Winder Assembly Automated Core Change Mechanism
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Solution Overview
Problem
The existing methods for changing cores in polymeric film winding processes are hazardous due to manual handling, which can result in operator injuries from nip points between rollers, and require manual positioning of material onto fresh cores, disrupting the continuous winding process.
Innovation Solution
A winder assembly with a turret assembly that indexes cores into position, a lay-on roll assembly, a transfer roll assembly, and a cutting mechanism to automate the core change process, ensuring safe and continuous operation by guiding the web material between rollers and nips without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual positioning of material onto fresh cores is used, then the core change process can be performed, but operator injury risk increases due to nip points between rollers
Solution Approach 1:
The system performs core changes automatically without operator intervention. The indexing mechanism self-positions empty cores, and the material transfer system self-guides the web onto new cores through defined nip points, eliminating the need for manual positioning and associated injury risks
Solution Approach 2:
The patent introduces intermediary components (indexing mechanism, transfer rollers, guide nip points) that mediate between the material source and the winder core. These intermediaries automate the transfer process and eliminate direct operator contact with dangerous nip points
2Ease of operation
If manual core changing is used, then core replacement can occur, but continuous operation is disrupted
Solution Approach 1:
The indexing mechanism maintains continuous operation by pre-positioning multiple empty cores on the turret. When one core is full, the system seamlessly indexes to the next empty core without stopping the winding process, ensuring uninterrupted production
Solution Approach 2:
Empty cores are pre-loaded onto the turret assembly before the winding process begins. This preliminary preparation allows immediate core changes without disruption, as empty cores are already in position and ready for indexing when needed
3Productivity
If automated indexing system is implemented, then continuous operation is maintained, but device complexity increases
Solution Approach 1:
The turret assembly is segmented into multiple discrete core positions arranged in a circle. This segmentation allows independent indexing of individual cores while maintaining a simple overall structure. Each core position is a separate, manageable unit that can be independently positioned
Data Source
AI summary
A winder assembly is provided and includes two or more cores mounted for rotation on a turret assembly and a web of sheet-type work material is wound around a core. A lay-on roll assembly roller and a core cooperate to define a first nip. A transfer roll assembly includes a roller coupled for rotation to a rail such that the roller and a core cooperate to define a second nip. A cutting means for cutting the work material includes a traverse assembly having a work material guide means. During operation, after cutting work material, the turret assembly indexes a core into a winding position and the work material guide means is moved to the operating position such that the roller coupled to the rail causes the work material to be fed into the second nip and begin winding around the core.