Winding Station Ring Motors for Tape Roll Uniformity
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Solution Overview
Problem
Existing winding stations for metal strips and foils produce rolls with varying diameters and tensions due to different cutting forces and shape tolerances, leading to inconsistent tape tensions and out-of-roundness, which affects the uniformity of the wound rolls.
Innovation Solution
A winding station with a non-rotatable carrier and separate ring-shaped electric motors for each winding core, allowing independent torque and speed control to maintain constant strip tension across multiple metal strips, ensuring uniformity in the wound rolls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a common drive shaft is used to rotate all winding sleeves together, then the device complexity is reduced, but the manufacturing precision of the rolls deteriorates due to varying tape tensions
Solution Approach 1:
The patent divides the drive system into separate electric motors for each winding sleeve, allowing independent control of each roll's tension and speed. This segmentation enables precise control over each metal strip during winding, compensating for different cutting forces and maintaining uniform roll quality across all positions.
Solution Approach 2:
The patent implements dynamic control capabilities where each electric motor can independently adjust its torque and speed based on real-time conditions of individual metal strips. This dynamic adjustment allows the system to compensate for variations in cutting forces, strip tensions, and winding diameters, maintaining consistent roll uniformity throughout the winding process.
2Manufacturing precision
If contact roller units with individual adjustment are used for each metal strip, then the manufacturing precision of rolls is improved, but the device complexity increases
Solution Approach 1:
The patent replaces the mechanical contact roller adjustment system with electric motors that provide direct rotational drive to each winding sleeve. This substitution eliminates the need for complex mechanical contact rollers while achieving superior control precision through electronic torque and speed regulation, thereby improving roll uniformity without proportionally increasing device complexity.
Solution Approach 2:
The patent controls winding parameters (torque, speed, tension) through electric motor regulation rather than mechanical adjustment. By changing the control method from mechanical (contact rollers) to electrical (motor parameters), the system achieves more precise and responsive control over each metal strip's winding process, improving roll uniformity with a more manageable complexity profile.
3Manufacturing precision
If separate electric motors are used for each winding sleeve, then the manufacturing precision of rolls is improved through constant tension control, but the device complexity increases
Solution Approach 1:
The patent implements feedback control through separate electric motors for each winding sleeve, enabling real-time monitoring and adjustment of tension and speed for each metal strip. This feedback mechanism allows the system to compensate for variations in cutting forces and strip properties, maintaining constant tension throughout the winding process and achieving superior roll uniformity despite the increased number of drive components.
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 solution ensures the production of rolls with greater uniformity by maintaining constant tape tension and web tension, reducing shape tolerances and out-of-roundness, and allowing for compact design with ring-shaped electric motors.
Implementation Method 1
a plurality of electric motors, by means of which at least two of the winding cores of the plurality of winding cores can be driven separately
Data Source
Figure 1~2
Figure 3
AI summary
A winding station (1.1, 1.2) for winding a plurality of metal strips (2.1, 2.2) into a plurality of tape reels (3.1, 3.2), comprising at least: - a frame (4), - a support (5) for receiving a plurality of winding cores (6), wherein the support (5) is attached to the frame (4), and - a plurality of drives (7) by means of which at least two winding cores (6) of the plurality of winding cores (6) can be driven separately. Furthermore, a method for winding a plurality of metal strips (2.1, 2.2) into a plurality of tape reels (3.1, 3.2) and the use of a plurality of ring-shaped drives (7) for separately driving a plurality of winding cores (6) at a winding station (1.1, 1.2) are proposed.