Winding Apparatus Rail Guide Groove Roller Positioning
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Solution Overview
Problem
Conventional pipe lining apparatuses are heavy, difficult to assemble, and costly due to their rigid design, which affects the accuracy and durability of the spirally wound pipe, and requires frequent maintenance and repair of rollers under heavy loads.
Innovation Solution
A lightweight and modular winding apparatus with a forming frame of interconnected links, rotatable guide rollers, and a rail with a guide groove to prevent roller movement deviations, reducing the need for thick materials and simplifying assembly, while using oil-impregnated metal powder sintered bearings for reduced wear and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rail is formed thick to receive heavy loads through the connector, then the strength and load-bearing capacity are improved, but the weight increases making assembly difficult and installation lengthy
Solution Approach 1:
The patent changes the structural parameters of the rail by introducing a hollow cylindrical shape with strategically placed recesses and protrusions. This allows the rail to maintain sufficient strength for load-bearing while reducing material usage and overall weight compared to a solid thick rail design.
Solution Approach 2:
The rail is segmented into functional zones with recesses and protrusions that create modular connection points. This segmentation allows for optimized material distribution, providing strength only where needed for load-bearing and connection, while reducing weight in non-critical areas.
2Measurement precision
If guide parts are attached to the rail to regulate roller movement, then the measurement precision and positioning accuracy are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The guide function is merged directly into the rail structure through integrally formed recesses and protrusions rather than being separate attached components. This reduces device complexity while maintaining positioning accuracy, as the guide features are built-in rather than added.
Solution Approach 2:
The rail uses a thin-walled hollow cylindrical structure with strategic reinforcements through recesses and protrusions. This approach provides guidance and positioning functionality with minimal material, reducing manufacturing complexity and cost compared to thick solid structures.
3Strength
If the roller is installed with bearings to support heavy loads, then the load-bearing capacity is improved, but the reliability decreases as the roller becomes easily damaged and requires frequent maintenance
Solution Approach 1:
The patent extracts the bearing component from the roller assembly and replaces it with a bearingless design. The roller shaft directly contacts the rail's recesses and protrusions, eliminating bearings that are prone to damage and maintenance, while the rail structure itself provides the necessary support for heavy loads.
Solution Approach 2:
The design uses simple, maintenance-free roller shafts without expensive bearings. While individual rollers may be simpler components, the overall system achieves higher reliability by eliminating the failure-prone bearing elements that require frequent maintenance and replacement.
4Strength
If thick materials are used to reinforce the lip part and rail, then the strength to support heavy loads is improved, but the manufacturing cost increases and manufacturing precision becomes difficult to achieve
Solution Approach 1:
The patent changes the manufacturing approach by using a hollow cylindrical rail structure with strategic recesses and protrusions rather than uniformly thick reinforced sections. This allows achieving necessary strength through intelligent structural design rather than simply increasing material thickness, thereby reducing manufacturing cost and improving precision.
Solution Approach 2:
The rail structure effectively creates a composite design with the hollow cylindrical form providing overall strength while the recesses and protrusions provide localized reinforcement. This composite structural approach achieves high strength-to-weight ratio and is more economical and precise to manufacture than solid thick sections.
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
The apparatus improves the reliability and durability of the winding process, reduces manufacturing and assembly costs, and enhances the accuracy of the spirally wound pipe, minimizing the need for roller replacement and maintenance, while allowing for efficient and precise pipe lining.
Implementation Method 1
with the bearing installed inside the roller 95 and the roller 95 contacting the inside of the guide part 96 contained within the rail 94
Data Source
AI summary
The winding apparatus has a forming frame which goes inside an underground damaged pipe, and a rail which regulates the circumference track of a forming frame as the joint mechanism interlocks adjacent portions of a plastic strips. The forming frame has a plurality of guides that are connected extend along with a rail. Each guide contains a guide roller which can rotate freely about an end of the corresponding roller shaft. Each guide roller has an outside large diameter part and an inside small diameter part. The rail has a guide groove portion for the large diameter part of a guide roller at each edge of a course in a width direction.