Winder Pitch Modulation at Transverse Limits
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Solution Overview
Problem
High forces at the limits of transverse motion in traverse winding machines, particularly when the arbor is moved in translation, lead to wear and reduced winding speed due to acceleration forces and torque spikes.
Innovation Solution
A computer-controlled winding machine system that modulates the pitch transition rate by reducing and then increasing the pitch magnitude as the carriage approaches and leaves the end of the form, respectively, to minimize accelerative forces without changing the arbor speed, using user-entered parameters to compute the necessary pitch modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the arbor speed is maintained at high constant speed during transverse motion limits, then winding productivity is improved, but harmful accelerative forces and torque spikes increase causing wear and reliability issues
Solution Approach 1:
The system proactively manages pitch transition rate before the carriage reaches the reversing limit points by detecting carriage position and computing required pitch changes in advance. This preliminary action allows the pitch transition to be constrained to a small distance near the end of the form, reducing accelerative forces while maintaining high arbor speed and productivity throughout the winding process
2Reliability
If the pitch transition rate is reduced to minimize accelerative forces, then reliability and wear are improved, but winding productivity may be reduced due to slower pitch changes
Solution Approach 1:
The pitch transition rate modification is applied locally only in the small distance region near the reversing limit points of the carriage, while the pitch remains constant and productive in the majority of the winding path. This localized application minimizes accelerative forces at critical moments without affecting overall winding productivity
Solution Approach 2:
The system dynamically changes the pitch parameter based on carriage position, computing the required pitch transition rate modification from pitch and other machine parameters. This parameter change allows smooth pitch transitions that reduce accelerative forces while maintaining high winding speeds
3Object-affected harmful factors
If the arbor speed is varied to accommodate pitch changes at transverse limits, then harmful forces are reduced, but manufacturing precision of pitch and winding pattern deteriorates
Solution Approach 1:
The control system computes the required pitch transition rate modification in advance based on detected carriage position and enters pitch and other machine parameters. This preliminary computation ensures that pitch changes are accurately managed without varying arbor speed, maintaining manufacturing precision while reducing harmful forces
Data Source
AI summary
A winding machine having a user-defined pitch between rotation of a form and translation of a point of winding material along the form, reduces damaging accelerative forces on the machine components by a slight modulation of the pitch near travel-reversal of the point of winding. The pitch of the windings over most of the form is unaffected and rotational speed of the form need not be modified.