Individually Controlled Winding Drives for Longitudinal Strip Tension
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Solution Overview
Problem
Conventional winding devices for longitudinally cut material webs face issues with precise control of individual windings due to varying friction coefficients and inability to detect errors until extreme deviations occur, leading to potential material tears or loose windings.
Innovation Solution
A winding device with individually controllable ring-shaped winding drives and a force measuring system that allows precise tension control, using external rotor electric motors and a stable axis with axial conductors for independent control and locking, combined with a force measuring device for web tension detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If friction-based winding shafts are used, then winding operation is simple, but dust is generated and winding tension control is poor
Solution Approach 1:
The patent replaces the mechanical friction-based winding system with an electric motor-driven system. Each winding shaft is equipped with an independent electric motor that directly drives the winding drum, eliminating the need for friction-based power transmission. This substitution eliminates dust generation from friction while maintaining operational simplicity through automated electric control.
Solution Approach 2:
The patent divides the winding system into multiple independently controlled modules, with each winding shaft having its own electric motor. This segmentation allows individual control of each winding position, improving tension control precision while maintaining the simplicity of operation through modular design.
2Device complexity
If friction-based winding shafts are used, then device structure is simple, but winding tension control precision is poor
Solution Approach 1:
The winding system is segmented into independently controlled modules, with each winding shaft equipped with its own electric motor. This allows precise individual control of winding tension at each position while maintaining relatively simple modular structure that can be replicated across multiple winding positions.
Solution Approach 2:
The patent implements dynamic control of winding tension through independently controllable electric motors at each winding shaft. The motor speed and torque can be dynamically adjusted to maintain optimal winding tension, significantly improving control precision compared to static friction-based systems.
3Manufacturing precision
If individually controllable winding drives are implemented, then winding control precision is improved, but device complexity increases
Solution Approach 1:
The system achieves individual winding control by segmenting the driving mechanism into separate electric motors for each winding shaft. While this increases component count, the modular nature of the segmentation allows for standardized designs that can be manufactured and maintained more easily, partially offsetting the complexity increase.
Solution Approach 2:
The electric motors used in the patent serve multiple functions: they provide the driving force for winding, enable precise speed control for tension management, and can be individually programmed for different winding patterns. This multi-functionality reduces the need for separate control mechanisms, thereby limiting the increase in overall device complexity.
4Manufacturing precision
If electric motor-driven winding shafts are used, then winding tension control is precise, but energy consumption increases
Solution Approach 1:
The electric motors in the patent are designed to provide precise control only when needed for tension management or variable winding requirements. During constant-speed operation, the motors can operate in efficient ranges, and energy-intensive precise control is applied only partially when actually required, rather than continuously, thereby limiting overall energy consumption increase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables precise and reliable winding of multiple longitudinal strips onto winding rolls, overcoming friction-related issues and ensuring consistent web tension, thus improving winding accuracy and reducing material waste.
Implementation Method 1
Each winding drive forms an external rotor electric motor and comprises a static inner sleeve and a rotatable outer sleeve. The static inner sleeve is mounted on the shaft in a rotationally secured manner and preferably with minimal play. Its outer surface carries a stator with the stator windings of the electric motor
Implementation Method 2
The device for providing an excitation magnetic field is advantageously formed by a plurality of permanent magnets. This enables a reliable and low-maintenance, brushless design of the electric motor.
Data Source
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AI summary
The invention relates to a device (20) for winding a longitudinally cut web of material with several longitudinal strips (12) onto a plurality of winding cores (16), each forming a winding roll. The device has an axle (24) and a plurality of annular winding drives (22) mounted on the axle, which can be individually controlled in their operating position. On their outer surface, the winding drives are each configured to receive a winding core (16) for winding a longitudinal strip (12) of the web of material. Each winding drive (22) forms an external rotor electric motor and comprises a static inner sleeve (40) and a rotatable outer sleeve (50). The static inner sleeve (40) is mounted on the axle (24) in a rotationally secured manner. On its outer surface, it carries a stator (44) with stator windings of the electric motor, as well as rolling bearings (48) for receiving the rotatable outer sleeve.The outer sleeve (50), which is rotatable on the rolling bearings (48), carries on its inner surface a device for providing an excitation magnetic field (52), which forms the outer rotor of the electric motor. On its outer surface, the outer sleeve has a locking device (58) for the winding sleeves to be received.