Unreeling Reel Crown Overload Release for High-Speed Wire Safety

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Solution Overview

Problem

Existing unreeling apparatuses are not designed to ensure operational safety at high working speeds, particularly when dealing with thicker wires, as they can be torn out of their foundation due to sudden high forces during wire knotting or other issues, leading to potential damage and injury.

Innovation Solution

The implementation of an unreeling apparatus with a safety apparatus featuring an overload safety device and a safety guide track, which includes a directional component and a press-down device, along with an aboveground displacement device and tilting mechanism, to stabilize the reel crowns and absorb residual forces, preventing damage and ensuring safe operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a multiple reel (double reel) configuration is used to increase working speed, then productivity is improved, but the risk of high forces tearing the apparatus out of its foundation increases due to potential wire knotting and sudden stops

Engineering Contradiction:

Improveworking speedVSAvoidoperational safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The reel crown is divided into two independent halves that can separate from each other along the safety guide track. This segmentation allows one half to remain stationary while the other moves freely in case of overload, providing both high-speed operation capability and safety against foundation damage

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A safety guide track is introduced as an intermediary element between the reel crown and the foundation. This track guides the movement of the reel crown half during overload conditions, allowing controlled displacement that absorbs residual forces and prevents the apparatus from being torn out of its foundation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If the reel crown is firmly fixed to the foundation to prevent movement, then stability is improved, but the apparatus cannot absorb sudden high forces during wire knotting without being torn out

Engineering Contradiction:

Improvereel crown stabilityVSAvoidfoundation damage risk

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The reel crown is designed with dynamic characteristics, allowing it to transition from a fixed state during normal operation to a movable state during overload. The safety guide track enables controlled movement when forces exceed safe limits, transforming the system from statically stable to dynamically adaptable

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The safety guide track and overload safety device provide beforehand cushioning by allowing the reel crown half to move along the track before residual forces can damage the foundation. This pre-planned movement path absorbs the shock of sudden stops and prevents foundation damage

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If the unreeling apparatus is stopped immediately upon detecting wire knotting, then operational safety is improved, but residual forces can still tear the apparatus out of its foundation

Engineering Contradiction:

Improveoperational safetyVSAvoidresidual force absorption

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The safety guide track is pre-configured to provide a movement path for the reel crown half before residual forces can cause damage. This preliminary arrangement allows the system to naturally absorb forces through controlled movement rather than requiring immediate stopping

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The harmful residual forces that would normally tear the apparatus out of its foundation are converted into beneficial controlled movement along the safety guide track. The reel crown half moves in the direction of the acting forces, transforming destructive energy into a safe displacement that protects the foundation

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Data Source

PatentUS11111101B2Unreeling apparatus and method

Publication Date: 2021.09.07 SMS GROUP GMBH

AI summary

In order to increase the operational safety of an unreeling apparatus and an unreeling method at high working speed, an unreeling apparatus for unreeling a ring of wire along a pull-off direction, having at least two reel crowns, which can each be brought into a pull-off position and into a preparation position and/or loading position by way of a displacement device, includes a safety apparatus having an overload safety device and having a safety guide track, which has a directional component that faces in the pull-off direction and acts independently of the other reel crown, at least for the reel crown situated in the pull-off position, wherein the overload safety device holds the reel crown situated in the pull-off position in the pull-off position and, in the event of an overload, releases the reel crown situated in the pull-off position into the safety guide track.