Web Winder Central Drive Mechanism for Reel Change
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing winders require pre-winding stations and are limited to specific winding directions, leading to inefficiencies and inconsistent winding conditions, especially when changing reels and handling films with asymmetric layer structures.
Innovation Solution
A winder design with two independently driven central drives that alternate between parking and winding positions, a movable contact roller unit, and slitting units for precise control of film web positioning and cutting, allowing for both left-hand and right-hand winding without a pre-winding station and maintaining consistent contact pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pre-winding station is used to prepare reels before winding, then winding conditions can be improved, but device complexity and assembly space requirements increase
Solution Approach 1:
The patent removes the pre-winding station from the system entirely. The central drive unit directly winds the reel without any preliminary preparation station, simplifying the overall device structure while maintaining reliable winding through direct central driving and controlled contact pressure application.
Solution Approach 2:
The central drive unit serves multiple functions: it provides the driving force for winding, controls contact pressure, and enables both left-hand and right-hand winding directions. This multi-functionality eliminates the need for separate pre-winding equipment while maintaining winding quality.
2Reliability
If a pre-winding station is used to prepare reels, then winding quality can be improved, but assembly space requirements increase
Solution Approach 1:
The pre-winding station is completely removed from the system. The compact central drive unit with movable contact roller provides all necessary winding functions in a space-efficient configuration, eliminating the need for additional pre-winding equipment and reducing overall assembly space requirements.
Solution Approach 2:
The patent transitions from a horizontal pre-winding station configuration to a vertical central drive arrangement where the contact roller moves vertically to apply pressure. This dimensional change allows the winding function to be performed in a more compact footprint.
3Device complexity
If the contact roller is fixed during winding, then structural simplicity is maintained, but winding conditions become inconsistent as reel size changes
Solution Approach 1:
The contact roller is designed to be movable rather than fixed. It can adjust its position vertically to maintain consistent contact pressure with the reel surface as the reel diameter changes during winding, ensuring reliable and consistent winding conditions throughout the process.
Solution Approach 2:
The movable contact roller system provides continuous contact with the reel, allowing for automatic adjustment and maintenance of optimal contact pressure. This feedback mechanism ensures consistent winding conditions by adapting to changing reel dimensions in real-time.
4Device complexity
If the winder is designed for a single winding direction, then device simplicity is maintained, but adaptability to different downstream processes is limited
Solution Approach 1:
The central drive unit is designed to accommodate both left-hand and right-hand winding directions. The movable contact roller and adjustable guide structures enable the same basic mechanism to perform both winding directions, providing versatility for different downstream processing requirements without increasing fundamental device complexity.
Solution Approach 2:
The winding mechanism includes adjustable and movable components that can be reconfigured for different winding directions. The contact roller and guide structures can be dynamically adjusted to accommodate either left-hand or right-hand winding as needed.
Data Source
AI summary
A device for winding and changing reels of web material includes two independently operable central drives for shifting winding shafts, a drivable winding shaft guide, a contact roller unit and slitting units. Both right-hand winding and left-hand winding are realized, whereby the device is without a prewinding station. For a winding shaft change, the drivable winding shaft guide is driven from the winding position into the parking position and is disconnected. Subsequently, the second central drive is connected to the winding shaft guide and is driven from its parking position into the winding position where the second central drive is connected with a new winding shaft. The contact roller unit is driven against the winding shaft and the web material is cut through by a slitting device and then wound to a new reel.