Spool Production Line Robotic Reel Loading Automation
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Solution Overview
Problem
The existing systems for loading parent reels onto unwinding stations in spool production machines are cumbersome and time-consuming, requiring complex operations due to the heavy and large size of the reels, which hampers the efficiency of spool production, especially when transitioning between parent reels.
Innovation Solution
A spooling line with an unwinding section featuring at least two unwinding stations, a winding station, and a feed path, equipped with an upender and a loading robot, such as an anthropomorphic robot, to simplify and expedite the handling of parent reels, including a welding station for seamless reel changes and a cutting station to manage web material into longitudinal strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual loading operations are used for parent reels, then operational flexibility is maintained, but loading time and complexity increase significantly
Solution Approach 1:
The loading robot autonomously performs the reel loading operation without human intervention. The robot picks up parent reels from the storage area, transports them to unwinding stations, and positions them on mandrels automatically, making the system self-servicing for this repetitive task.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system. The loading robot uses mechanical arms, sensors, and control systems to perform loading tasks that were previously done manually, reducing both time and human labor requirements.
2Manufacturing precision
If complex manual operations are used to handle heavy parent reels, then precise positioning can be achieved, but operational complexity and time consumption increase
Solution Approach 1:
The patent replaces complex manual positioning operations with an automated robotic system equipped with sensors and control algorithms. The robot achieves precise positioning through automated control rather than complex mechanical adjustment mechanisms, simplifying the overall system while maintaining precision.
Solution Approach 2:
The loading robot acts as an intermediary between the parent reel storage area and the unwinding stations. It handles the heavy reels, performs positioning, and coordinates with the unwinding system, reducing the complexity at each individual station while maintaining overall precision.
3Productivity
If multiple unwinding stations work alternately, then continuous production is maintained, but system complexity increases
Solution Approach 1:
The loading robot serves multiple functions: it loads reels onto unwinding stations, transports reels between stations, and manages reel storage. This multi-functional approach allows the system to maintain continuous production without requiring separate specialized equipment for each function, thereby reducing overall complexity.
Solution Approach 2:
The robot prepares parent reels in advance by positioning them in the storage area and pre-positioning them at unwinding stations before they are needed. This preliminary action allows unwinding stations to operate continuously without waiting for manual reel preparation, maintaining productivity while simplifying operational coordination.
Data Source
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AI summary
The line comprises: an unwinding section (3) for unwinding parent reels (Ba, Bb, Bm) of web material (Na, Nb), with at least a first unwinding station (5; 7); at least a winding station (15) downstream of the unwinding section (3); a feed path from the unwinding section (3) toward the winding station (15); The unwinding section (3) is associated with a loading arrangement of the parent reels (Bm), which comprises: an upender (253; 306) configured to upend the parent reels (Bm) positioning them with their axis horizontal; and a loading robot (263; 313), configured to position a parent reel (Bm; Ba, Bb) on an unwinding mandrel (9) of the unwinding section (3).