Winding Machine Independent Contact Roller Units for High-Speed Core Changes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing winding machines face challenges in maintaining high product quality while switching from a full to an empty winding core, often requiring a reduction in feed speed, which leads to inefficiencies and potential product defects.
Innovation Solution
The implementation of a winding machine with two independent contact roller units that can be moved and positioned separately to accommodate different winding core fill levels and diameters, allowing for continuous winding without interruptions by tracking the material and seamlessly transferring it between cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single contact roller unit is used and exchanged between winding cores, then the device complexity is reduced, but the productivity decreases due to time-consuming exchanges and speed reductions
Solution Approach 1:
The single contact roller unit is segmented into multiple independent contact roller units (at least two), each assigned to a specific winding core. This segmentation eliminates the need to exchange contact roller units during core changes, allowing continuous high-speed winding while maintaining manageable device complexity through modular design
Solution Approach 2:
Multiple contact roller units are prepared in advance and assigned to different winding cores before the winding process begins. This preliminary assignment ensures that when core changes occur, the appropriate contact roller unit is already in position, eliminating downtime and speed reductions associated with exchanges
2Reliability
If the feed rate is reduced during core changes, then the web-like material can be properly attached to the empty sleeve, but the productivity decreases
Solution Approach 1:
The winding process maintains continuous operation without speed reductions by having multiple contact roller units ready on different cores. When one core is being wound, another core with its assigned contact roller unit is prepared simultaneously, ensuring uninterrupted high-speed feeding and attachment of the web-like material
Solution Approach 2:
The empty winding core with its assigned contact roller unit is prepared in advance before the current core is filled. This preliminary preparation ensures that when the core change is needed, the system can immediately switch to the pre-prepared core at full speed without compromising material attachment quality
3Adaptability or versatility
If contact roller units are moved and exchanged during winding, then adaptability to different core fill levels is achieved, but the time required for core changes increases
Solution Approach 1:
The system segments the contact roller units and assigns them permanently to specific winding cores, eliminating the need to move or exchange them during operation. Each core has its dedicated contact roller unit that remains in place, reducing core change time to only the essential mechanical exchange of the winding core itself
Solution Approach 2:
While contact roller units are fixed to their assigned cores, the winding cores themselves are dynamically exchangeable. The system allows flexible replacement of entire core-and-contact-roller-unit combinations, providing adaptability without the time penalty of moving contact roller units during the winding process
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
This solution enables high-speed core changes without compromising product quality, ensuring uninterrupted and efficient winding processes by allowing continuous feeding and tracking of the web-like material, even during core exchanges.
Implementation Method 1
The contact roller units serve to feed the web-shaped material to the winding cores on the winding shafts
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a winding machine (10) for web-type materials, comprising a feeding device for a web-type material (11) and at least two winding shafts (15). The winding shafts (15) are preferably arranged on a turning frame and are designed to each hold a winding tube/core (16) for winding up web-type material (11). The winding shafts (15) can preferably be driven independently of each other. The winding machine (10) is characterized in that at least two contact roller units (20, 21) are provided for feeding the web-type material (11) to the winding tubes/cores (16) on the winding shafts (15) at a winding point. Also described is a method for winding a web-type material (11) onto winding tubes/cores (16), in particular by means of a winding machine (10) according to the invention.