Spool Transfer Gripper Mechanism for Wire Winding Automation
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Solution Overview
Problem
Existing methods for transferring elongated elements from one spool to another during continuous supply are complex, often result in long trailing ends ('pig tails') during unwinding, and require intricate mechanisms, limiting automation and increasing operational complexity.
Innovation Solution
A method involving guiding the elongated element to a second spool using a capstan and pulleys, gripping and cutting it when full, then transferring to an adjacent empty spool without interrupting supply, using a gripper that rotates to form windings on the new spool, eliminating the need for complex mechanisms and temporary storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire is snagged on the shaft of the empty spool or caught between catcher plates, then the transfer can be initiated, but a long trailing end ('pig tail') is formed and the wire cannot be kept on the core until the very last winding
Solution Approach 1:
The gripper is positioned upstream of the second spool and grips the wire before it reaches the spool, allowing the wire to be transferred in a controlled manner without forming long trailing ends. The gripper rotates with the empty spool to wind the wire directly onto the core, eliminating the need for complex catcher mechanisms and preventing pig tail formation.
2Productivity
If a rotatable arm mechanism is used to exchange spools, then continuous winding operation can be maintained, but the mechanism becomes rather complex and requires precise control during continuous operation
Solution Approach 1:
The spool exchange process is segmented into independent steps: the full spool is removed, the empty spool is positioned, and the wire transfer is executed using a simple gripper mechanism. This segmentation allows each step to be performed independently without requiring complex coordinated control, while maintaining continuous production through the accumulator.
Solution Approach 2:
An accumulator is introduced as an intermediary device between the wire supply and the spool. The accumulator temporarily stores wire and releases it at the required rate, decoupling the wire transfer operation from the winding operation. This allows the spool exchange and wire transfer to occur independently without disrupting continuous winding, eliminating the need for complex rotatable arm mechanisms.
3Manufacturing precision
If the gripper grips the wire upstream and rotates to form windings on the empty spool, then the wire can be transferred without forming pig tails, but the apparatus requires precise positioning and control mechanisms
Solution Approach 1:
The gripper is integrated with the empty spool assembly, combining the gripping function with the winding function. As the gripper rotates with the empty spool, it simultaneously performs the winding action, eliminating the need for separate positioning mechanisms. This integration simplifies the apparatus while maintaining precise control over the wire transfer process.
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 seamless, high-speed transfer of elongated elements without speed reduction, simplifies the apparatus, and prevents 'pig tail' issues by maintaining tension and direct winding, allowing full automation and flexibility with spool weights and configurations.
Implementation Method 1
guiding an elongated element to a second spool e.g. by means of a capstan and one or more pulleys
Implementation Method 2
gripping the elongated element by means of the gripper and cutting the elongated element between the gripper and the second spool
Implementation Method 3
rotating the gripper around the axis of the first spool to form windings of the elongated element on the first spool
Data Source
AI summary
An elongated element (10) is transferred from a second (full) spool (13) to a first (empty) spool (14). A gripper (16) is positioned on the elongated element (10). The gripper (16) catches the elongated element (10) and the elongated element (10) is cut between the gripper (16) and the second spool (13) thereby leaving a leading end (19). Thereafter the gripper (16) is positioned with the leading end (19) at the level of the first empty spool (14). The gripper (16) is rotating around the axis of the first spool (14) to form first windings to fix the elongated element (10) on the first spool (14). The method allows full automation and assures the use of the wound element (10) until its final end.