Wire Winding Module Layout for Robotic Spool Doffing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wire winding installations require manual doffing, which is hazardous and reduces efficiency, as operators must handle full spools and capstans from the same side, necessitating human intervention and potentially dangerous situations.
Innovation Solution
The winding module and installation design reverses the orientation of capstans and shafts, making it impossible for one operator to service both from the same side, and incorporates doffing robots that operate on a gantry, allowing for safe and efficient doffing at normal running speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual doffing is implemented with operators servicing both capstans and spools from the same side, then ease of operation is improved, but safety deteriorates due to hazardous situations
Solution Approach 1:
The patent inverts the conventional arrangement by positioning capstans and spools on opposite sides of the winding shaft. Instead of both being accessible from the same side (which creates safety hazards), the capstan is accessible from one side while the spool is accessible from the other side, eliminating the need for operators to work in hazardous zones while maintaining operational capability through automated doffing systems
2Adaptability or versatility
If manual doffing operations are performed, then adaptability is improved for handling spool changes, but productivity deteriorates due to line speed reduction and operational interruptions
Solution Approach 1:
The patent implements automated doffing robots that perform spool changes autonomously without requiring manual intervention. The system includes robotic arms equipped with grippers that can automatically detach full spools, transfer them to transport mechanisms, and replace them with empty spools, thereby maintaining continuous production at normal line speeds while adapting to different spool configurations
Solution Approach 2:
The patent introduces intermediate transport mechanisms (such as conveyors or robotic transfer systems) that bridge the gap between the winding station and spool storage areas. These intermediaries handle the physical transfer of spools, allowing the main production line to continue operating uninterrupted while spool changes occur in the background
3Reliability
If two operators are deployed at both sides of the take-up bench for manual doffing, then reliability is improved for safe operation, but device complexity increases
Solution Approach 1:
The patent replaces the mechanical system of manual operator intervention with automated robotic systems. Robotic arms with specialized end effectors perform the doffing operations that previously required human operators, eliminating the need for multiple personnel while maintaining or even improving safety through consistent, error-free automated execution of the doffing sequence
Data Source
AI summary
A winding module and a winding installation including winding modules for winding metal wire. In such a winding installation or take-up bench a driven capstan is used to pull the metal wire through a processing installation before being led onto a take-up spool. The spool is driven by a cantilever supported shaft. In prior art take-up benches, both the capstan and the spool is reachable by an operator from the same side. This means that the capstan direction—the direction from the driven side of the capstan to the operator side—is equal to the shaft direction—the direction from the drive side of the shaft to the open end of the shaft. In the inventive winding module the capstan direction is opposite to the shaft direction, which provides a completely different operation of the winding module and the winding installation and facilitates the introduction of doffing robots.