Absorbent Article Folding Conveyor Speed Control
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Solution Overview
Problem
Current methods for folding absorbent articles on high-speed production lines often result in misaligned or undesirably configured end edges due to uncontrolled movement and turbulence during the folding process, particularly when transferring the leading end portion from a secondary roll to a transfer roll or conveyor.
Innovation Solution
The use of a multi-stage conveyor system with synchronized speed adjustments and vacuum conveyors to smoothly transfer, decelerate, and accelerate different portions of the absorbent article, ensuring minimal relative movement and maintaining alignment, involves a drum with a first conveyor assembly and a second conveyor assembly, each with movable surfaces traveling at specific speeds to manage the article's movement effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a transfer roll or conveyor is used to receive the leading end portion from the secondary roll, then the leading end portion can be held and transferred back to the primary roll, but the relative speed difference causes rapid acceleration that results in wrinkled or crooked configurations
Solution Approach 1:
The conveyor surface speed is made variable rather than constant. The system dynamically adjusts the conveyor speed to match the speed of the leading end portion when it is received from the secondary roll, then gradually accelerates the conveyor to match the speed of the primary roll. This dynamic speed adjustment eliminates sudden acceleration forces that cause wrinkling while maintaining reliable transfer and alignment.
Solution Approach 2:
The patent changes the speed parameter of the conveyor from a fixed constant value to a variable value that can be adjusted during operation. By controlling the conveyor speed to transition from matching the secondary roll speed to matching the primary roll speed, the system prevents harmful acceleration forces while ensuring proper alignment of the leading end portion with the trailing end portion.
2Manufacturing precision
If the surface speed of the transfer conveyor is set to match the primary roll speed, then alignment during folding is improved, but the leading end portion experiences rapid acceleration upon contact causing uncontrolled movement
Solution Approach 1:
The system performs preliminary speed matching by initially setting the conveyor speed to match the secondary roll speed before the leading end portion is transferred. This preliminary action ensures that when the leading end portion contacts the conveyor, there is no relative speed difference and thus no sudden acceleration. The conveyor then gradually accelerates to match the primary roll speed, maintaining configuration stability throughout the transfer process.
Solution Approach 2:
The conveyor operates with dynamic speed control rather than a fixed speed setting. The speed is adjusted in two stages: first matching the secondary roll speed to ensure stable reception of the leading end portion, then gradually increasing to match the primary roll speed for proper alignment during folding. This dynamic approach maintains both configuration stability and manufacturing precision.
3Reliability
If a vacuum system is used to hold the leading end portion to the transfer roll, then uncontrolled movement is minimized, but the frictional forces may cause wrinkling during transfer
Solution Approach 1:
The patent employs a vacuum system to hold the leading end portion to the conveyor surface during transfer. The vacuum pressure provides reliable adhesion that minimizes uncontrolled movement and maintains alignment. By combining this pneumatic holding mechanism with the dynamic speed matching approach, the system achieves both reliable control and reduced friction-induced wrinkling, as the vacuum force distributes evenly rather than concentrating stress at single contact points.
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 ensures a more precise and controlled folding process, reducing the occurrence of misaligned or wrinkled configurations, thereby improving the quality of folded absorbent articles by maintaining consistent speeds and minimizing frictional forces across the folding process.
Implementation Method 1
The secondary roll(s) may employ vacuum pressure to pull the leading portion of the absorbent article off of the primary roll and hold the pulled off portion to the secondary roll surface of the second roll
Implementation Method 2
the outer surface of the rotating secondary roll will move relative to or slip under leading end portion of the article. Frictional forces resulting from the relative movement or slippage between the leading end portion of the article can cause in undesirable resulting configurations
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
Aspects of the present disclosure involve methods and apparatuses for folding absorbent articles.