Web Winding Apparatus with Folding Finger for Camber Reduction
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Solution Overview
Problem
Existing methods for winding narrow web materials often subject them to camber, which can cause permanent deformation, especially when using level winding processes, and there is a need for an alternative that minimizes camber exposure.
Innovation Solution
A method and apparatus for winding and unwinding web materials with multiple narrow lanes, where each lane is wound up to a maximum radial height, folded to pass across and alongside the spool, and then realigned parallel to adjacent lanes, using a folding finger and bonding device to manage the web material, and a controlled traverse system to minimize camber during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If level winding process is used to provide stable roll, then roll stability is improved, but web material is subjected to camber causing permanent deformation
Solution Approach 1:
The winding process is segmented into distinct phases: winding phase where web is deposited in straight lanes, and traverse phase where web moves to next lane position. This segmentation allows the web to be wound without camber for most of the time, only experiencing camber briefly during lane transitions.
Solution Approach 2:
The winding process uses periodic index wind motion, where the web is wound in-line for a predetermined number of layers, then traverses to the next lane position. This periodic action minimizes camber exposure by confining it to discrete traverse periods rather than continuous exposure.
2Productivity
If web material is traversed across lanes during winding, then multi-lane spool is formed, but camber is introduced to the web material
Solution Approach 1:
The traverse device dynamically adjusts the spool position relative to the web source, enabling controlled movement between lanes. The S-shaped velocity profile dynamically varies the traverse speed to minimize camber while maintaining efficient lane transitions.
Solution Approach 2:
The winding system changes operational parameters during the process: winding diameter increases as layers are added, traverse width adjusts based on lane position, and velocity profile changes during traverse to minimize camber. These parameter changes optimize both productivity and minimize harmful camber effects.
3Object-affected harmful factors
If S-shaped velocity profile is used during traverse, then camber is minimized, but traverse time increases
Solution Approach 1:
The S-shaped velocity profile is applied only during the traverse portions between lanes, not during the actual winding phases. This partial application minimizes camber when needed while avoiding unnecessary time consumption during the productive winding phases.
Data Source
AI summary
The present invention relates to apparatus and methods for winding and unwinding web materials, the web materials having a plurality of narrow lanes which form a spool. In a first aspect of the invention each lane of web material is defined by a width measured in the axial direction of the spool and between a minimum and a maximum radial height measured radially from a central axis of the spool. Each lane is wound, in turn, with web material up to the maximum radial height, the web material is folded by a first, second, third and fourth folds so that the web material is realigned parallel to the adjacent lane and wound to form the adjacent lane.