Spring-Mounted Winding Mandrel for Liner Hose Tension Control
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Solution Overview
Problem
The existing winding mandrels for producing liner hoses face issues with mechanical stress differences and folds due to fabrication-caused tolerances in the inner film hose diameter, which affect the strength of the liner hose after curing, as the mandrel diameter cannot be adjusted during production and results in either excessive stretching or insufficient tension.
Innovation Solution
A winding mandrel with a spring-mounted belt system that maintains constant tension on the inner film hose, allowing the mandrel diameter to adjust automatically during production, ensuring consistent tension and preventing mechanical stress differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the winding mandrel diameter is set based on nominal film diameter, then the device structure remains simple and easy to operate, but fabrication tolerances cause mechanical stress differences and folds in the film
Solution Approach 1:
The patent converts the static mandrel structure into a dynamic one by introducing spring-mounted guide mechanisms that can automatically adjust their position. The springs allow the guide mechanisms to move radially, enabling the mandrel to dynamically adapt to actual film diameter variations during production, thus maintaining uniform film tension despite fabrication tolerances.
Solution Approach 2:
The patent changes the physical state of the mandrel from fixed to adjustable by incorporating spring elements. These springs allow radial movement of the guide mechanisms, changing the effective mandrel diameter parameter to match the actual film diameter, thereby eliminating mechanical stress differences caused by diameter mismatches.
2Reliability
If the winding mandrel diameter is increased to accommodate larger film tolerances, then film shifting is prevented, but excessive stretching occurs when the film diameter is smaller
Solution Approach 1:
The patent implements a self-adjusting mechanism where the spring-mounted guide mechanisms automatically adapt to the actual film diameter without external intervention. The springs self-regulate the radial position of the guides based on the film's actual dimensions, preventing both film shifting and excessive stretching through automatic tension equalization.
Solution Approach 2:
The spring elements act as cushioning elements that anticipate and compensate for diameter variations before they cause problems. The springs are pre-loaded to provide a baseline tension that prevents film shifting, while their elasticity allows them to absorb excess tension when the film diameter is smaller, preventing over-stretching.
3Strength
If the winding mandrel diameter is decreased to prevent film stretching, then film strength is maintained, but the film does not sit firmly and can shift during winding
Solution Approach 1:
The dynamic spring-mounted guide mechanisms allow the mandrel to adapt its diameter during operation. The springs provide enough tension to keep the film firmly seated while allowing radial movement to prevent over-tensioning, thus simultaneously maintaining film strength and preventing shifts.
4Manufacturing precision
If the winding mandrel diameter is adjusted for each film batch, then uniform film tension is achieved, but production time increases due to re-adjustment requirements
Solution Approach 1:
The spring-mounted guide mechanisms automatically adjust to each film batch's actual diameter without requiring manual intervention. The springs self-regulate the radial position based on the film's dimensions, maintaining uniform tension throughout production while eliminating the time-consuming manual re-adjustment process.
Solution Approach 2:
The springs are pre-configured to provide the necessary tension range to accommodate normal fabrication tolerances. This beforehand cushioning allows the system to handle diameter variations automatically during production, maintaining precision without sacrificing productivity through frequent adjustments.
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
The spring-mounted belt system ensures consistent tension on the inner film hose, compensating for fabrication-caused diameter variations, resulting in a liner hose with reduced mechanical stress and improved strength during curing.
Implementation Method 1
the circulating belt (16) of the second guide mechanism (12) can be moved in a plane extending perpendicularly to the feed direction (A) and is forced away from an upper side of the base body (8) by means of a pressing means (18; 118) with a substantially constant force
Data Source
AI summary
A winding mandrel (1) in a winding apparatus for producing a liner hose (2) for the lining of channels and pipelines, which comprises an inner film hose (4) and a layer arranged thereon made of at least one fibrous strip (6) wound in an overlapping manner, which is impregnated with a liquid reaction resin, with a base body (8), on which at least two guide mechanisms (10, 12) are accommodated, each comprising a continually circulating belt (14, 16), by means of which the inner film hose (4) is moved in a feed direction (A), is characterized in that the first guide mechanism (10) is coupled by fixed mounting to the base body (8), and in that the circulating belt (16) of the second guide mechanism (12) can be moved in a plane extending perpendicularly to the feed direction (A) and is forced away from the upper side of the base body (8) by means of pressing means (18; 118) with a preferably substantially constant force.