Winding Method Decoupling Speed and Tensile Force

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Solution Overview

Problem

Existing winding systems are limited by the maximum speed at which structures can be wound, and materials sensitive to mechanical handling require methods that minimize or eliminate tensile forces during the winding process.

Innovation Solution

A winding apparatus and method that decouples winding speed from material transport speed, using a rotating drum with multiple winding stations, a web stabilizing bed, and a cutting anvil to wind structures with minimal tensile force application, allowing for the creation of layered rolls from discrete or continuous web materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional winding systems operate at higher winding speeds, then productivity increases, but materials sensitive to mechanical handling are subjected to excessive tensile forces

Engineering Contradiction:

Improvewinding speedVSAvoidtensile forces on materials

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The winding process is segmented into distinct phases: web transport to the drum, drum rotation to build the roll, and web release. This segmentation allows the web transport speed and drum rotation speed to be independently controlled, enabling high productivity without subjecting materials to excessive tensile forces during the winding phase.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts speeds between web transport and drum rotation. The drum can rotate at variable speeds independent of the web transport line, allowing optimization of winding speed for material sensitivity while maintaining high overall productivity through continuous operation and multiple winding stations.

Inventive Principle:

Principle #15Dynamics

2Speed

If web tension is increased to maintain web stability during high-speed winding, then winding speed can increase, but material quality deteriorates due to mechanical stress

Engineering Contradiction:

Improvewinding speedVSAvoidmaterial quality

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The drum surface acts as an intermediary between the web transport system and the wound roll. The web is transferred to the drum surface which provides a stable, low-friction interface for winding, reducing the need for high web tension and thereby protecting material quality while enabling high-speed operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces traditional tension-based web control with a drum surface-based transfer mechanism. Instead of relying on mechanical tension to maintain web stability, the drum surface provides geometric constraint and friction-based holding, reducing mechanical stress on sensitive materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If multiple webs are wound simultaneously to increase productivity, then output increases, but web alignment and layer quality become difficult to control

Engineering Contradiction:

ImproveoutputVSAvoidweb alignment

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Multiple winding operations are merged onto a single rotating drum with multiple stations. This allows simultaneous winding of multiple webs while maintaining precise alignment through the common rotational reference frame of the drum, ensuring consistent layer quality and inter-web alignment throughout the wound structure.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10183825B2Winding method

Publication Date: 2019.01.22 DURACELL US OPERATIONS INC

AI summary

A winding method includes rotating a winding drum; transferring a first web structure from a first lay down station to the web stabilizing bed of a first winding station; cutting the web structure; contacting the web structure with a web assembly hold down element, winding the web structure into a roll assembly; and discharging the roll assembly from the winding drum.