of rotation. This segmentation allows the spool to be supported at both ends rather than in a cantilevered manner, distributing the load and eliminating the high flexural moments that caused structural failures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of supporting the spool from one side (cantilevered support), the invention inverts the support approach by providing support from both sides (bilateral support). The half-reels can be displaced to close against each other, providing support at both ends of the spool, which reverses the problematic single-side support configuration.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If the spool weight projects on the reel, then the spool can be supported during coiling, but flexural forces are generated causing axial misalignment and non-uniform coiling

Engineering Contradiction:

Improvespool supportVSAvoidcoiling uniformity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

By segmenting the reel into two independently displaceable half-reels, the spool weight is distributed to both half-reels rather than concentrating it on one side. This bilateral support configuration eliminates the flexural forces that caused axial misalignment and non-uniform coiling, ensuring the spool remains properly aligned throughout the coiling process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The half-reels can be displaced along the axis of rotation to adjust their position, allowing optimization of the support configuration. This parameter change enables the system to adapt to different spool sizes and weights while maintaining proper alignment and uniform coiling by distributing the load appropriately.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If the reel structure is designed for cantilevered support, then the coiling machine can operate, but the final width of wound spools is limited by structural strength

Engineering Contradiction:

Improvecoiling operationVSAvoidspool width

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The segmentation of the reel into two independently displaceable half-reels removes the structural limitation on spool width. With bilateral support, the reel structure can accommodate much wider spools (up to 4 meters in diameter as mentioned in the patent) without experiencing the flexural forces that limited previous single-side supported designs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The half-reels are designed to be displaceable along the axis of rotation, allowing dynamic adjustment of the reel configuration. This dynamic capability enables the machine to handle various spool sizes and widths by adjusting the position of the half-reels, greatly increasing the adaptability and versatility of the coiling machine.

Inventive Principle:

Principle #15Dynamics

4Productivity

If automatic tying is implemented, then the production cycle is improved, but the machine complexity increases

Engineering Contradiction:

Improveproduction cycleVSAvoidmachine structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The tying device is merged with the rotating reel assembly, with the tying mechanism integrated into the reel structure. The semi-channels are formed as part of the half-reels, and the tying operation is combined with the coiling operation. This integration allows automatic tying to be performed during the coiling process without requiring separate handling or unloading steps, improving productivity while managing complexity through consolidation.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9114896B2Coiling pipes in spool form and tying said spool

Publication Date: 2015.08.25 F B BALZANELLI AVVOLGITORI

AI summary

A machine for coiling pipes in the form of large-size heavy spools includes a reel rotating about a longitudinal axis for coiling the pipes fed to the reel in a feeding direction, the reel including: a first rotating half-reel; a second half-reel coaxial with and arranged opposite the first half-reel in the longitudinal direction; said first and second half-reels being displaceable in both senses of the longitudinal direction from a relative position where the two half-reels are closed in contact with each other in the longitudinal direction for coiling the spool, to a position where the two half-reels are separated from each other for unloading the finished and tied spool; and an assembly for tying the spool using a strap.