Wrapping Apparatus Tension Control via Feedback Brake
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Solution Overview
Problem
Existing mechanical apparatuses for wrapping materials around cylindrical pieces with a center hole struggle to maintain sufficient tension, especially when the wrapping material's properties vary, leading to inefficiencies and mechanical complexity, as they require frequent adjustments and are prone to failure.
Innovation Solution
An apparatus with a tension detection system that provides feedback to the drive means, allowing for internal or external feedback mechanisms to maintain consistent tension, including the use of electric motors and pressure-roller arrangements, which simplifies construction and enables effective re-reeling of the wrapping material, accounting for changes in distance between the wrapping shuttle and the piece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If mechanical apparatuses are used to control the tension of the wrapping material, then the wrapping process can be automated, but the device complexity increases and reliability decreases due to wearing components
Solution Approach 1:
The patent replaces complex mechanical tension control apparatus with a simplified system using a reel that pays out wrapping material. The tension is controlled by a brake mechanism that applies friction to the reel, eliminating the need for complex mechanical tensioning devices with wearing components. This substitution maintains automation while improving reliability by reducing mechanical complexity.
Solution Approach 2:
The patent introduces a brake mechanism as an intermediary between the motor and the wrapping material. The brake applies friction to the reel to control the tension of the wrapping material, serving as a simple yet effective mediator that replaces complex mechanical tension control systems while maintaining automated operation.
2Stability of the object's composition
If mechanical apparatuses are used to control the tension of the wrapping material, then tension can be maintained, but the device complexity increases due to additional mechanical components
Solution Approach 1:
The patent replaces complex mechanical tension control apparatus with a simplified system using a reel and brake mechanism. The brake applies friction to the reel to control tension, eliminating the need for complex mechanical tensioning devices while maintaining stable wrapping material tension throughout the wrapping process.
Solution Approach 2:
The patent incorporates feedback control where the actual tension of the wrapping material is measured and compared with the desired tension. The brake force is automatically adjusted based on this feedback to maintain stable tension, eliminating the need for complex mechanical pre-tensioning devices while achieving consistent wrapping quality.
3Adaptability or versatility
If the wrapping shuttle moves along an oval wrapping track through the centre hole of the piece, then wrapping can be achieved on cylindrical pieces with centre hole, but the distance between the wrapping shuttle and the piece surface varies considerably, making tension control difficult
Solution Approach 1:
The patent uses feedback control where sensors measure the actual tension of the wrapping material and the position of the wrapping shuttle. The control system adjusts the brake force on the reel in real-time based on this feedback, maintaining constant tension despite the varying distance between the shuttle and piece surface during the oval track motion.
Solution Approach 2:
The patent dynamically adjusts the brake force parameter on the reel based on the wrapping shuttle's position along the oval track. When the shuttle is closer to the piece surface, less brake force is applied, and when farther away, more brake force is applied, maintaining constant wrapping material tension throughout the cycle.
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 consistent tension throughout the wrapping process, simplifies mechanical implementation, and allows for variations in wrapping material properties, reducing the need for frequent adjustments and minimizing the risk of mechanical failure.
Implementation Method 1
measuring means for detecting the tension of the wrapping material, from which a feedback is arranged to the drive means
Implementation Method 2
drive means including an operating device fitted to the assembly and arranged to act on the wrapping-material source, in order to maintain the tension in the wrapping material arranged to be discharged from it
Data Source
AI summary
The invention relates to an apparatus (10) for wrapping a wrapping material (16), which includes an assembly (14), a discharge arrangement (30) at least partly fitted to the assembly (14) for a wrapping-material source (11). The discharge arrangement includes a support-element arrangement (12) for the wrapping-material source, from which the wrapping material (16) is arranged to be discharged, and drive means (13, 20, 33) arranged to act on the wrapping-material source, in order to maintain the tension of the wrapping material arranged to be discharged from it. In addition, the apparatus includes measuring means (17) for detecting the tension of the wrapping material, from which feedback (18) is arranged to the drive means. The tension of the wrapping material is arranged to be detected from the discharge arrangement. In addition, the invention also relates to a method and system for wrapping a wrapping material, a wrapping device (31) and a control unit (20).