Winding Machine Removal Fork Pivoting for Automatic Web Transfer
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Solution Overview
Problem
Existing turret winders require manual intervention and glue points for changing the winding sleeve, leading to inefficiencies and increased operational downtime during the winding process.
Innovation Solution
A winding station with a removal fork that pivots a nearly full winding from a front to a rear position, utilizing three wedge gaps formed by rolls, belts, or guides to automatically guide the material web around a new winding sleeve, eliminating the need for glue points and enabling continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual intervention and glue points are used for changing the winding sleeve, then the material web can be securely attached to the new sleeve, but the operational downtime increases and the change process becomes less efficient
Solution Approach 1:
The wedge gaps are pre-formed by the feeder system (rolls, belts, or guides) before the material web needs to be attached to the new winding sleeve. This preliminary preparation of the guiding structure allows the material web to be automatically directed onto the new sleeve without manual intervention or glue points, thereby reducing operational downtime while maintaining secure attachment
Solution Approach 2:
The wedge gaps formed by the feeder system act as an intermediary mechanism between the material web and the new winding sleeve. These gaps guide and direct the material web onto the sleeve automatically, replacing the need for manual attachment methods while ensuring proper positioning and secure attachment during the winding change process
2Loss of substance
If a cutting device is used to cut the foil web at a right angle, then waste material is minimized, but the device complexity increases due to additional components
Solution Approach 1:
The feeder system components (rolls, belts, or guides) that form the wedge gaps serve multiple functions: they guide the material web during the winding change, create the wedge gap structure for automatic circulation, and work together with the winding sleeve to secure the material web. This multi-functionality reduces the need for separate specialized cutting devices while maintaining the right-angle cut capability and minimizing waste material
3Reliability
If the material web is manually fitted against the winding sleeve and secured with glue points, then the attachment is secure, but the ease of operation decreases due to manual intervention requirements
Solution Approach 1:
The wedge gaps formed by the feeder system enable the material web to automatically direct itself onto the new winding sleeve without manual intervention. The material web is pulled into the wedge gap and guided around the sleeve by the feeder components, creating a self-service mechanism that maintains secure attachment while dramatically improving ease of operation during winding changes
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
Facilitates a fully automatic and rapid change of the full winding without stopping the operation, maintaining consistent web tension and reducing waste by ensuring the material web is securely attached to the new sleeve without manual intervention.
Implementation Method 1
a removal fork that pivots, during a continuous operation of the winding station, a nearly full winding from a front position to a rear removal position
Implementation Method 2
The wedge gaps ensure an automatic circulating of the material web around the winding sleeve since the material wedge or strip is pulled into the respective gap and, in part, is guided around the winding sleeve
Data Source
AI summary
A winding station and a method for winding material webs, in particular foils or films, wherein during a continuous movement of the material web, a removal fork pivots the nearly full winding sleeve from a front position to a rear removal position while a new winding sleeve is moved to the winding position. The winding station is provided with a device to wind the material web automatically onto a new winding sleeve following the separation of the completed winding.