Winding Machine Speed Control via Dynamic Envelope
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Solution Overview
Problem
Winding machines face mechanical stress and potential damage due to centrifugal forces and imbalances during high-speed operation, with existing speed monitoring methods being inadequate as they rely on fixed speed limits that do not account for changing winding spool geometry, leading to increased mechanical stress as the spool fills.
Innovation Solution
A method to determine a variable 'safe envelope speed' for the winding spool by calculating a ratio of the actual speeds of the winding and feed spools, allowing for continuous adaptation of speed limits based on the changing geometry, without the need for costly physical dimension measurements, using a control unit to implement this method.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed speed limit is used for the winding spool, then the monitoring system is simple to implement, but the mechanical stress on the winding spool increases as the spool fills and the diameter increases
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed speed limit to a dynamic speed limit that changes with the winding spool diameter. The monitoring system continuously adapts the safe speed envelope based on the current diameter, ensuring that the speed limit is appropriate for each stage of the winding process. This resolves the contradiction by making the monitoring system complex enough to adapt dynamically while preventing excessive mechanical stress through appropriate speed adjustment.
Solution Approach 2:
The patent applies parameter changes by modifying the speed limit parameter based on the winding spool diameter parameter. As the diameter increases during winding, the safe speed envelope is recalculated and adjusted accordingly. This allows the system to maintain optimal mechanical stress levels throughout the winding process by continuously adapting the speed parameter to the current geometric state of the spool.
2Measurement precision
If the winding spool diameter is measured physically during the winding process, then the speed monitoring accuracy is improved, but the system complexity and cost increase
Solution Approach 1:
The patent applies the intermediary principle by using the relationship between the feed spool and winding spool as a mediator to determine the winding spool diameter. Instead of directly measuring the winding spool diameter with complex sensors, the system uses the known feed spool diameter and the speed ratio between the two spools to calculate the winding spool diameter indirectly. This intermediate calculation approach achieves accurate diameter tracking without requiring direct physical measurement of the winding spool.
Solution Approach 2:
The patent applies mechanics substitution by replacing direct mechanical measurement systems with a calculation-based approach. Instead of using physical sensors, laser measurements, or other complex measurement devices to determine the winding spool diameter, the system substitutes these with a mathematical model that calculates the diameter based on the feed spool parameters and speed ratio. This eliminates the need for complex measurement hardware while maintaining measurement precision.
3Reliability
If the speed limit is reduced to account for increased diameter, then mechanical damage is prevented, but the productivity of the winding machine decreases
Solution Approach 1:
The patent applies dynamics by implementing a dynamic speed envelope that adjusts the safe speed limit based on the current winding spool diameter. During early stages when the diameter is small, higher speeds are permitted, maximizing productivity. As the diameter increases, the speed envelope is dynamically reduced to prevent mechanical damage. This dynamic adjustment resolves the contradiction by allowing high productivity when safe and reducing speed only when necessary for safety.
Solution Approach 2:
The patent applies parameter changes by continuously modifying the speed limit parameter as the winding spool diameter parameter changes. The system calculates an appropriate speed envelope for each diameter state, allowing the winding machine to operate at optimal speeds for each stage of filling. This prevents unnecessary speed reductions that would reduce productivity while ensuring safety limits are never exceeded.
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 approach effectively monitors and adjusts the winding speed to prevent mechanical damage by dynamically adjusting the speed limits according to the changing spool geometry, ensuring safe operation and reducing the risk of equipment damage and personnel harm.
Implementation Method 1
If centrifugal forces (due to mass/weight) and/or imbalances (due to mass distribution) occur during the rotation of the winding spool, which usually rotates at high speeds during the winding process, the winding spool is subject to severe mechanical stress.
Implementation Method 2
If, during the rotation of the winding spool, which usually rotates at high speed during the winding process, it is subject to high mechanical stress due to centrifugal forces and/or imbalances in resonance
Data Source
Figure 1
AI summary
The invention concerns a method for determining a monitoring rotating speed (reliable envelope curve rotating speed) for a winding coil of a winding machine, a control unit for the winding machine and the winding machine. The winding machine is used for winding a winding material on the winding coil rotating at the practical rotating speed of the winding coil during winding of winding material, wherein a supply coil is located ahead of the winding coil in the winding machine, so that the winding material is conveyed to the winding coil through the supply coil rotating at the practical rotating speed of the supply coil during winding. To protect the winding coil against mechanical damage during winding, the ratio of the practical winding thickness of the winding coil is formed by the practical rotating speed of the winding coil and the practical rotating speed of the supply coil and the monitoring rotating speed of the winding coil is determined through the predetermined limit rotating speed (the reliable rotating speed of unused winding coils) of winding coils free of winding and the ratio describing the pratical winding thickness of the winding coil.