Material Strand Segmentation for High-Speed Spool Changes
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Solution Overview
Problem
Conventional suction guns struggle to handle voluminous material strands with high deniers, requiring production speed adjustments that lead to undesirable property changes in the material during the extrusion process.
Innovation Solution
A method and device that divide the material strand into two partial strands before spool change, allowing one to be cut and picked up by a suction device while the other is used for bobbin change, utilizing a movable separating means to ensure clear separation and efficient handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional suction guns are used to pick up voluminous material strands with high deniers, then the strand can be handled during spool change, but the production speed must be reduced which causes undesirable changes in material properties
Solution Approach 1:
The material strand is divided into two separate partial strands immediately before the spool change point. One partial strand is designated for continuous winding while the other is designated for spool change operations. This segmentation allows the suction gun to handle only the thinner partial strand during spool change, maintaining high production speeds without compromising material properties, while the other partial strand continues to be wound normally.
2Ease of operation
If production speed is reduced to allow manual removal of finished coil, then spool change can be performed, but material strand properties change undesirably
Solution Approach 1:
By dividing the material strand into two partial strands, the system enables spool change operations to be performed on one partial strand without affecting the continuous production and properties of the other partial strand. This allows spool changes to proceed without reducing overall production speed, thereby maintaining material strand properties.
Solution Approach 2:
One partial strand is extracted from the main material flow specifically for spool change operations. This extracted partial strand can be handled independently by the suction gun during spool change, while the main material continuation proceeds uninterrupted at high speed, preventing any undesirable changes in material properties.
3Ease of manufacture
If conventional suction guns are used, then standard tools can be employed, but they cannot accommodate voluminous strands with high deniers
Solution Approach 1:
The material strand is segmented into two partial strands with different thicknesses. The thinner partial strand is specifically prepared for handling by conventional suction guns, which have limited capacity. This allows standard tools to be used without modification while still enabling the processing of high-denier material through strategic division.
Solution Approach 2:
Different sections of the original material strand are given different qualities after division. One partial strand maintains the original high-denier characteristics for continuous winding, while the other partial strand is prepared with suitable characteristics for suction gun handling during spool change operations.
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 reliable bobbin changes at high production speeds without altering the extrusion speed, maintaining material properties and minimizing material loss, using conventional suction guns and mechanical separation for efficient strand management.
Implementation Method 1
a first partial strand is cut before winding and picked up and removed by a suction device
Implementation Method 2
a second partial strand is used for the spool change and guided by the suction gun
Data Source
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AI summary
A method and a device for winding a strand of material (9) is described, which can be produced from one or more ribbons in an upstream extrusion plant (1). In this process, the strand of material (9) is wound discontinuously into spools (18) at the end of the extrusion process on a spool spindle (8.2) and, during a spool change, is picked up by a suction gun (11.1) and guided to a waste container (11.2). In order to avoid production interruptions during spool changes when working with material strands with high titers and relatively high production speeds, the material strand (9) is divided into two partial strands (9.1, 9.2) immediately before the spool change, wherein a first partial strand (9.1, 9.2) is cut before winding and picked up and removed by a suction device (13, 13.1) and wherein a second partial strand (9.1, 9.2) is used for the spool change and is guided by the suction gun (11.1).For this purpose, an auxiliary device (11) has a dividing device (12) arranged upstream in the material flow, by which the material strand can be divided.