Sensor-Aligned Winding Coupling for Wear-Free Mode Changes
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Solution Overview
Problem
Existing winding machines require manual and time-consuming alignment of coupling elements, leading to potential wear and inaccurate alignment during mode changes between drum and pallet operations, causing wear and damage.
Innovation Solution
A winding machine with a turntable on a swivel arm, utilizing sensors and a fixing device to automatically position and secure coupling elements in a form-fitting or force-fitting manner, ensuring precise and secure engagement without manual intervention, and a drive device for both drum and pallet modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment of coupling elements is used during mode changes, then the coupling process can be completed, but it is time-consuming and leads to wear and inaccurate alignment
Solution Approach 1:
The system uses sensors to automatically detect the positions of coupling elements and actuates drive devices to align them oppositely without manual intervention. The coupling elements self-align through the automated positioning system, eliminating the need for manual alignment operations.
Solution Approach 2:
The patent replaces manual mechanical alignment with an automated system combining sensors (electrical/magnetic fields) and drive devices (motors). This substitution of mechanical manual operation with sensor-driven automation resolves the contradiction by eliminating time-consuming manual alignment while ensuring precise opposite positioning.
2Reliability
If manual alignment of coupling elements is used during mode changes, then the coupling process can be completed, but it causes wear and damage to coupling elements
Solution Approach 1:
The system automatically positions coupling elements in opposite positions using sensors and drive devices, eliminating manual handling that causes wear. The coupling elements are brought into engagement through controlled automated motion, preventing the impact and misalignment damage associated with manual alignment.
Solution Approach 2:
The sensors detect coupling element positions and the drive devices pre-position them in opposite alignment before engagement. This preliminary automated positioning ensures that coupling elements are perfectly aligned before contact, preventing wear and damage during the coupling process.
3Manufacturing precision
If coupling elements are not precisely aligned, then manual alignment can be performed, but it results in inaccurate positioning and potential jamming
Solution Approach 1:
The patent replaces manual alignment with an automated sensor-driven system that detects coupling element positions and actuates drive devices to achieve precise opposite positioning. This mechanical-to-automated substitution ensures high alignment precision without the time penalty of manual operations.
Solution Approach 2:
Sensors continuously detect the positions of coupling elements and provide feedback to the control system. The drive devices adjust positioning based on this feedback until precise opposite alignment is achieved, ensuring manufacturing-level precision automatically without manual intervention time.
Data Source
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AI summary
A winding machine (10) for winding and/or unwinding band-shaped or strip-shaped material (12) has at least one rotary plate (16), which is mounted on a pivot arm (24) and can be driven via at least two opposing coupling elements (20, 22), wherein at least one coupling element (20) is assigned to the rotary plate (16), and the rotary plate (16) can be moved via a pivot device (30) between at least one decoupled state and at least one coupled state. Because the coupling elements (20, 22) can be positioned opposite one another in a coupling position using sensors, this enables a coupling process which is as wear-free as possible.