Tube Winding Machine Marking Sensor for Precise Cutting
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Solution Overview
Problem
Existing methods for cutting tubes to size on spools suffer from imprecision due to the distance between measuring and cutting devices, leading to non-uniform spool lengths and frequent decalibration of meter-counting wheels, resulting in machine downtime.
Innovation Solution
A method and apparatus that incorporates a sensor for detecting a marking on the tube, a meter-counting device, and a control unit to precisely cut the tube by calculating the time interval between the marking detection and the cutting blade, ensuring accurate cutting regardless of tube deformations, with the measuring and marking unit positioned at a considerable distance from the cutting device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If the measuring device is situated at a large distance from the cutting device, then the tube can be measured and cut in an automated manner, but the longitudinal deformations of the tube cause high imprecision in cutting length
Solution Approach 1:
A marking device is introduced as an intermediary element between the measuring device and the cutting device. The marking device applies a marking on the tube at a predefined distance from the cutting blade, and a sensor detects this marking to trigger the cutting blade. This intermediary marking system eliminates the need for direct measurement-cutting synchronization over long distances, thereby maintaining precision despite tube deformations during transport.
2Measurement precision
If meter-counting wheels are used for measuring the tube, then the tube length can be measured, but frequent decalibration occurs requiring maintenance and machine downtime
Solution Approach 1:
The patent replaces the mechanical meter-counting wheels with an optical/electronic marking and detection system. Instead of using mechanical wheels that physically contact the tube and are prone to decalibration, a marking device applies a visual marking and a sensor detects it to determine tube length. This substitution eliminates mechanical wear and decalibration issues, improving reliability while maintaining measurement precision.
3Device complexity
If the measuring device is positioned far from the cutting device, then the machine dimensions can be reduced, but the tube deformations along the path cause incorrect spool length
Solution Approach 1:
The marking device performs a preliminary action by applying a marking on the tube at a predefined distance from the cutting blade before the cutting operation. This advance marking allows the sensor to detect the exact position where the tube should be cut, compensating for any deformations that occur during transport. The cutting blade then operates at the correct position based on the pre-applied marking, ensuring uniform spool length despite the distance between measuring and cutting devices.
Data Source
AI summary
Machine for winding tubes (1) in spool form, comprising a structure (10) carrying a rotating reel (11), a device for feeding a tube (1) to the reel (11) in a longitudinal direction (X-X), a blade (12) for cutting the tube (1), movable in both senses along a transverse direction (Y-Y), a unit (20) for measuring the length of the tube (1), a device (22) for marking the tube (1) when a predefined length of the tube to be wound is reached, said device being arranged upstream of the machine, and a device (30) for detecting a marking (1b) applied to the tube (1), which device is arranged upstream of the cutting blade (12) at a predetermined distance (D) from said blade in the longitudinal direction (X-X).