Description:

FORM 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10; rule 13)

1. Title of the invention – A MULTI-LAYER FILTER CARTRIDGE WINDING MACHINE

2. Applicant(s)

(a) NAME: MMP FILTRATION PVT. LTD.
(b) NATIONALITY: INDIAN
(c) ADDRESS: C3 / 602, ANUSHRUTI TOWERS, SG HIGHWAY, THALTEJ, AHMEDABAD – 380059 INDIA

3. PREAMBLE TO THE DESCRIPTION

The following specification particularly describes the invention and the manner in which it is to be performed.

 
A MULTI-LAYER FILTER CARTRIDGE WINDING MACHINE

FIELD OF THE INVENTION

The present invention is related to a multi-layer filter cartridge winding machine. More particularly, a winding machine which being capable of providing the graded filter cartridge and addresses the limitations of conventional winding systems through advanced PLC-controlled automation and programmable pattern generation.

BACKGROUND OF THE INVENTION

String wound filter cartridges represent a critical component in industrial filtration systems, where a perforated tube is precisely wound with yarn to create depth filtration media. In these systems, liquid to be filtered passes from the outside through multiple yarn layers into the perforated tube core, with dust particles and contaminants being trapped within the yarn matrix according to the specific micron rating of the filter construction.

The manufacturing of such filter cartridges requires sophisticated winding machinery capable of laying yarn in helical patterns from one end of the tube to the other, with precise control over winding geometry, yarn tension, and layer distribution. Various winding modes are employed in the industry, including random winding, precision winding, and step-precision winding, with precision or step-precision modes being preferred for filter applications due to their ability to maintain consistent wrap counts and uniform yarn distribution throughout the winding process.

Conventional filter winding machines available in the market typically employ mechanical systems for controlling winding patterns, where the number of wraps wound on the tube from one end to the other determines the filtration characteristics. These mechanical systems often require manual adjustment of gear ratios, cam profiles, or belt drive configurations to achieve different winding patterns, resulting in significant downtime during pattern changeovers and limited flexibility in producing customized filter specifications. The manufacturer of the winding machine provides values of teeth of gear set for various micron patterns. To change micron pattern, the user changes teeth of the gear set. The user would not have any detailed idea about the pattern produced and does not have facility to precisely create the own desired patterns.

Electronic filter winders are also available in the market. To get a particular micron pattern, the user has to input a specific value. Usually, the machine manufacturer provides the input values for different micron patterns. To change the micron pattern, the user changes input value in the control pattern. Electronic filter winding machines are also available in the market to produce graded filter cartridges. In these machines, the user has to input value and corresponding value that decides the extent to which the layer continues.

In both; mechanical filter winders and electronic filter winders, only limited data is available for the user in terms flexibility in micron pattern changes. The user does not have any detailed vision about the patterns he produces.

Many times, the user of filter winder requires replication of a particular winding pattern received from the buyer. The buyer gives a cartridge sample and expects replication of the sample cartridges. Very often, the user does not know the gear teeth values to be used (for mechanical winders) or input value (for electronic winders). Therefore, the user cannot produce replicas of the sample received and loses the order. With the developed invention, the user of the filter winding machine can also replicate the winding pattern of the cartridge sample given by the buyer or from the market.

Users of filter winders mostly outsource the yarn. Minor changes in the yarn diameter are most likely. Limited micron gear sets in case of mechanical winders and lack of knowledge of input values in case of electronic filter winders becomes problematic in this situation. Change in the yarn diameter creates visual difference in the filters produced. The visual difference can be tackled to some extent by having a new specific gear set in case of mechanical winders or precise change in input value of electronic winders. Due to lack of knowledge, the user of the filter winding machine cannot take any corrective action. The invention intends to overcome this draw back too.

Some users of the filter winding machines would be interested to produce their own different winding patterns as a part of research and development. The invention provides flexibility to the users of the filter winding machine to produce their own winding patterns. The invention is of great help for research and development.

In a wound filter, yarn should be wound in such a way that the yarn covers the entire length of the core tube. If the yarn fails to cover the entire length of the tube, it is not acceptable. Conversely the yarn layers projecting excessively beyond core tube ends are also not acceptable. A specific input value is suitable for a specific yarn and core tube length in this regard. If the core tube length becomes narrower or wider marginally, the problem can arise. The core tube length specified by different cartridge buyers for a given nominal length may vary marginally. For an example, for 20-inch filter winding machine, core tube length of one buyer may be 508 mm and the other may be 512 mm. With one specific input value, it will not be possible to satisfactory winding on both core tube lengths. With the invention, the user can derive suitable input values for both the tube lengths.

A significant limitation of existing winding technology is the inability to efficiently produce graded filter cartridges, which are increasingly demanded in industrial applications. Graded filters feature variable porosity from outside to inside, typically starting with coarse filtration layers (e.g., 10-micron) on the exterior, progressing through intermediate layers (e.g., 5-micron), and concluding with fine filtration layers (e.g., 1-micron) near the core. This graduated structure significantly extends filter life by preventing premature surface loading and distributing particle capture throughout the filter depth.

Prior art in automatic winding systems, as exemplified by EP3549893B1, discloses yarn winding systems with quality control mechanisms. This patent describes an automatic winder that controls winding speed based on yarn quality indices such as hairiness and defect detection. The system includes acquisition units for monitoring yarn quality and controllers that adjust winding parameters to maintain quality within predetermined threshold ranges. However, this prior art focuses primarily on textile yarn winding applications and does not address the specific requirements of filter cartridge manufacturing, particularly the need for multi-layer winding with independently controllable parameters for each layer.

The EP3549893B1 system, while incorporating advanced quality monitoring through yarn monitoring devices with optical sensors, lacks the capability for programmable pattern generation essential for filter cartridge production. The disclosed system controls winding speed based on yarn quality feedback but does not provide means for creating the complex geometric patterns required for effective depth filtration, such as rhombus or diamond-shaped winding configurations that are critical for achieving specific micron ratings.

Furthermore, existing electronic precision filter winders require operators to input numerical values representing winding ratios or gear relationships, without providing intuitive control over the actual filtration characteristics. Users typically lack understanding of the relationship between these input values and the resulting winding patterns, making it difficult to achieve desired filtration performance or to reproduce specific customer requirements.

Current market solutions also suffer from limited automation in multi-layer production. While some machines can produce graded cartridges, they typically require manual intervention between layers or complex mechanical changeover procedures that increase production time and introduce potential for human error. The lack of integrated recipe storage and recall functions further compounds these limitations, making it difficult to maintain consistency across production batches.

The precision winding patterns essential for filter cartridge performance are characterized by three critical parameters: the number of diamonds or rhombus patterns along the tube axis, the number of diamonds around the circumference, and the center-to-center distance between adjacent yarns. Existing systems do not provide direct input control over these fundamental parameters, instead requiring operators to work with indirect mechanical ratios that must be calculated and converted, leading to potential errors and inefficiencies.

Additionally, conventional filter winding machines lack sophisticated yarn tension control systems that can adapt to different yarn materials, diameters, and winding speeds. Proper tension control is critical for achieving uniformity in filters produced and preventing defects such as loose winding, yarn breakage, or irregular winding pattern formation that can adversely affect filtration performance.

The increasing demand for customized filtration solutions in industries such as water treatment, pharmaceuticals, food and beverage processing, and chemical manufacturing has highlighted the need for more flexible and programmable filter winding systems. Modern applications require wound filter cartridges with specific micron ratings, custom geometries, and multi-zone filtration characteristics that cannot be efficiently produced using conventional mechanical winding systems.

There exists a clear need in the art for a fully automatic, programmable filter cartridge winding machine that can produce multi-layer filter cartridges with precise control over winding geometry, yarn tension, and layer-specific parameters. Such a system should enable direct input of filtration-relevant parameters, provide automated pattern changeover capabilities, support recipe storage and recall functions, and incorporate real-time quality monitoring to ensure consistent production of high-performance filter cartridges.

To overcome all these drawbacks of the prior arts, the inventors of the present invention came up with a multi-layer filter cartridge winding machine.

OBJECT OF THE INVENTION

The principle objective of the present invention is to provide a fully automatic, programmable multi-layer filter cartridge winding machine that addresses the significant limitations of existing mechanical and electronic winding systems in the filter manufacturing industry. The invention aims to enable precise, repeatable production of high-performance depth filter cartridges with customizable micron ratings and multi-zone filtration characteristics.

Another objective of the present invention is to provide direct, intuitive control over filtration-relevant winding pattern parameters. The invention enables users to directly input rhombus count patterns along the cartridge length and circumference, yarn-to-yarn distance measurements, and layer-specific parameters. The invention covers a wide range of filter cartridge lengths say from 5 inches to 70 inches. Any yarn distance can be adjusted, say up to 9 mm.

Another objective of the present invention is to enable uninterrupted change over from one layer to the other during multi-layer winding with independent parameter control for each layer, facilitating the production of graded filter cartridges with variable porosity from outside to inside. This capability addresses the increasing industry demand for extended filter life through graduated filtration structures that prevent premature surface loading and distribute particle capture throughout the filter depth.

Yet another objective of the present invention is to provide an advanced yarn tension control and breakage detection systems that automatically monitor and adjust yarn conditions during winding operations. The manually adjustable limit switch rod mechanism linked to ceramic tubes arrangements in zigzag configuration provides precise tension control while ensures immediate machine shutdown upon detection of yarn breakage or improper tension conditions.

Yet another objective of the present invention is to enable dual-spindle operation with independent parameter control for each spindle, effectively doubling production capacity while maintaining precision and quality standards. This configuration allows simultaneous production of different filter specifications or identical cartridges for increased throughput.

SUMMARY OF THE INVENTION

The present invention may provide a multi-layer filter cartridge winding machine that represents a significant advancement in programmable filter manufacturing technology. The system addresses critical limitations in existing mechanical and electronic winding systems by providing comprehensive digital control over all aspects of the winding process, enabling the production of high-performance depth filter cartridges with customizable micron ratings and multi-zone filtration characteristics.

At its core, the invention may comprise a PLC-controlled programmable logic system that enables automated production of multi-layer filter cartridges with plurality of independent layers, each having different winding parameters. The system features a revolutionary user interface that allows direct input of filtration-relevant parameters rather than requiring operators to work with indirect mechanical ratios or complex calculations. Users can directly specify rhombus count patterns along the cartridge length and circumference, yarn-to-yarn distance measurements (1-9 mm), cartridge length (5-70 inches), tube outer diameter, layer counts (1-10,000 per layer), and individual winding speeds for each layer.

A key innovation is the intelligent pattern validation system that incorporates built-in mathematical verification to prevent invalid parameter combinations. The system ensures selection of correct numbers of rhombus counts and thereby avoids incorrect winding pattern that could compromise filter performance.

The machine features an advanced mechanical cam system with horizontal looping movement on the cam shaft, protected by cam boxes for uninterrupted operations. This system may work in conjunction with dual-spindle configuration that enables simultaneous production on two spindles with independent parameter control for each, effectively doubling production capacity while maintaining precision and quality standards.

Precise yarn tension control being achieved by a series of ceramic tubes arranged in the zig-zag configuration and an adjustable leaf spring tensioner. This system provide optimal tension control while incorporating automatic yarn breakage detection with immediate machine shutdown capability. The yarn detection rod being capable of maintaining continuous contact with the yarn and stops the winding operation immediately upon detection of yarn breakage or slackening. A filter cartridge diameter sensor automatically cuts off operation upon achieving the defined diameter.

The invention enables automated multi-layer winding with independent parameter control for each layer, facilitating the production of graded filter cartridges with variable porosity from outside to inside. This capability addresses the increasing industry demand for extended filter life through graduated filtration structures that prevent premature surface loading and distribute particle capture throughout the filter depth. For example, a graded cartridge can start with coarse filtration layers (10-micron) on the exterior, progress through intermediate layers (5-micron), and conclude with fine filtration layers (1-micron) near the core.

The system may incorporate a user-friendly human-machine interface with touch-enabled screen operation that displays real-time winding status, error diagnostics, and parameter feedback. This interface reduces operator training requirements and improves overall system usability while providing immediate access to machine status and troubleshooting information.

Advanced sensor integration includes filter cartridge diameter sensors for automatic operation cutoff, yarn detection systems for continuous monitoring, and comprehensive error detection with specific solutions for common issues such as cam rotation over count, servo alarms, yarn cuts, and electrical faults. The system provides detailed error descriptions and step-by-step solutions to minimize downtime and facilitate rapid problem resolution.

The mechanical design accommodates a wide range of cartridge specifications, supporting lengths from 5 inches to 70 inches, various tube outer diameters (30-38 mm), and yarn-to-yarn distances ranging from 1 mm to 9 mm. The rhombus pattern capability ranges from 3.5 to 103.5 depending on cartridge length, providing exceptional flexibility for diverse industrial applications and customer requirements.

The invention enables the generation of complex winding patterns including rhombus-shaped, diamond-shaped, helical, and spiral geometries through precise control of the mechanical cam system. The cam controls the axial movement of yarn relative to the rotating core, creating the desired geometric patterns that determine the filtration characteristics of the finished cartridge.

Servo or stepper motors drive the core shaft and cam shaft motors, with the controller providing closed-loop control using encoder feedback for precise positioning and speed control. This ensures consistent and repeatable winding patterns across all production runs while maintaining the high precision required for effective depth filtration.

The invention provides superior production consistency and quality control compared to conventional mechanical winding systems while reducing setup time, minimizing human intervention, and enabling remote monitoring and diagnostics capabilities suitable for modern manufacturing environments. The combination of programmable automation, intelligent control systems, and mechanical precision enables manufacturers to achieve zero-defect production, reduced downtime, and custom micron-rated filter cartridges at industrial scale within a compact and energy-efficient platform.

BRIEF DESCRIPTION OF DRAWINGS
The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific methods and structures disclosed herein. The description of a method step or a structure referenced by a numeral in a drawing is applicable to the description of that method step or structure shown by that same numeral in any subsequent drawing herein.

Figure 1 to 4 shows the assembly drawing of the multi-layer filter cartridge winding machine, illustrating both side and front views of the complete system configuration including the dual-spindle arrangement, mechanical cam systems, and control electronics housing.

DETAILED DESCRIPTION OF INVENTION

The present invention overcomes the aforesaid drawbacks of the above, and other objects, features and advantages of the present invention will now be described in greater detail. Also, the following description includes various specific details and are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that: without departing from the scope of the present disclosure and its various embodiments there may be any number of changes and modifications described herein.

It must also be noted that as used herein and in the appended claims, the singular forms "a", "an," and "the" include plural references unless the context clearly dictates otherwise. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, the preferred, systems and methods are now described.

As per the main embodiment of the present invention, multi-layer filter cartridge winding machine (100) comprising a base frame (101) being capable of providing mechanical stability during high-speed winding operations; and a main frame (102) being mounted on said base frame (101); at least one spindle assembly comprising a spindle core shaft (103) being provided for holding a filter core; and a core shaft housing (103a) being provided to support said core shaft (103); and a core shaft motor (104) configured to rotate said core shafts (103); at least one cam system comprising a mechanical cam (105) being mounted on a cam shaft (106) such as said mechanical cam (105) being capable of moving in horizontal direction from one end of cam shaft (106) to another end of cam shaft (106) in looping; and a cam shaft housing (106a) being provided to support said cam shaft (106); and a cam shaft motor (107) configured for providing the drive to said mechanical cam (105) enables the horizontal to and fro movement of said mechanical cam (105) on said cam shaft (106); a yarn being feed from yarn feeding system passes through a yarn tension controller (108) and yarn breakage detection means (109); said yarn tension controller (108) being capable of control the tension of the yarn while winding in order to improve the tightness of yarn on filter cartridge; said yarn detection rod (109b) continuously in contact with said yarn; a filter cartridge diameter sensor (110) being capable of cut off the operation upon achieving defined diameter of said filter cartridge; a controller configured to control the winding operation based on an user-defined parameters.

Figure 1 to 4 shows the assembly drawing of the filter winding machine. The assembly demonstrates a dual-spindle configuration designed for simultaneous production of filter cartridges. It is evident that the person skilled in the art being capable of adding or remove a plurality of the spindle assembly to construct the machine of the present invention customized.

The accompanying drawing illustrates an exemplary embodiment of the winding machine (100) according to the present invention. The drawing is provided for the purpose of understanding the invention and is not intended to limit its scope.

The winding machine (100) comprises a main frame (102) supporting a core shaft motor (104) for rotating the filter cartridge core and a mechanical cam (105) driven by a cam shaft motor (107) for controlling the axial movement of the yarn traverse guide (105a). The machine further includes a tension controlling unit comprising a plurality of ceramic tubes (108a) arranged in a zigzag configuration to maintain yarn tightness before winding onto the filter core.

A yarn breakage detection means (109) is provided, including a limit switch arrangement (109a) positioned to detect yarn breakage or improper yarn tension and automatically stop the winding operation. The controller is operatively connected to both the core shaft motor (104) and the cam shaft motor (107) to synchronize their operation for producing predetermined winding patterns, such as rhombus-shaped, diamond-shaped, helical, or spiral geometries. The controller further manages multi-layer winding with independent parameters for each layer, validates rhombus count combinations, and stores winding parameter recipes for repeatable production.

The drive system may incorporate servo motors or stepper motors with encoder feedback to enable closed-loop control of position and speed. A human-machine interface (HMI) with a touch-enabled display is mounted on the machine to receive operator input for winding parameters and display real-time process data.

The winding sequence implemented by the machine produces a filter cartridge having at least two filtration zones with different micron ratings an outer coarse filtration layer and progressively finer inner layers. The machine accommodates cartridge lengths ranging from 5 inches to 70 inches, yarn-to-yarn distances between 1 mm and 9 mm, layer counts from 1 to 10,000, and rhombus pattern counts ranging from 3.5 to 103.5, depending on the cartridge length and pattern settings.

As per the detailed embodiment of the present invention, the winding machine may comprising plurality of winding assemblies which being capable of working independently from each other. Each winding assembly mainly comprising spindle core shaft (103), core shaft housing (103a), core shaft motor (104), mechanical cam (105), cam shaft (106), cam shaft housing (106a), cam shaft motor (107), and yarn feeding system.

As per the detailed embodiment of the present invention, the cam shaft (106) being covered with the cam shaft housing (106a) for the uninterrupted operations and provides structural support and precise alignment for the cam mechanism.

As per the detailed embodiment of the present invention, said tension controller (108) having plurality of ceramic tubes (108a) being arranged in a zigzag configuration in order to provide the tightness while winding the yarn on said filter core. The winding machine comprises a tension controlling unit operatively positioned between the yarn supply source and the winding station. The tension controlling unit is configured to regulate and maintain a desired level of yarn tightness during the winding operation, thereby ensures uniform and compact winding on the filter core. The tension controlling unit includes a plurality of ceramic tubes (108a), each formed from high wear-resistant ceramic material to withstand continuous yarn contact and reduce frictional wear. These ceramic tubes (108a) being arranged in a zigzag configuration such that the yarn passes sequentially over and under alternate tubes, creating a serpentine yarn path. This zigzag arrangement increases the contact length between the yarn and the ceramic surfaces, thereby enhancing frictional resistance and providing a controlled tension to the yarn as it advances towards the winding head.

As per the detailed embodiment of the present invention, the yarn breakage detection mean (109) including a limit switch arrangement (109a) configured to automatically stops the winding operation upon detection of yarn breakage or improper yarn tension.

As per the detailed embodiment of the present invention, said limit switch (109a) arrangement comprises a manually adjustable limit switch rod (109b) mechanism.

As per one embodiment of the present invention, the winding machine is configured with a controller capable of monitoring and/or adjusting multiple winding parameters to ensure consistent quality and performance of the filter cartridge. The parameters can include, but are not limited to:
• Rhombus count along cartridge length - the number of diamonds along any row along cartridge length.
• Rhombus count around cartridge circumference - the number of diamonds along any row along cartridge circumference.
• Yarn distance between adjacent yarns - the lateral spacing between parallel yarn strands in a given winding layer.
• Cartridge length - the overall axial dimension of the cartridge being wound.
• Tube outer diameter - the external diameter of the cartridge core on which the yarn is wound.
• Layer count for each winding layer - the number of distinct yarn layers deposited during a complete winding cycle.
• Winding speed for each layer - the rotational and/or traverse speed applied for each successive winding layer.
These parameters may be set manually by the operator or automatically adjusted through a control unit linked to controller integrated within the winding system. In operation, the control module dynamically adjusts drive speeds, traverse rates, and yarn tension in accordance with the preset or computed parameters, thereby producing a filter cartridge with uniform geometry, consistent pore size, and improved structural integrity.

As per detailed embodiment of the present invention, the winding machine is equipped with a controller operatively connected to a shaft motor and a cam shaft motor (107). The controller being configured to synchronize the operation of the shaft motor (103), which rotates the filter cartridge, with the cam shaft motor (103), which drives the mechanical cam (105), in order to produce predetermined winding patterns on the filter cartridge. The controller being further configured to perform multi-layer winding wherein each layer may be assigned a set of independent winding parameters, such as winding speed, yarn tension, yarn spacing, and traverse profile. This enables the production of filter cartridges having variable micron ratings across different layers, thereby allowing graduated filtration performance within a single cartridge. The controller comprises a memory unit configured to store and recall multiple predefined winding parameter sets, thereby facilitating repeatable cartridge production without requiring manual re-entry of parameters for each batch.

As per the detailed embodiment of the present invention, the controller is additionally configured to validate rhombus parameter combinations prior to initiating a winding sequence, by ensuring that twice the rhombus count along the cartridge length does not have any common factor (except 1) with the rhombus count around the cartridge circumference. This validation ensures the correct selection of rhombus parameters.

As per the detailed embodiment of the present invention, the winding machine further comprises servo motors or stepper motors for driving the core shaft motor (104) and the cam shaft motor (103). The controller is configured to operate these motors under a closed-loop control system incorporating encoder feedback to ensure precise positioning, accurate traverse coordination, and consistent speed control throughout the winding process.

In another embodiment, the winding machine comprises a mechanical cam (105) configured to generate, but not limited to, rhombus-shaped or diamond-shaped winding patterns by precisely controlling the axial movement of the yarn relative to the rotating core. The mechanical cam (105) being capable of translating the rotational motion into a controlled traverse motion of the yarn traverse guide (105a), thereby defining the geometry of the winding pattern on the filter cartridge.

The winding machine is further configured to accommodate cartridge lengths ranging from 5 inches to 70 inches, enabling production of cartridges for a variety of filtration applications. A yarn-to-yarn distance parameter defines the lateral spacing between adjacent yarn strands in millimetres, with a programmable range of 1 mm to 9 mm, thereby allowing adjustment of the filter cartridge porosity.

Each layer of winding can be programmed with a layer count ranging from 1 to 10,000 layers, permitting the creation of cartridges with varying thickness, density, and filtration characteristics.

As per another embodiment of the present invention, the electronic plate holder (201) located on the outer part of said main frame (102) being capable of controlling the electronics of the machine.

In yet another primary embodiment of the present invention, method for manufacturing multi-layer filter cartridge using the winding machine, comprising the following steps;
a. inputting winding parameters via the human-machine interface including rhombus counts, yarn distance, layer counts, and winding speeds;
b. validating the parameter combination to ensure proper winding pattern formation;
c. mounting a filter core on said spindle assembly;
d. executing a multi-layer winding sequence wherein the controller controls the core shaft motor (104) and cam shaft motor (107) to wind yarn according to the input parameters;
e. automatically transitioning between layers with different winding parameters to create variable micron zones within a single cartridge;
f. monitoring yarn tension and detecting yarn breakage during the winding process;
g. automatically stopping the winding operation upon completion or detection of an error condition.

In yet another embodiment, the winding sequence being configured to produce a filter cartridge having at least two distinct filtration zones with different micron ratings. The outermost layer is wound to provide coarse filtration, while one or more subsequent inner layers are wound to provide progressively finer filtration. This graduated structure enables sequential removal of contaminants of varying particle sizes, thereby enhancing overall filtration efficiency and cartridge service life.

The winding patterns employed for forming these filtration zones can include, but are not limited to, rhombus-shaped, diamond-shaped, helical, or spiral geometries. Pattern transitions between successive layers are precisely controlled by the mechanical cam system (105), enabling smooth changes in yarn orientation and spacing without causing discontinuities or overlaps that could impair cartridge performance.

In certain embodiments, the controller is further configured to store validated winding parameters including but not limited to geometric configurations, layer counts, micron ratings, and tension settings as a recipe in its memory. Such stored recipes can be retrieved for future batch production of identical filter cartridges, ensures consistent quality and reducing setup time between production runs.

As per the detailed embodiment of the present invention, the winding machine further includes a human-machine interface (HMI) comprising a touch-enabled display screen. The HMI is configured to receive user input for setting winding parameters such as winding speed, yarn tension, layer count, rhombus configuration, and micron rating targets. The interface is further adapted to display real-time operational data, including current winding layer, rotational speed, traverse speed, yarn tension readings, and process completion status.

As per the detailed embodiment of the present invention, to proceed with the operational parameter setup, the user has to touch anywhere on the screen. The machine’s functional menu is password protected. Therefore, the user has to enter the correct password to initiate the operations. Upon entering the password the screen displays the real-time running parameters for all the spindle. The parameters can be but not limited to the winding speed (RPM), layer count, pattern Ratio, Machine status indicators (running/ idle). The user can only view the aforesaid parameters. To adjust the winding parameters the user have to select the system menu button (may provide at the bottom corner of the screen).

As per the detailed embodiment of the present invention, if the machine is showing the error, the user can view the machine errors and the solutions by taping the Error Display Page (may provide at the bottom corner of the screen). Further, the user being capable of getting the Running Status Indicators. The indicators may be categorised in the green indicator, yellow indicator, or red indicator. The green indicator is showing that the machine (100) is running and producing cartridges as per the entered parameters. The yellow indicator is showing that the machine (100) is ready to run as per the entered parameters. The red indicator is showing that the machine (100) cannot run due to the parameter mismatch. If the red indicator is there, the user have to recheck and correct the values of the parameters.

As per the detailed embodiment of the present invention, the user can easily view the error type and suggested solutions from the error display page. The error type may common for all spindle adopted in machine with plurality of the cartridge lengths. The preset error type can be but not limited to the S1L1 CAM Rotation Over Count, S2L2 CAM Rotation Over Count, S3L3 CAM Rotation Over Count, CAM Servo Alarm, FILTER Servo Alarm, YARN Cut, and STOP PB Wire. The below mentioned table showing the error type and the solution of the same.

Error Type Solution
S1L1 CAM Rotation Over Count Calculation of Layer 1 mismatched in Ratio as per Cartridge length, recheck again and enter correct value, error will solve
S2L2 CAM Rotation Over Count Calculation of Layer 2 mismatched in Ratio as per Cartridge length, recheck again and enter correct value, error will solve
S3L3 CAM Rotation Over Count Calculation of Layer 3 mismatched in Ratio as per Cartridge length, recheck again and enter correct value, error will solve
CAM Servo Alarm In any good reason CAM Servo not moved
Forward or Backward, Check
1. Follower Key stuck in CAM,
2. CAM Stuck,
3. Bearing Not working properly,
4. Servo Timing Pully OR Timing Belt not fixed properly,
this error will be coming up, Check the CAM box Inside and Outside Mechanical parts and error will resolve
FILTER Servo Alarm In any good reason FILTER Servo not moved
Forward or Backward, Check
1. Filter Shaft Bearing,
2. Filter Shaft Spring Operation,
3. Filter Shaft stuck with brake Lever,
4. Servo Timing Pully OR Timing Belt not fixed properly,
this error will be coming up; Check the Filter Shaft Mechanical parts and error will resolve
YARN Cut If the given Yarn moved out or loosen from the given Limit Switch ROD arrangement, Limit Switch activated and Machine will Stop, kindly put yarn on the Limit Switch ROD arrangement before start winding, without Put Yarn on the Limit Switch ROD arrangement, machine will not start.
STOP PB Wire In any good reason, if the machine Start Push Button, Stop Push Button not work properly or any Electric wire mismatched, machine error will coming up and machine will not start check the wiring and error will solve.
Table 1 Error Type and Solution
As per the detailed embodiment of the present invention, the system main menu can be accessed by the user from the SYSTEM button. The system menu further comprising the plurality of sub menu buttons. The sub-menu comprising the buttons for the recipe of plurality of spindles to enter the desired pattern parameters. Each spindles may offer plurality of recipes for the cartridge pattern settings. From said plurality of recipes, some of the recipes can be the default recipes which are not editable, and the others can be user-editable for custom cartridge designs. For example if the spindle 1 offers 15 recipes for the cartridge pattern settings may be the first 6 recipes can be the default recipes which are not editable, and the others can be user-editable for custom cartridge designs. The below mentioned tables showing the different parameters and the ideal values of the parameters.

Parameter Input Value
Rhombus on Main Axle Number of Rhombus along cartridge length.
OR
Number of diamonds along a row along cartridge length.
(This can be whole number or a half number, e.g. 3, 3.5, 4, 4.5 etc.)
Rhombus per Round Number of Rhombus around cartridge circumference.
OR
Number of diamonds along a row along cartridge circumference.
(This can be a whole number e.g. 1,2,3 etc.)
Table 2.1 Parameters
Any numbers cannot be taken as Rhombus on Main axle and Rhombus per round but depends upon their divisibility properties. An error is generated if the user selects incorrect numbers. A combination is valid only if twice the rhombus on the main axle does not have any common factor (except 1) with the rhombus per round. Moreover, the ratio of value of valid number of Rhombus on Main axle and Rhombus per round has to be within certain range. Too high ratio causes yarn getting wound beyond the tube length. Too low value will not cover the yarn across the tube length. For given tube length and cam stroke, the user has to make sure that the ratio of number of Rhombus on Main axle and Rhombus per round lie within a range. Some valid and invalid combinations of Rhombus on Main axle and Rhombus per round are given below:

Rhombus on Main Axle Rhombus per Round Result
3.5 1 ☑ - Valid
8 1 ☑ - Valid
7.5 3 ⮽ - Invalid
10.5 2 ☑ - Valid
12.5 5 ⮽ - Invalid
15.5 3 ☑ - Valid
37 5 ☑ - Valid
103.5 8 ☑ - Valid
39 9 ⮽ - Invalid
100.5 8 ☑ - Valid
Table 2.2 Parameters
From the above table, it is clear that the combination may be valid when twice the rhombus on main axle value is not exactly divisible by the Rhombus per Round value.

Cartridge Length (Inches) Enter the Cartridge length in which we want to produce on machine, it must be enter in “inches”
(E. g. 5”, 10”, 20”, 30”, 40”, 50”, 60”, 70” etc. as per Cartridge length)
Yarn Distance (mm) Enter the Yarn Distance between two yarn we want on cartridge pattern, basically the Gap between yarns based on thickness. The yarn distance cam be positive or negative.
(E. g.
• If the thickness of the yarn is 2 mm and a space of 2 mm is required between adjacent yarns, then enter 4 mm as the YARN DISTANCE parameter.
• If the yarn thickness is 2 mm and the adjacent yarns are required to touch one another without any gap, then 2 mm should be entered as the yarn distance parameter,
• If the yarn thickness is 1.5 mm, space of 2 mm between adjacent yarns is desired than enter 3.5 mm as the yarn distance parameter,
This parameter is useful when have different variation in yarn thickness)
Tube OD (mm) Enter the Tube outer diameter which is either PP, SS, TIN etc., which can be easily holds on Winding Shaft.
(E. g. Values can be 32 mm, 36 mm, 38 mm etc.)
Micron Pattern After entering all the required parameters and successfully verifying them after winding, user should enter the Micron Pattern Number. This will make it easier to identify the pattern whenever needed. For example, user can enter a number such as 1, 2, 3, and so on, up to 999.
Table 2.3 Parameters
The below mentioned tables shows the recommended machine input parameters for the PP yarn filter cartridges. These values may be ideal and exceeding the specified limits may result in machine errors or malfunction. These values of the input parameter of the different cartridge lengths.

Input Parameter of Cartridge Length 10”
Parameter Input Value
(Minimum) Input Value
(Maximum)
Rhombus on Main Axle 3.5 26.5
Rhombus per Round 1 11
Cartridge Length (Inches) 10” 10”
Yarn Distance (mm) 0.1 mm 99 mm
Tube OD (mm) 30 mm 38 mm
Micron Pattern number 1 999
Table 2.4 Parameters
Input Parameter of Cartridge Length 20”
Parameter Input Value
(Minimum) Input Value
(Maximum)
Rhombus on Main Axle 6.5 55.5
Rhombus per Round 1 11
Cartridge Length (Inches) 20” 20”
Yarn Distance (mm) 0.1 mm 99 mm
Tube OD (mm) 30 mm 38 mm
Micron Pattern number 1 999
Table 2.5 Parameters
Input Parameter of Cartridge Length 30”
Parameter Input Value
(Minimum) Input Value
(Maximum)
Rhombus on Main Axle 11 81.5
Rhombus per Round 1 11
Cartridge Length (Inches) 30” 30”
Yarn Distance (mm) 0.1 mm 99 mm
Tube OD (mm) 30 mm 38 mm
Micron Pattern number 1 999
Table 2.6 Parameters
Input Parameter of Cartridge Length 40”
Parameter Input Value
(Minimum) Input Value
(Maximum)
Rhombus on Main Axle 14.5 103.5
Rhombus per Round 1 11
Cartridge Length (Inches) 40” 40”
Yarn Distance (mm) 0.1 mm 99 mm
Tube OD (mm) 30 mm 38 mm
Micron Pattern number 1 999
Table 2.7 Parameters
For initiating the operations, the user has to select the winding pattern from the Recipe page and configure cartridge production in single-layer, two-layer, or three-layer modes. By pressing the Spindle button, the setup screen appears with input cells for entering the required parameters. The first parameter, Input Recipe No., allows the operator to choose a recipe number (for example, from recipe 1 to recipe 15) from the Recipe page of the selected spindle. For multi-layer cartridges, the same process is repeated for Layer 2 and Layer 3. The second parameter, Input Layer No., requires entering the desired layer count (ranging from 1 to 10,000) based on the cartridge diameter or exact production requirements. In the case of multi-layer production, the winding pattern will automatically change to the next selected pattern once the specified layer count is completed. The third parameter, Speed (rpm), involves entering the desired winding speed (from 50 to 999 rpm) for each layer. When producing two-layer or three-layer cartridges, the speed will change automatically to the next layer’s setting after the completion of the specified layer count. The procedure for entering values is identical for each layer, enabling precise control over winding patterns, layer counts, and speeds for accurate and efficient cartridge formation.

Without further description, it is believed that one of ordinary skill in the art can, using the preceding description and the illustrative examples, make and utilize the present invention and practice the claimed methods. It should be understood that the foregoing discussion and examples merely present a detailed description of certain preferred embodiments. It will be apparent to those of ordinary skill in the art that various modifications and equivalents can be made without departing from the scope of the invention.

 
REFERENCE NUMERALS
Multi-layer filter cartridge winding machine (100)
Base frame (101)
Main frame (102)
Spindle core shaft (103)
Core shaft housing (103a)
Core shaft motor (104)
Mechanical cam (105)
Yarn traverse guide (105a)
Cam shaft (106)
Cam shaft housing (106a)
Cam shaft motor (107)
Yarn tension controller (108)
Ceramic tubes (108a)
Yarn breakage detection means (109)
Limit switch arrangement (109a)
Limit switch rod (109b)
Filter cartridge diameter sensor (110)
Electronic plate holder (201)
, Claims:CLAIMS
We Claim,
1. A multi-layer filter cartridge winding machine (100) comprising:
a base frame (101) being capable of providing mechanical stability during high-speed winding operations; and a main frame (102) being mounted on said base frame (101);
at least one spindle assembly comprising:
a spindle core shaft (103) being provided for holding a filter core; and
a core shaft housing (103a) being provided to support said core shaft (103); and
a core shaft motor (104) configured to rotate said core shafts (103);
at least one cam system comprising:
a mechanical cam (105) being mounted on a cam shaft (106) such as said mechanical cam (105) being capable of moving in horizontal direction from one end of cam shaft (106) to another end of cam shaft (106) in looping; and
a cam shaft housing (106a) being provided to support said cam shaft (106); and
a cam shaft motor (107) configured for providing the drive to said mechanical cam (105) enables the horizontal movement of said mechanical cam (105) on said cam shaft (106);
a yarn being feed from yarn feeding system passes through a yarn tension controller (108) and yarn breakage detection means (109); said yarn tension controller being capable of control the tension of the yarn while winding in order to improve the tightness of yarn on filter cartridge;
a filter cartridge diameter sensor (110) being capable of cut off the operation upon achieving defined diameter of said filter cartridge;
a controller configured to control the winding operation based on an user-defined parameters.

2. The multi-layer filter cartridge winding machine (100) as claimed in claim 1, wherein said cam shaft (106) being covered with a cam shaft housing (106a) for uninterrupted operations.

3. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said tension controller (108) having plurality of ceramic tubes (108a) being arranged in a zigzag configuration in order to provide the tightness while winding the yarn on said filter core.

4. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said yarn breakage detection mean (109) including a limit switch arrangement (109a) configured to automatically stops the winding operation upon detection of yarn breakage or improper yarn tension.

5. The fully automatic multi-layer filter cartridge winding machine as claimed in claim 1, wherein said limit switch arrangement (109a) comprises a manually adjustable limit switch rod (109b) mechanism which continuously in contact with said yarn.

6. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said parameters can be but not limited to rhombus count along cartridge length, rhombus count around cartridge circumference, yarn distance between adjacent yarns, cartridge length, tube outer diameter, layer count for each winding layer, winding speed for each layer.

7. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said controller being configured to synchronize said shaft and cam shaft motor (107) to produce predetermined winding patterns on said filter cartridge.

8. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said controller further configured to control multi-layer winding with independent parameters for each layer, enabling production of filter cartridges with variable micron ratings across different layers.

9. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said controller further having a memory unit configured to store and recall predefined winding parameter sets for repeatable cartridge production.

10. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said machine further comprising servo motors or stepper motors for driving the core shaft motor (104) and cam shaft motor, wherein said controller provides closed-loop control with encoder feedback for precise positioning and speed control.

11. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said machine further comprising human-machine interface with a touch enabled screen being configured to receive user input for the winding parameters and display the real-time winding status.

12. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said mechanical cam (105) being configured to generate but not limited to a rhombus-shaped or diamond-shaped winding patterns by controlling the axial movement of yarn relative to said rotating core.

13. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said winding machine being configured to accommodate cartridge lengths ranging from 5 inches to 70 inches.

14. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein said yarn-to-yarn distance parameter defining the spacing between adjacent yarn strands in millimetres, with a range of 1 mm to 9 mm.

15. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein each layer can be programmed with a count ranging from 1 to 10,000 layers.

16. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein number of rhombus patterns ranging from 3.5 to 103.5 depending on cartridge length.

17. The multi-layer filter cartridge winding machine as claimed in claim 1, wherein an electronic plate holder (201) being located on the outer part of said main frame (102) being capable of controlling the electronics of the machine.

18. A method for manufacturing multi-layer filter cartridge using the winding machine as claimed in claim 1, comprising the following steps;

a. inputting winding parameters via the human-machine interface including rhombus counts, yarn distance, layer counts, and winding speeds;
b. validating the parameter combination to ensure proper winding pattern formation;
c. mounting a filter core on said spindle assembly;
d. executing a multi-layer winding sequence wherein the controller controls the core shaft motor (104) and cam shaft motor (107) to wind yarn according to the input parameters;
e. automatically transitioning between layers with different winding parameters to create variable micron zones within a single cartridge;
f. monitoring yarn tension and detecting yarn breakage during the winding process;
g. automatically stopping the winding operation upon completion or detection of an error condition.

19. The method for manufacturing multi-layer filter cartridge as claimed in claim 18, wherein the winding sequence produces a filter cartridge having at least two filtration zones with different micron ratings, with an outer layer providing coarse filtration and subsequent inner layers providing progressively finer filtration.

20. The method for manufacturing multi-layer filter cartridge as claimed in 18, wherein the winding patterns include rhombus-shaped, diamond-shaped, helical, or spiral geometries, and wherein pattern transitions between layers are controlled by the mechanical cam system (105).

21. The method according to for manufacturing multi-layer filter cartridge as claimed in claim 18, further comprising storing the validated winding parameters as a recipe for future retrieval and batch production of identical filter cartridges.

Dated this 03rd Sep 2025